Mikey UC Posted January 23, 2012 Share Posted January 23, 2012 I say crack – what actually happened was that I was doing the k series 1.4 to 1.8 conversion and got to the bit where I had to grind away some of the block webbing near the starter motor. I thought I had ground away just enough material to get the starter motor on, then noticed a crack appearing, which was about a mm wide and 5mm long, which I guess must go through to a water or oil way. So I’m rather hoping I haven’t completely trashed by block (my daughter said daddy was saying lots of bad words in the garage at about this time). I have seen some liquid metal epoxy glue on the internet that is meant to seal cracks in aluminion, and was wondering if it is any good ? Thanks for any help Link to comment Share on other sites More sharing options...
Eugene Posted January 23, 2012 Share Posted January 23, 2012 Have it welded and pressure tested... Only get to get a guaranteed solution IMHO. Link to comment Share on other sites More sharing options...
oilyhands Posted January 23, 2012 Share Posted January 23, 2012 Mail me a photo... Oily Link to comment Share on other sites More sharing options...
Mark Durrant Posted January 23, 2012 Share Posted January 23, 2012 It depends where it is on the block but hopefully it casn be ally welded. Send Oily a photo as he is the expert 😶🌫️ Link to comment Share on other sites More sharing options...
Mikey UC Posted January 24, 2012 Author Share Posted January 24, 2012 I have uploaded a couple of photos – here We have a ductwork company that works for us that said they would be able to weld over the gap, although I was wondering if the whole rib needs to be built back up with some plate as the ground surface is now pretty thin. I assume it is a water way that I have found ?? Edited by - Mikey UdaleClarke on 24 Jan 2012 08:47:57 Link to comment Share on other sites More sharing options...
oilyhands Posted January 24, 2012 Share Posted January 24, 2012 What you have found is the bolthole for one the head bolts, these holes are also designed as oil drains to the sump. In removing so much material you have compromised the strength of the tunnel that the bolt goes through so you will need this to be re-eastablished with some weld build up or the tunnel will 'crush' when the engine is bolted together. This will likely cause HGF on that corner of the block. Oily Link to comment Share on other sites More sharing options...
Englishmaninwales Posted January 24, 2012 Share Posted January 24, 2012 I think the cylinder head bolts pass down this channel plus return oil from cylinder head. Not sure if this damage will affect the structural integrity of the K series head/cylinder block bolt system I expect someone with more knowlege will be along soon Link to comment Share on other sites More sharing options...
Englishmaninwales Posted January 24, 2012 Share Posted January 24, 2012 Must type faster Link to comment Share on other sites More sharing options...
Mark Durrant Posted January 24, 2012 Share Posted January 24, 2012 Mikey I know of a K Series block with a hole in the same place that was successfully welded and did not experience any head gasket issues. Link to comment Share on other sites More sharing options...
Mikey UC Posted January 24, 2012 Author Share Posted January 24, 2012 Thanks for the advice, I’ll get it welded. Its good to hear the k series has been welded in the same place before and survived. Had a crap morning – couldn’t hit a thing at cricket practice, so thought a bit of Caterham tinkering therapy was in order. Perhaps I should have stuck to my crossflow as I’m obviously too ham fisted for a k series. Link to comment Share on other sites More sharing options...
Mikey UC Posted January 31, 2012 Author Share Posted January 31, 2012 Engine block all welded back together. here Done by Sansoms near Farnham for £15 Going to hide my angle grinder before it gets me into any more trouble. Link to comment Share on other sites More sharing options...
Englishmaninwales Posted January 31, 2012 Share Posted January 31, 2012 Mikey Just a thought, your engine is fully assembled..there will be metal from the original grinding inside waiting to cause havoc....unless you are planning to rebuild? Malcolm Link to comment Share on other sites More sharing options...
combine Posted January 31, 2012 Share Posted January 31, 2012 Just shows how thin these modern engines are , god knows what a 2011 engine's like ! Link to comment Share on other sites More sharing options...
Roger Ford Posted January 31, 2012 Share Posted January 31, 2012 I don't think a few shavings of aluminium in the oil would do much damage. And they should get picked up by the oil filter pretty quickly, right? Link to comment Share on other sites More sharing options...
oilyhands Posted January 31, 2012 Share Posted January 31, 2012 If any get washed up into the lower part of the bore when the oil surges you will pretty soon muller the piston skirts. Oily Link to comment Share on other sites More sharing options...
Mikey UC Posted February 3, 2012 Author Share Posted February 3, 2012 Wasn’t planning on a rebuild just yet, Maybe if I took the sump off I could get a view of that oil way and clear away any shavings ??? Link to comment Share on other sites More sharing options...
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