Cracked case. Any repair ideas?

[VW_Jimbo]

So, finally got 30 minutes to myself. Been way too busy this week. I had to let my lead employee go on Thursday. Really throws a wrench in the works, as I then get to complete the work ordered that are scheduled for me and him. SUCKS! On to finding a replacement.

Picked up the case from my welder buddy, Rod. Great guy, with some serious talent.

He did a great job. Told me he had to double the width of the notch so that he could get the welder in the space. Now, I know. That will make it easier on him in the future.

Here are the pictures of the welding.

So, looks like I will run a 1/4” reamer into the hole, taking the weld overflow out. I will follow it up with a series of drill bits to get it out for a 1/4”NPT tap. Tap the threads and install a 1/4”NPT to 1/8”NPT reducer. Then I will bolt the case together, installing my old rubber bearing plugs, into the bearing saddles and pressure test the case, to 100psi.

I get to work all day (bet you can’t guess why), so doubt I am going any further this weekend, so maybe next weekend.

I need some opinions here. Should I remove that oil galley plug at the rear of the case, which is in-line with the repair, to clean it out. My gut says I should just in case some splatter ended up down in that hole. Thinking better safe than sorry. Unless, someone with more experience has another method or thought.

Thanks!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[rodeking]

No question on removing the plug to make sure it's cleaned out. The risks of not doing it are too great compared to the little bit of work involved.

[grandpa red]

[Ebel]

Do you have a milling machine or drill press? If you have a mill start with an end mill. It will cut a round hole. I can see bad things happening with a reamer in a drill press. If you have a drill press I’d use a cone shaped burr. You need to get it round and centered first.

[grandpa red]

Ya it would be best to have a machinist fix it.

If it was mine I could take it to work and use a mill.
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'72 Beetle

[VW_Jimbo]

Thank you to both of you! Always enjoy reading the thought processes of others. It is a great way to learn to look at a situation in a new direction.

I have no milling machine. I would absolutely love to have one, but just have no more room for big machinery. I tackle ALOT of woodworking projects in this same garage. And since I have owned three custom cabinet shops, I have a lot of large stationary machines sitting around the perimeter of the garage. So many that there is no more space. I gave up my workbench to get the washing tank. However, I am in process of selling off a few of my old Rockwell machines. If those sell, I will have the space and the cash for a mill!

So, I have a really nice Rockwell drill press. I like the idea of chucking a tapered grind bit and going for it. You know, I have some a tapered carbide reamer, that I could chuck up and go for it. Once I have a hole again, I am going to drill it out for a 1/4NPT thread, for a brass reducer.

I used one on the spring plate cluster when I narrowed my front beam.

_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[rodeking]

Clean it up by hand with a 1/8 or so cylindrical carbide burr in a dremel or die grinder. Then drill it with the 7/16 for the 1/4 NPT tap. If you do anything in the drill press make sure the case is clamped to the table. I would not use that tapered countersink tool.

[grandpa red]

Yes don't use the tapered bit.
You want a 7/16" diameter for the 1/4 NPT.
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'72 Beetle

[VW_Jimbo]

Well, let me finalize this thread.

Happy Father’s Day to all of you blessed to have children. I spent the morning helping the eldest child purchase a newer vehicle. Spent 5 hours at CarMax! Fun times!

After that, we returned to the house. The wife and kids went for a ride in the new to us car. SO.......I went out to the garage to work on the case.

Here’s is the starting point.

Took the welded case and by hand, with a rough half round file, filed it square to the hole. Then with a round file, again by hand, opened up the hole, almost to the original size. Then with a 7/16” drill bit, chucked up in a cordless drill, 1/8” at a time, all the way to the bottom.

Then chased that drilled out hole with a 1/4”NPT tap. All the way down into the case hole, about 1/8” at a time, pouring some really light oil into the tap openings. I would remove the tap each time and vacuum off the tap and vacuum out the hole. All the way down.

I then took the brass plug and ran it through the die, since it had a tapered thread.

Look okay?

Thank you again. Thank you Scott, great idea!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Igpoe]

Thread sealant?

[VW_Jimbo]

After I pull the galley plugs and clean it good.

Thanks!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[mark tucker]

I would of machined it down to totaly get the crack out and used a push in plug either a disc like vw uses or a welsh plug brass or aluminum. then pick up the pressure somewhere else. just be sure you dont impeach on the flow. I bought a new case and it was cracked at the plug that we pull to do full flow. I machined back about 1" and retaped it, pluged both ends of the oil supply from the pump gally that was now exposed. crack kils if you dont get it fixed.

[FreeBug]

I'd be tempted to ask to weld it up completely, and make the hole and threads all over again from scratch.

But you seem to have it all under control and sorted. Carry on.

[rodeking]

looks great

[modok]

Red threadlocker on the outside and 565 on the inside.
Better than new.

[VW_Jimbo]