crack in case, help needed

bigbrotherjohn · 08-28-2004, 06:48 PM

Hi guys,
Today was the first time that I ran my just rebuilt engine. It ran well and I was quite pleased because it was the first engine that I ever did. It started up right away, didn't leak oil from the case and had good oil pressure.
Any way I ran it for a while and I had to change a fitting for the remote oil filter. The one I was using was stopping me from turning the distributor in order to dial in the timing. I had one that would be better but when i put it in I tightened it too mu ch and the case cracked, oil sprayed all over. (see pics below)
So what do I do. I suppose the proper thing would be to take it all apart, have it welded and then tapped by a machine shop. Is there anything that I can do that would not require complete disassembly and removal of the engine. Is JBweld a possibilty (i've heard it's great stuff, if it could fix this then its amazing). Would TIG welding the crack be possible while the engine is still in the car.
Thanks a lot guys.

Hoffman912 · Hoffman912's Garage

youve put alot of money into it so far rebuilding it, right? do it right, dont half ass it.

bigbrotherjohn · 08-28-2004, 08:01 PM

Ok i'll do it. I just need someone to push me so thanks hoffman. Look at it this way I get to do 2 rebuild for the price of one, yippee. Could any one recomend a good shop to do this repair once I have the case apart. Would it have to be a porsche specific shop. I am in southern NY. Close to the city. thanks

Hoffman912 · Hoffman912's Garage

you could send it to competition engineering. best porsche machine shop out there, but 2 things.. expensive and youve gotta be patient.

othet than that, when you get it back it will be as good as new.
http://competitioneng.com/

or may i also recomend vic skirmants

http://356enterprises.com/

both are top notch. just dont know if vic still does street engines or not.

either way you'll be happy as a clam when you get it back

C. Clark · C. Clark's Garage

Welding the crack is not a half ass fix, a qualified welder more than likely can repair the crack and cosmetically return it to near normal appearences. The problem is you probably will need to remove the engine and dis-assemble the case, but if your hell bent on sending it out you have to do most of that anyway, forget about JB weld, for your sitiuation it not the answer. Contact the best welder you can find for advice and recommendations.
let us know what happens,
Chas.
69/912
63/356

bigbrotherjohn · 08-29-2004, 06:46 AM

thanks C.Clark.
Would a TIG welder probably be used for this. Also would welding this crack necesitate tapping the hole again, and thus creating aluminum shavings that would have to be cleaned up?

Hoffman912 · Hoffman912's Garage

Chas, thats what i was telling him to do, send it to a machine shop and have it welded.

i was saying jb weld would be half assed.

bigbrotherjohn · 08-29-2004, 01:46 PM

Would it be a possibility to do this at home. A friend of mine can do TIG welding and tapping the hole should be easy. The reason I ask is because it would save me alot of money and I don't want to ship my case from NY to CA and back.

Hoffman912 · Hoffman912's Garage

i dont know if tig would work, because of the compostition of metal that the cases are made of. they are made of a high silicon and aluminum alloy. im not a welder and dont know much about the subject so i cant say for sure. but i do know that there are different types of welding for different compositions, purposes etc.

you dont have to ship it to california. you could send it to vic skirmants in michigan, http://356enterprises.com/

you could sent it to Maryland to http://www.stuttgartperformanceengineering.com/

you could call youre local pca, or a reputable porsche mechanic, and ask them if they know of any competent machine shops in the new york/new england area. infact thats what i would honestly do if i were you.

C. Clark · C. Clark's Garage

Alloys are generally welded with a "Mig" welder. I broke a 3rd piece once and was amazed at how easy it was repaired, being that the crank seal was involved in the repair....it's been several years and still holds oil, no leaks. Call around and get a good welder to look at the situation.

Mr. Hoffman I certainly never ment to offend you...I noticed your comment was a little bulwark, all I'm trying to do is help a fellow owner who needs advice on how he should proceed, I've been in the car game 40 of my 56 years and feel I have gathered a little knowledge of how "certain things" are done.
Chas.
69/912
63/356

cgarr · cgarr's Garage

That should be an easy one if thats all it is, a good welder could get that one right in the car. But what made it crack down that low? when you threaded in the fitting? can you see the crack, you know there is a casting mark there, sure it aint leaking at the fitting?

cg

bigbrotherjohn · 08-30-2004, 06:44 PM

Thanks cgarr, It would be a huge time saver if this could be welded in the car. I have gotten in touch with Competition Engineering and they have told me a bit about the process that they usually use. From the begining of this project (the 912) I had intended to learn everything that I could about anything that I was faced with. I might consider welding this at home if I feel confident that it will come out right.

Cgarr, the Al cracked while I was tightening the fitting. The guys at CE said that the crack probably happened because I used teflon tape on the fitting. They said that it is a little known secret that Teflon should not be used. I never would have thought to not use teflon but they are more experienced than me. Probably the Teflon causes the fitting to turn much more easily when you are tightening it and this could result in over torqueing and cracking. In response to your other question, yes I am sure that it is cracked (oil sprayed out of the crack). After removing the fitting and by using a mirror it was easier to see the crack, it's not casting mark.