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PostPosted: Fri Jan 26, 2018 10:14 am 
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4 BBL ''Hyper-Pak''

Joined: Mon Jan 22, 2018 6:51 pm
Posts: 33
Car Model*: 1962 Dodge Lancer
Hello all,

Does anyone have any tips on fixing these corroded holes in my aluminum engine block? Sounds like Belzona is the thing to use. How do I clean up the metal on the inside?

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PostPosted: Fri Jan 26, 2018 11:38 am 
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Joined: Sat Oct 12, 2002 11:22 am
Posts: 3494
Location: Sonoma, Calif.
Car Model*: Many Darts and a Dacuda
- Completely dis-assemble the engine down to the bare block.
- Degrease / clean the engine block.
- Media blast the areas to be repaired. (all the water jacket area)
- Cut & grind the large corrosion holes to where there is solid aluminum on all sides to be welded.
(shaping the holes into square or rectangular "windows" is helpful)
- Cut and fit aluminum "patch pieces" into the holes.
- Weld, and weld... and weld-in all the patch pieces and voids.
( Do NOT weld on any areas surrounding the cast iron bore lines)
- Grind the welds flush / near flush to check for porosity or cracks.
- Use epoxy to repair minor corrosion areas, voids or small cracks.
Optional:
- Use block filler "plaster" to coat the backwall and the floor of the water jacket area.

Once complete, resurface the deck (and the cylinder head) then re-assemble the engine.
DD

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PostPosted: Fri Jan 26, 2018 3:13 pm 
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Joined: Fri Nov 01, 2002 5:02 pm
Posts: 1559
Location: Waterloo, Iowa
Car Model*: '23 T-bucket
Hey, 62......are you located near Aurora, California?

Roger


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PostPosted: Fri Jan 26, 2018 6:25 pm 
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4 BBL ''Hyper-Pak''

Joined: Mon Jan 22, 2018 6:51 pm
Posts: 33
Car Model*: 1962 Dodge Lancer
Arcata CA


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PostPosted: Fri Jan 26, 2018 8:18 pm 
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Joined: Fri Nov 01, 2002 5:02 pm
Posts: 1559
Location: Waterloo, Iowa
Car Model*: '23 T-bucket
That's really too bad. I happen to have a good, usable bare aluminum block, but at 78 pounds or so, along with the size, the shipping alone would be rather painful.

Roger


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PostPosted: Fri Jan 26, 2018 11:43 pm 
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Joined: Thu Oct 31, 2002 5:39 pm
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Location: North America
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Shipping an aluminum block is not difficult or very costly; I've carried them in the front door of FedEx Office and had them pack and ship across the country for something like $150.

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PostPosted: Sat Jan 27, 2018 3:33 am 
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Joined: Sat Oct 19, 2002 12:06 pm
Posts: 6893
Location: Silver Springs, Fl.
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My personal opinion, forget using your block. Unless you have a really strong reason for wanting to use an aluminum block, just replace yours with a iron block. The few special pieces needed for the aluminum block will be pricey.If you really want the aluminum engine get the block from GTS225. Shipping will be cheaper then repairing your block.

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PostPosted: Sat Jan 27, 2018 4:07 am 
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Joined: Mon Oct 21, 2002 11:08 am
Posts: 12517
Location: Blacksburg, VA
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Those are some big holes and will require plenty of work. I agree with Charlie.

Lou

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PostPosted: Sat Jan 27, 2018 4:21 am 
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Joined: Fri Nov 01, 2002 5:02 pm
Posts: 1559
Location: Waterloo, Iowa
Car Model*: '23 T-bucket
Lou should be able to vouch for the condition of my block. He looked it over, either in Kearney, or at one of the dinner gatherings in Des Moines one year.

Roger


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PostPosted: Sat Jan 27, 2018 4:23 am 
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Supercharged

Joined: Thu May 12, 2005 11:50 pm
Posts: 5894
Location: So California
Car Model*: 64 Plymouth Valiant
Use an iron block.

Repair the aluminum as time and money allow.

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64 Valiant 225 / 904 / 42:1 manual steering / 9" drum brakes
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PostPosted: Sat Jan 27, 2018 6:44 am 
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Supercharged
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Joined: Sat Feb 16, 2008 1:25 pm
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Location: Downeast Maine
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Those photos show only what one can see. How many hidden thin areas are lurking within bowels of water jacket. I'd hold on to it until aluminum scrap prices go back up, and locate an iron engine that is running. Done, and Bob's your uncle. (a little British lingo there) You will have that nice looking Valiant over the curb and burning gas in no time.

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PostPosted: Sat Jan 27, 2018 1:26 pm 
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4 BBL ''Hyper-Pak''

Joined: Mon Jan 22, 2018 6:51 pm
Posts: 33
Car Model*: 1962 Dodge Lancer
GTS225 wrote:
That's really too bad. I happen to have a good, usable bare aluminum block, but at 78 pounds or so, along with the size, the shipping alone would be rather painful.

Roger


Hi Roger, I'm at least interested. I sent you a message.


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