Engine block woes

[Akula69]

Sort of a "Have you ever" kind of questions:

 

While rebuilding a 4.0L for 'Junior' I got a little too enthusiastic while cranking the water pump bolts which cracked the upper right 'ear' on the block. Normally I would just trash the block and start over, but this particular block has intrigued me (a 1987 casting with 300,000 miles on it: the cylinders had little/no apparent wear with no ridge ring and did not need overbore, took standard bearings on cam, crank and rods). It had NOT been rebuilt - still had original bearings.

 

I should say that the water jacket is NOT compromised, its it the outside of the mounting bolt hole that fractured. I cannot see any cracks in the gasket surface itself, nor any cracks through the 'ear' into the jacket area.

 

First question: Has anyone ever bored that 'ear' all the way through (so the bolt could have more gripping strength)? if so it would preclude having to weld/repair the block.

 

Second question: Has anyone successfully used 'JB Weld' or any of its cousins on a block?

 

Third question: If neither of the first two are successful, has anyone ran a block with only the three bolts? The water pump has numerous brackets that attach on that side and the brackets attach to the block in other locations....they could (in theory) keep the pump tightly in place...

 

Thanks!

 

[jimoshel]

Question 2, Yes.  In no or low stress areas. I have fixed several cracks. In some cases I have applied heat to the cracked area. The JB liquifies and flows down into the crack.  In some cases similiar to what you describe I have taken welding rod and built up the area, then rethreaded the hole.

[Akula69]

Thanks Jim!

[Jeep Driver]

Without pics.........

 

 

 

Could braze in a stud.........?