Oops!!

[sarran1955]

Hello,

A bit of Full frontal engine Porn for you.....



This is the soft under belly of a 1981'ish, (reconned by VW long ago)...CU 2 litre Aircooled

The more observant among you will spot the central oil strainer bolt is well off centre..

Caused I think by over enthusiastic tightening of the 'blind' nut.. presumably to stop an oil leak..breaking the stud off inside the case.. engine apart..

20 centimes of washer might have saved the day...

Never mind... it's all a learning curve....

So, I now strip down the block and look to see whether I can get away with welding surgery ......or.....

Any one got a GOOD CU case out there,

I'll keep you posted..



Cordialement

[horizontal kipper]

Oh dear not another one jinx over on vzi has lots of type 4 motor spares he may have a good CU case if your stuck.

[sarran1955]

Hello,

Well, I split the case today, and as you can see there is serious damage to both sides:

The sump plate bolt had been progressively over tightened, presumably to stop oil leaking around the sump plate..

Eventually the cross bolt gives way....

and there is oil all over the place



This is the RHS, with the bolt hole all the way through, .... peeled like a banana...



This is the 'blind' side.....

So much force was used on the case that the cross bolt ended up like this:



However, all, IMHO, is not yet lost....

If I get made a heat sink copper bar to sit in the cam bearing housings, and a sleeve for the bolt housing..

then I reckon welding surgery is on.....

Hopefully the patient will survive!!

Cordialement...

[300CE]

Keep us informed on how you get on Sarran! Always good to see how these kind of problems are resolved

[smnbyt]

As it happens I'm sure I have a CU case in my loft I shall look tomorrow if you wish??

Simon

[sarran1955]

Hello,

Please do.....

We will do photos and thumbail test..

Cordialement..

[smnbyt]

No probs, I shall have a rumage tomorrow

Simon

[Plasticman]

i sense a tig moment approaching,zzzzzzzzzzzzzzzzzzz crackle zzzzzzzzzzz
mm

[smnbyt]

Right, I've found it. If you let me have your email address I can send some pictures of it

Simon

[sarran1955]

Right, I've found it. If you let me have your email address I can send some pictures of it

Simon

Hello,

You have PM

Cordialement,

[AdrianC]

i sense a tig moment approaching,zzzzzzzzzzzzzzzzzzz crackle zzzzzzzzzzz

There's two people I can think of on 80-90 who could glue that back together... Mickey & John. Walk in the park!

[sarran1955]

Hello,

Thank you for all the interest..

Bearing in mind the proximity of the cracked parts to the line of the cam bearings..

I'm getting a copper bar machined to be clamped in the housings to act as a heat sink..

and a sleeve to go into the bolt hole.

However.. as I want to put in as little heat as possible, considering the angle of attack and that I will have to build up some long beads.

I will go for MIG welding, using Argon/Helium mix, and a magnesium/ silicone rich aluminium welding wire...

I will grind back to sound metal using a diamond air tool to avoid contamination...

All this has to be ordered in the week...

from the UK..... because it is so much cheaper...

Cordialement,

[tobydog]

Laser welding's good for getting down holes, though expensive.

http://www.carrswelding.co.uk/classic_p ... icles.html" onclick="window.open(this.href);return false;

[sarran1955]

Hello,

Thanks for the link.......(drool Icon)..

Compare the heat inputs on the table below..

http://www.carrswelding.co.uk/why_laser_welding.html" onclick="window.open(this.href);return false;

This is why I would use a 'foundation' of tig, then build up in MIG.

The decision on whether to weld or go second hand will be price determined this week..

Keep you posted..

Cordialement,

[sarran1955]

Hello,

Well I've had a busy sunday....



So here is the case that has been prepped to take the 'splints'



Here are the made up inserts with aligning bolt



The inserts are tack welded in



Then a good penetrating run down either side..



All the excess is ground off and prepared for the second pass with this air tool



Then 'building up' with more metal..



Clean again and look for' pinholes and shorts'



Check that the bolt moves freely in the new thread..



Here is the case split apart again with the weld being smoothed to take out any stresses..



The case now nipped up and the oil strainer and bottom plate in place... torqued up..

and going to be left a couple of days....

Now to start work on the cylinder heads....

Cordialement,