Can I repair 964 engine case with alumaloy

[toma8344]

Hello a racing friend got me a 3.6L engine case that I will be using to build a pretty stock street motor. The case specs fine and ran fine but has previous damage in the bottom webbing area between 2/5 cylinders from a connecting rod failure. I want to repair four areas each less than 1/2 inch square with Alumaloy an aluminum alloy used to repair aluminum with just a propane torch (ie. reclose the blind tapped area for two head studds and 1/8 inch wide grinder disk notches left behind at the bottom of the area where cylinder barrel fits). I am concerned the hot spots of the air cooled 964 case are greater than the 728 degree melting point of Alumaloy which would cause a catastrophic failure of the motor. Anybody have experience using Alumaloy to repair 964 or 993 engine cases or what should I do if anything since the case ran fine as it is.

Thanks!

Toma

[JeTexas]

Hello a racing friend got me a 3.6L engine case that I will be using to build a pretty stock street motor. The case specs fine and ran fine but has previous damage in the bottom webbing area between 2/5 cylinders from a connecting rod failure. I want to repair four areas each less than 1/2 inch square with Alumaloy an aluminum alloy used to repair aluminum with just a propane torch (ie. reclose the blind tapped area for two head studds and 1/8 inch wide grinder disk notches left behind at the bottom of the area where cylinder barrel fits). I am concerned the hot spots of the air cooled 964 case are greater than the 728 degree melting point of Alumaloy which would cause a catastrophic failure of the motor. Anybody have experience using Alumaloy to repair 964 or 993 engine cases or what should I do if anything since the case ran fine as it is.

Thanks!

Toma

I can't speak for Alumaloy, but I repaired the aluminum heat exchanger on a boat with Marine JB Weld, which is supposedly good to 600 f. It's lasted about 9 months so far with no issues. However, the repair is sitting in coolant, so I doubt it gets THAT hot.

Is there not a shop that could re-weld the spots for you? That would be my first choice.

[Loren]

I have had those cases and heads welded at specialty machine shops. Be sure the shop has experience with the Porsche alloys. The weld process is much much stronger than any of the mix-up epoxy-like kits.

The few of these that I have had done were pretty reasonably priced.