Blockhead
 

I blew a head gasket on a '89 944 and during removal, broke the block. The cooling outlet has a bolt that sits in the forward corner of the head. Corrosion on the threads prevented removal of the bolt so I cut off it's head and as careful as I was when I tried to remove the stud, the corrosion on the threads was pulled into the hole and I broke the side out of the threaded hole.

Is there a way to fix the problem properly? I hate to think that I have to have it welded. I spoke to a machinist and given the material, it has to come out and be completely disassembled so it can be preheated in an oven before welding.

Any ideas? Much appreciation to those that can help.

I assume you are referring to this part of the block:
http://forums.pelicanparts.com/uploa...1216697134.jpg

That bolt is notorious for getting stuck!
*usually* heating the piece in an oven is the best route. This is true with large castings of both Aluminum and Magnesium. It is very difficult to A: keep the area hot enough to flow the metal while welding, and B: has a tendency to warp while cooling. This being said... I have seen a similar repair made to a 944 block before. It was actually tig welded with the engine still in the car and everything else was covered with welding blankets. The bolt in that case tore out the outside portion of the block, not the internal water path portion. The area was first gently heated with a propane torch then welded, then very slowly was allowed to cool while still be heated by the torch. I am NOT advising that as a route to take!!! DO NOT try to do it on your own, seek out a darn good welder! Just letting you know that I have seen a similar repair without the whole engine being torn down.

Hope it helps!
-Nick

I have heard of people leaving that bolt out completely and it sealing. Whether or not you want to chance the leaks is something you need to decide.

I had the same problem with that bolt on my 951. I ended up heating it up and it came right out with a pair of vice grips.

I do remember someone who broke that piece off..they ended up having it welded back on. As long as you have the original piece and you can find someone good at TIG welding, it can be fixed.

Sorry if my first post sounded negative, I din't mean for it to.
I was posting late in the evening, and didn't want anyone to start attacking their block with a welder, just because I said it would work :)

Depending on a few variables (if you have the broken out piece, if you know a really good welder, how big and location of break) I think it could be welded without being torn down.

Sorry for any confusion!
-Nick