I came upon an OMG moment

[tevake]

I'm in the process of fixing an oil leak in my SC.
While cleaning the oil mess from the lower part of the engine I found a crack in the case that took my breath away.
I'm wondering if a welding fix could be done, and what it might take to do that.

Here is a link to my thread in the 911 forum. Many here may not look in over there frequently, so I wanted to see if any one here could share insight on this issue.

Cheers Richard

While the engine is out?

[motion]

Originally Posted by tevake

I'm in the process of fixing an oil leak in my SC.
While cleaning the oil mess from the lower part of the engine I found a crack in the case that took my breath away.
I'm wondering if a welding fix could be done, and what it might take to do that.

Here is a link to my thread in the 911 forum. Many here may not look in over there frequently, so I wanted to see if any one here could share insight on this issue.

Cheers Richard

AB Lifestyle Linens - Airstream Forums

Nice linens!

[tevake]

Sorry Motion, the correct link is up now.

[motion]

OH man, looks like something whacked the case and cracked it. Ouch.

[Chocaholic]

Looks like someone took a hand grinder to the area, perhaps an attempt to prepare it for welding?

[tevake]

It did topple over with some wood blocking on my first engine drop. Pun intended,
But not far, and I dndnt see this crack at the time.
It's the little bit of grinding on it that causes me pause.

I didn't do that and it's only been in a shop a couple of times since If had it, with no mention of this.
So could it have been there since before it came to me? That area has been covered with oil grunge since shortly after the last time it was out.
It's been cleaned pretty well a few times, but while sitting on wooden blocks than may have blocked view of this.

Very puzzeling and disturbing.

But really what is relavent at this point, is what if any thing to do about it now.

Not so cheerie Richard

[Jim Richards]

Time for a 3.6 conversion?



Sorry about that crack, Richard.

[LakeCleElum]

I put a hole in a motorcycle engine case once. I did have it welded w/o disassembling the engine. Worked fine; put another 80,000 miles on it and still have the engine....Take pic's to a good local welder........Sorry about this Richard.

[908/930]

I'm quite sure it can be welded, unfortunately your engine will have to be taken apart.

If you can find a shop with a new high end TIG welder that can minimize heat distortion, they would preheat to help. Getting it totally clean will be important and a small v groove where the crack is let the welder determine this.

[porsche930dude]

Was it leaking? It does look cracked but are you sure its a crack and not casting marks. Like the upper left area looks like mold marks

[Joe Bob]

Clean it, buff it, JB Weld it.....keep an eye on it.....

[1990C4S]

I think if it were more serious it would be leaking. I suspect it will be fine for a long time.

When it leaks, if it does, drill a small stress relief hole, then JB Weld...or yank it now and bite the bullet.

[Arizona_928]

I know a really good tig welder that is in Phoenix that I have used many times.
Has a ton of experience in repairing cases. I'll pm you his cell phone number.

[Eric Coffey]

Originally Posted by AZ_porschekid

I know a really good tig welder that is in Phoenix that I have used many times.
Has a ton of experience in repairing cases. I'll pm you his cell phone number.

Not a welder/pro, but I am guessing that a "surface" repair is probably not ideal. However, it may be the next best option before complete disassembly and thorough/proper inspection and repair.

If you do have it welded, just be sure that whoever does it is highly experienced in CAST aluminum welding. They should dye check the cracks to find the ends, and preferably drill-stop them all. There are also some filler rod options that "wet" better than others. The weld areas should probably be thoroughly "arc cleaned" before laying in rod material too. Good luck!

Oh, and AZP: If you could, please PM me your guy's name/contact info as well.

[ossiblue]

Originally Posted by porsche930dude

Was it leaking? It does look cracked but are you sure its a crack and not casting marks. Like the upper left area looks like mold marks

This was my thought as well. Maybe a PO thought it was a crack and began a scuffing to address it? All speculation, but the scuff marks don't appear to be clearly focused on the mark, or the person who did them quit after the first pass. Maybe they also figured it was a casting mark after all. I think an experienced Porsche engine rebuilder could determine if it is, in fact, a crack that somehow compromises the case. Now that it's clean, you should be able to tell if it leaks.

[cstreit]

Seems really odd that it wouldn't be leaking oil.

Are you SURE it's a crack and not a casting mark? Hot oil will seep out of everything. Frankly I'd try and get it "lightly" TIG'd without removal/disassembly.

[john walker's workshop]

Lots of casting flash on engine/trans cases. Plenty of threads here from worried people. You might take a 2" angle grinder and a 80 grit roloc disc and smooth it out, then see if it's still there. Should be leaking if it was a crack.

[Bill Douglas]

Let a bit of grease+oil leaks+road film build up over it and it will become a distant memory.

[Dan J]

If that was a crack oil would be pouring out. Is there liquid coming out?
Clean it, put it in and watch it. I don't think it's a crack

[legion]

Here's my crazy theory:

A previous owner notices this "crack". He starts prepping the area for welding with a grinder, but decides to get a second opinion. The second opinion is that it is a casting mark. He stops.