Broken bolt flange on heat exchanger, Can it be welded back on? Options

[DC_neun_vierzehn]

During reinstall of a freshly rebuilt motor we discovered one of bolt flanges (also called dog ears?) on the driver's side heat exchange was cracked at the weld. We decided to proceed with installing knowing that I would need to get it addressed soon. Well ... that flange completely broke off when mounting it.

I have no experience welding nor do I own the welding equipment - my question is can that be welded back on good as new ... or do I have to replace the exchanger?

The heat exchanger is in great shape with no signs of rust or leaks anywhere. So it would be great if I can have it welded vs. needing to replace.

Thanks in advance.

[DC_neun_vierzehn]

Sharing an update on my repair process so that others don't make the same mistakes ...

I found a metal shop nearby that would TIG weld all 4 ears on my drivers side 2.0 HE for $95 (it's the hourly rate and their minimum). 1 dog ear was completely broken off, 2 were still attached but starting to separate from the HE, and the 4th ear was fine but they wanted to reinforce to prevent it from tearing in the future.

I picked up the HE a couple of days later and got under the car to mount it. Problem: the dog ears weren't lining up with the head studs. They must have shifted a hair when they were re-welded. I instantly wanted to kick myself for not dropping off an old head with the HE.

FIRST LESSON LEARNED: when taking a HE to have the dog ears re-welded, take an old cylinder head with you so that they re-weld the dog ears to line up with the studs.

So I took the HE back to the shop w/ an old head. I was told that my heads were identical (same castings - that the only difference was the PS had the head temp sensor hole) and that it didn't matter which head I took them. They said they wouldn't charge me since the mistake was on their end not putting the dog ears exactly where they needed to go (but how could they know w/o having an old head)?

I waited in the shop lobby while they re-welded HE for the second time. I got the HE home and got under the car to mount it and the dog ears were still not lining up with the studs. They were actually more off than the first time. However, it fit on the old cylinder head I took them (which was a PS head).

SECOND LESSON LEARNED: when taking a HE to have the dog ears re-welded, take an old cylinder head from the same side as the HE with you and make sure it's the right side head for the HE.

Just dropped the HE off at the metal shop for the 3rd time (I'm sure they're going to charge me this time). I'm learning lessons the hard way.

Thought I'd share so that others don't have to endure the same humiliation, waste of time, and expenses.