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repairing a block

I don't have experence at it but was a welder for 20 years. The block would have to be compleatly stripped and cleaned. The crack would have to be veed out to be able to get full penitration of the weld. The whole block would have to be pre-heated to over 400f. The welding rod or wire would have to be matched to the exact type of cast iron that the block is made of. After the welding the block would have to be post heated slowly dropping the temp. Everything would have to be remachined. With a crack in the cylinder wall there could be a issue of uneven ring wear because of different hardness.
I reallt doubt that it would be very cost effective considering a new aftermarket block is only $1200.Good used core blocks up to $500. I doubt that anyone would garrenty a welded block, so it could cost you for another block anyhow. Just my take on it.
 
its prob not worth it Matuva, a crack in the outside water jacket could be welded,crammed and peened in case of a freeze crack.
just welding usually cracks again.The cost of having it done is prob more than obtaining an other block,used or new.
A small horizontal crack in a cyl could be fixed by sleeving that bore.I would'nt realy trust it.
 
I've welded a fair bit of cast iron, some of it high stress parts. As Bison pointed out though the only part I would weld would be an external crack
 
Thank you for your input guys.
I and my mechanic were watching a cracked block, and thought it's really a pity to junk it.
Considering too local prices, we were wondering if there were any possibility to repair it, what kind of stick metal should be used , etc...

Used engines and blocks are not available here. Anybody who get ones keep it for himself.
Only solution is to buy it to the 2 guys who import that stuff here: they offer a reman long block for $9500 to $11 200.

Yes, somebody's making money...
 
Send it over Matuva, I'll weld it for you as an experiment. I just wouldn't do it on my dime. Too much work to R&R if the weld doesn't hold.
 
You can't contact a place like Clearwater and buy a block and have them ship it to you? Or do you have to go through an importer?
 
Thanks for the proposal NVW, I would be happy to send it to you, but shipping it back and worth should be around $5 000 (plane, for 2 weeks) or $ 2 000 (sea + 6 months).

Clearwater should do, I will contact them for that.
Jamie at diesel depot may help too, thogh he looks busy at the moment.
I also saw a engine dealer, 6.5l, who is proposing good rates...
 
Bypass the middleman ,get the damn thing straight from china man,bare block around 800 to a thou.Another $400 and its on your doorstep.
 
That's a good suggestion, Matuva doesn't have a lot of options living on a pretty tropical island.
 
Clearwaters are Chinese, probably 99% are now. PM Bison, he got one direct.
 
matuva, here's some info you might find interesting. This is part of a post on a DTR BB. He repaired a 5.9 Cummins. You can find locknstitch on the web.

This is when I decided to research the cold method of repair. After many phone discussions and searches on the Internet, I felt that Locknstitch was the way to go. Locating a repair craftsman near Kansas City was the next adventure. I contacted the Locknstitch Company in California for help in finding a repair craftsman near Kansas City. I call them craftsman, because this is an art. They were able to locate a craftsman in our area. They referred me to Steve at KC Machine.
Steve at KC Machine was contacted. I phoned Steve and described the problem. He is mostly into industrial type repairs. I also sent him pictures of the problem. Pictures were off the forums. Steve said he was sure it could be done, . but since he is mostly into industrial type repairs, He referred me to a machinist 2 two hours from me. I made an appointment with John Bethel at the Carquest Machine Shop in Chillicothe, Missouri and arranged to have my wife follow me. We headed for Chillicothe, Missouri. Located Car Quest machine shop. John Bethel, expecting us, invited us in his office.

John Bethel has been doing LocknStitch repairs for 2 years. He explained most of what I had already read on the website. and confirmed that welding cast iron is not a good idea. He was excited and very enthusiastic about this product. You could tell that his confidence was abounding. He uses this for cracked blocks, and heads. Aluminum can also be done. He says Locknstitch also makes a great thread replacement product. John had never experienced the 53 problem, but after seeing it, had no reservations about doing the job. I left my truck knowing it was going to get the care it needed.

The key to the job was doing it in the frame. A task for the nimble to overcome this challenge, John rented a lift for a day from a garage down the street. Since we were working with roughly a ¼ inch of wall thickness he used Locknstitch’s smallest C-series stitching pin. . This pin contains the patented Spiralhook threads. Most pins spread the crack. This pin actually pulls the cast together when inserted. It also has a intricate sealing system. This is how he was able to do this without some sort of locking mechanism. The location created problems with using locks.

John’s only approach was from the bottom. The only item that needed removal was the heat exchanger from the automatic transmission. John needed to extract the coolant so it was below his working level. He still had very tight quarters to work in. He cleaned and magnaflux the area to determine exactly where the crack was. John then drilled holes about a pins width beyond the crack. This was to relieve any stress left on the block, and hopefully keep it from cracking further. Using a harden steel jig provided for this particular pin John then drilled every other hole. After that he tapped the holes with a special tap provided for these pins. John then countersunk the holes with another special tool so when the break-off torque was reached the pin would be flush with the block. He then repeated what he did to the existing crack to achieve an overlapping effect. This was done throughout the length of the crack. John then pressure checked the system to be sure he got it tight. He then grinded down, and painted the area. With a little road grime, a guy couldn’t even tell it happen.

Everybody wants to know the cost. John spent the greater part of a 10 hour day doing this. I ask him to take pictures, some of which did not focus correctly. I did not even ask John what his labor rate was. He just said it would be between $500 and $1000. That was good enough for me! He charged me $692.00. It all amounted to the lift, parts, and labor. As long as it worked I was happy with that.
 
do you have any way to contact this John Bethel, i needed to have the thread replacement inserts that he mentiond done and if it would be cheaper to have it done then buy the tools im all for it. Chillicothe is only 3.5 hours from here and there is another guy loccal that neededs it done as well.
 
Josh,
I do not know him personally. I just googled KC machine and got this.

http://www.kc-machine.com/

Scroll down to the bottom where they list their services. It list "crack repair" and mentions the locknstitch method, so I'm quite sure this is the place.

They are located in Excelsior Springs, Mo. #816-630-2035

Good luck

Upon rereading your request you might need to call Carquest in Chillicothe, Mo. 660-646-2985
 
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matuva said:
That's a good idea .
Though, chinese blocks are not from equal quality, and I don't who to join and how ---
Click to expand...

Al I bought a Chinese block for my project engine, it machined very well when I put the splayed mains in it, you were considering a weld repair on a junk block, I think a whole Chinese one would be superior to a repaired OEM one based on my own experiences,.

Given your remoteness, and other options being much more expensive I'd give it a try, China does not always = junk, they are far superior than they once were, remember there was a time when made in Japan was considered to be pure junk as well. Something to consider.
 
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