What to about this broken bolt hole on a 968 block
 

Hi,

Check out the photos. What would one do to address this broken bell housing mounting hole?

Thanks.

http://forums.pelicanparts.com/uploa...1458266775.jpg

http://forums.pelicanparts.com/uploa...1458266831.jpg

http://forums.pelicanparts.com/uploa...1458266883.jpg

do you have the piece that is missing? weld it back on.
don't have the piece? weld a new chunk of aluminum on, drill and tap...

Thanks.

I don't have the missing piece. Do you think I should I have a good aluminum welding shop just build up material using a welding process then drill and tap, or grind it flat and weld a piece of aluminum to the block?

Hi Das944, If the engine is out of the car, call around and find the best welder for aluminum and have the section built up, drilled and taped. Some welders will not touch anything next to oil but your block should be OK.

Cheers,
Larry

Thank you.

After welding up the end of the block, make sure that the surface is flat, then use the bell housing as the jig for drilling and tapping the hole for the bolt. Antiseize the hell out of it when installing the bolt.

The reason that the boss on the engine broke is due to crossthreading the bolt into the engine, then using an impact wrench. The damage could have been avoided by a careful mechanic who was aware of the limits of the materials.