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Crack in bottom cover @ drain plug

  • Thread starter Thread starter MidWestCoast442
  • Start date Start date
Glad I stumbled across this thread. Just chipped off a big ol' glob of JB weld on the drain bung of my gs400. had thought it was mud baked on the pan... but no. I'm going through my engine entirely so I already had planned take the case off and weld up the crack. Can you find out the process the guy at the machine shop took to weld it up? I had planned to drill a small hole at the end of the crack to take the stress off the metal from cracking more. wasn't sure if that was necessary.

pictures would be cool too.
 
I'll ask him to detail the process for me and I'll post it on here. Should be picking it up later this week.

Sounds like drilling the hole wouldn't do much good for you. The plan, as he described to me, was to do a full weld-up -> drill & tap -> chamfer for o-ring on case & plug. The o-ring will help seal it without needing to torque the plug as tight - which should help to prevent future cracking.
 
Okay. So the crack seems to be fixed.

Dan at Dan's Metal Works in Santa Rosa, CA did the work. He seems to be pretty sharp; says that he mostly works on Harley repairs because their junk is always breaking (hah!). The whole procedure cost me $100.

So he attempted to weld the crack & threads as-is, but the alloy doesn't weld very easily. So he did what he could, then started adding material on top of it to have something to work with. After layering metal over the crack and threads, he plugged the crank case except for one of the holes. He then connected his compressed air line to this hole and proceeded to positively pressurize the crank case with air while he drilled & tapped the new hole for the drain plug. After doing that, he chamfered and flattened the area around the hole, added an o-ring to the plug, and threaded it in. The end.

My only concern is that some metal shavings could be in the crank case, despite the positive pressure. The oil filter would pick these up, I think. But what about the transmission?

Thoughts?
 
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