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Crack in the Case meet Devcon Titanium Putty - Part II
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shadetreemech
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PostPosted: Sun Sep 26, 2021 1:07 pm    Post subject: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

Back in late March this year I posted a Trip Report:
https://www.thesamba.com/vw/forum/viewtopic.php?t=751966&highlight=
that ended with a crack in the case at the alternator bracket:
Image may have been reduced in size. Click image to view fullscreen.

In August I posted a topic showing the start of the crack

Image may have been reduced in size. Click image to view fullscreen.

and the tools and materials I intended to use, as an experiment, to repair the case.
https://www.thesamba.com/vw/forum/viewtopic.php?t=757586&highlight=

Turns out, the cracking was more extensive than I first thought.

Image may have been reduced in size. Click image to view fullscreen.

I cut a piece of 1/8" aluminum plate and contoured it to fit inside the case behind the extent of the crack.
Image may have been reduced in size. Click image to view fullscreen.
I drilled 1/8" holes through it, then buttered it with the Devcon Putty mixture 3:1, making sure the putty oozed out the holes to the other side. I figured, once the putty dried, the putty in the holes would act as rivets to hold the plate in place. I clamped the plate to the case leaving a margin for the head gasket;
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

I've since filled the voids at the end of the plate.

I ground the crack into a "V" starting with a round head bit on the Dremel, switching over to a conical one as I got farther in:
Image may have been reduced in size. Click image to view fullscreen.

I applied putty in layers, grinding out voids and peaks in between each layer:
Image may have been reduced in size. Click image to view fullscreen.

As of this morning, I've ground, filed and polished the area around the crack to where I'm close to starting reassembly:
Image may have been reduced in size. Click image to view fullscreen.

I purchased all the aftermarket heavy duty brackets and bars available. I'm set with a head gasket kit and the proper tools. My next post will be a follow up on how the Devcon Putty performed.

Happy Trails & Best o' Luck

Dan
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Last edited by shadetreemech on Sun Sep 26, 2021 5:37 pm; edited 1 time in total
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dobryan Premium Member
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PostPosted: Sun Sep 26, 2021 1:47 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

I can't wait for the conclusion! Very Happy
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https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

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PostPosted: Sun Sep 26, 2021 1:51 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

I love it when sculpture comes into play Very Happy

Hoping it works out successfully, looking forward to the results.
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djkeev Premium Member
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PostPosted: Mon Sep 27, 2021 1:53 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

You get a very high score for making what you have on hand work!

I sincerely wish you the best results in real world use.

Me?
I'd worry about that repair failing every mile of every journey I took.

Any failure is tow truck worthy. There is no roadside repair possible.

My fear would be failure along a road like Montana 200 somewhere........
I worry about finding timely gas opportunities on 200!

Dave
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PostPosted: Mon Sep 27, 2021 3:31 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

thats going to last 62,8496 miles according to my analysis run on a Cray. The standard error of the MTBF calculation is still running.

Enjoy it, worry free.
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danfromsyr
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PostPosted: Mon Sep 27, 2021 4:51 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

nice work but I'd figure out how to mount an alternator (maybe a smaller one) on the AC mount side of the engine.
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shadetreemech
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PostPosted: Mon Sep 27, 2021 7:58 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

djkeev wrote:


Me?
I'd worry about that repair failing every mile of every journey I took.

Any failure is tow truck worthy. There is no roadside repair possible.

Dave


It's an experiment, just like everything else I've never done before.

Epictetus said, "It's not what occurs but how you respond that matters."

I'm in. Forward.

Dan
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?Waldo?
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PostPosted: Mon Sep 27, 2021 8:45 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

I appreciate your willingness to experiment. I recently purchased a Primeweld TIG225X for $825. Plus consumables, gas, cart, table, some additional safety gear I'm at ~$1000. That's ~10X the cost of the putty but the machine is very highly reviewed, the warranty is excellent, and the ongoing operational cost for being able to weld aluminum is much lower than the cost of the putty. If you experience a failure and ascribe any value at all to your time, then it is likely your single use of the putty will end up being more expensive than purchasing a similar machine. If it succeeds, then it will obviously be significantly less expensive for that single repair. Again, I appreciate your willingness to experiment and I'm not saying there is anything wrong with your approach. We each strike our own balance between time, cost, risk, etc...
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djkeev Premium Member
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PostPosted: Mon Sep 27, 2021 3:52 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

shadetreemech wrote:
djkeev wrote:


Me?
I'd worry about that repair failing every mile of every journey I took.

Any failure is tow truck worthy. There is no roadside repair possible.

Dave


It's an experiment, just like everything else I've never done before.

Epictetus said, "It's not what occurs but how you respond that matters."

I'm in. Forward.

Dan


Oh, don't get me wrong.
I'm not throwing rocks for I truly reside in a glass house with my many documented hair brained ideas!

That is just beyond my personal assumed risk threshold.

Dave
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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

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PostPosted: Mon Sep 27, 2021 4:00 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

I so want this to work…
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The West Coast Westy
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794
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sanchius Premium Member
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PostPosted: Mon Sep 27, 2021 4:06 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

danfromsyr wrote:
nice work but I'd figure out how to mount an alternator (maybe a smaller one) on the AC mount side of the engine.

Or this: Flat plate fix for failed alternator bracket case mounts https://www.thesamba.com/vw/forum/viewtopic.php?p=9682632&highlight=#9682632

You need to make sure you get the final alternator angle and location dead on.

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alaskadan
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PostPosted: Mon Sep 27, 2021 7:31 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

That's killer! I've had a few jb weld type of fixes that have held up well and some not so much. I apologize for laughing when I saw the second putty sculpture pic.
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PostPosted: Tue Sep 28, 2021 5:58 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

I’m on my sixth season running a British Seagull outboard engine with a cracked crankcase fixed with 3M 5200 putty.
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4Gears4Tires
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PostPosted: Wed Sep 29, 2021 7:34 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

It's not quite as a vital repair, but I fixed my aluminum thermostat housing with Steelstik. 10k miles later it's holding just fine.

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I'm thinking OP is going to be just fine. I sure hope so anyway!
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Bulli Klinik
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PostPosted: Wed Sep 29, 2021 9:43 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

I waterproofed the screen door on the hull of my boat with Flex Seal. I’m halfway to Hawaii and no leaks! Also replaced my traditional coffee with Sanka and feel like 100 bucks!

Good luck with your repair.
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PostPosted: Wed Sep 29, 2021 9:49 am    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

You do know that that Hawaii is pretty strict about Covid. Once you get there, expect to quarantine yourself and have a proof of a vaccine. If not, they will have you turn back. Very Happy
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PostPosted: Wed Sep 29, 2021 3:34 pm    Post subject: Re: Crack in the Case meet Devcon Titanium Putty - Part II Reply with quote

I think you need to enter “ metaphor” into Waze…..
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