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Old Dec 10th, 2011, 11:13 am   #1 (permalink)
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Engine case repair

I acquired an 05 DS 1000 engine complete with a cracked/ broken front engine mount on thr left side crank case. I removed both cylinders so I could get access to the crack for a weld repair. Any opinion on welding up the crack without splitting the cases? The crack is actually more than just a crack the entire upper half of the mount is broken away so it can be beveled back for a decent weld.
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Old Dec 11th, 2011, 10:52 am   #2 (permalink)
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This is going to be tricky to do well. Find a real expert in TIG welding. Spend a lot of time cleaning the weld area, especially down in the crack area. Al welding is very sensitive to contamination. Pre-heat the case as much as possible to minimize heat stresses and burn off contaminents. Good luck!
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Old Dec 11th, 2011, 10:55 am   #3 (permalink)
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Originally Posted by ian996 View Post
I acquired an 05 DS 1000 engine complete with a cracked/ broken front engine mount on thr left side crank case. I removed both cylinders so I could get access to the crack for a weld repair. Any opinion on welding up the crack without splitting the cases? The crack is actually more than just a crack the entire upper half of the mount is broken away so it can be beveled back for a decent weld.
Any photos please? Hard to say without seeing the crack itself?
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Old Dec 11th, 2011, 2:58 pm   #4 (permalink)
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here are 3 shots of the damaged engine mount as you can see this is more than a crack and is probably easier to make a quality repair. I think the broken piece can be beveled to create decent "V" for welding... but then again I am not a welder. The dark grey material on the case is the remains of the epoxy repair from the previous owner.
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Engine case repair-dsc01505.jpg   Engine case repair-dsc01506.jpg   Engine case repair-dsc01507.jpg  
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Old Dec 12th, 2011, 2:46 am   #5 (permalink)
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Originally Posted by ian996 View Post
here are 3 shots of the damaged engine mount as you can see this is more than a crack and is probably easier to make a quality repair. I think the broken piece can be beveled to create decent "V" for welding... but then again I am not a welder. The dark grey material on the case is the remains of the epoxy repair from the previous owner.
Off topic a little, but just being nosey - how did they manage to crack the case there, was it from being in a crash and had crash bungs fitted or something else?
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