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> Need Massive Help, Case failure
Mblizzard
post Aug 9 2019, 05:32 PM
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Ok so some of you may know I am doing the build of my life.

Put the case together for checking fit all went fine everything turned great. Disassembled and found this break in the case at the cam.

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I have a massive amount of money in this case and it is opened for my 102s.

Anyone think of if and where I can get this repaired quickly?
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mepstein
post Aug 9 2019, 05:47 PM
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Ask Ben if it’s something that he can do.

@MB911
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Chi-town
post Aug 9 2019, 06:11 PM
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If you have it welded you're still going to have to take it back to the machine shop to have it checked/honed
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mb911
post Aug 9 2019, 07:32 PM
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It looks like aluminum so most any good TIG welder can do it. I leave for Nashville mid next week so if you wanted me to get at it I would need it Tuesday so I could ship back Wednesday
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Mblizzard
post Aug 9 2019, 07:40 PM
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QUOTE(mb911 @ Aug 9 2019, 05:32 PM) *

It looks like aluminum so most any good TIG welder can do it. I leave for Nashville mid next week so if you wanted me to get at it I would need it Tuesday so I could ship back Wednesday


Bit can you machine it back to being true?
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thelogo
post Aug 9 2019, 10:35 PM
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QUOTE(Mblizzard @ Aug 9 2019, 04:32 PM) *

Ok so some of you may know I am doing the build of my life.

Put the case together for checking fit all went fine everything turned great. Disassembled and found this break in the case at the cam.

I have a massive amount of money in this case and it is opened for my 102s.

Anyone think of if and where I can get this repaired quickly?




Your scaring me

Maybe their is a suabru conversion in your future
(Where the long block only cost a few hundred bucks)
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Larmo63
post Aug 9 2019, 10:42 PM
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Just do a /6 and get it over with.
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90quattrocoupe
post Aug 9 2019, 10:52 PM
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Sorry to see this.

It can be welded up. Maybe a little extra material welded to the back side.

Then have the cam bore can be rebored.

Greg W.
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Valy
post Aug 10 2019, 01:41 AM
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QUOTE(Mblizzard @ Aug 9 2019, 04:32 PM) *

Ok so some of you may know I am doing the build of my life.

Put the case together for checking fit all went fine everything turned great. Disassembled and found this break in the case at the cam.

I have a massive amount of money in this case and it is opened for my 102s.

Anyone think of if and where I can get this repaired quickly?

It can be repaired but not cheap as you need to weld and rebore the bearing seat.
But,do I see a hairline crack between the cam bearing and the left pushrod tube hole?
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Superhawk996
post Aug 10 2019, 02:54 AM
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Slow down. Desperation and trying to do anything quickly at this point will only lead to more problems.

Anything can be fixed with enough time and money.

Question is do you have enough of both?

Old joke is you can have only two of the three.
Quick job
Affordable job
Quality job

If you want affordable repair and a quality repair it won't be quick.
Want a quick repair and don't want to spend money, it won't be quality work.

(In no way am I referring to Ben - he will do quality and will do affordable to help a member I'm sure. But the machine work isn't quick)

Think long and hard about trying to save this case. At a minimum you will need to line bore the cam. After welding the cam I'd closely remeasure the crank bores for deformation. Highly likely you would want to line bore the crank too in addition to the need to line bore the cam.

Line boring cases is not for the faint of heart. I know it is commonly done but honestly it is hard to do it right and maintain proper dimensional relationship between crank and cam bores. Even at the factory they dealt with this by select fitting cam gears to take up any dimensional variation between crank centerline and cam centerline.

Are you ready to consider rechecking the cylinder openings too after welding?

After all that - a new case looks better and better.

I am so sorry that you're in this situation. I can feel the pain and anguish, and I've been there before too!
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IronHillRestorations
post Aug 10 2019, 05:25 AM
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Easiest thing to do is get a new/different case
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Mark Henry
post Aug 10 2019, 05:54 AM
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QUOTE(IronHillRestorations @ Aug 10 2019, 07:25 AM) *

Easiest thing to do is get a new/different case


Aww man...that really sucks (IMG:style_emoticons/default/sad.gif)

I have to agree with Perry, get another case, too high end of a build to risk on a shaky foundation.
I've never done this, but as far as having an expensive fuch up building an engine BTDT.
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HAM Inc
post Aug 10 2019, 06:45 AM
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This is a terrible turn of events for Michael. I know how much this build means to him. He's been planning it for years and we've worked together on getting his heads prepped just right for the build.

I'm very sorry for you Michael. It looked like everything was coming together for you to be ready for Okteenerfest.

As for a repair, I would not be worried about this low amperage weld repair distorting the main saddles or the cylinder spigot. In the hands of a talented TIG welder the heat affected zone will not be that expansive. It is possible, however, that it could distort the adjacent lifter bore. It would probably need to be reamed, though that would remain to be seen. But one thing for sure is the cam saddle would have to be re-machined.

I've put a lot of thought into how to facilitate a quality repair of this case, Michael, but I keep coming up with the sad reality that it makes more sense to replace it and move on.
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Cairo94507
post Aug 10 2019, 08:12 AM
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OMG! I am sorry to see that. We all know what it takes to put these cars together and I don't mean just the cash. If it were mine, I would source another case. Sorry to say that. I hope your machine shop will do you right on prepping another case. Good luck. (IMG:style_emoticons/default/beerchug.gif)
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76-914
post Aug 10 2019, 09:46 AM
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(IMG:style_emoticons/default/sad.gif) My condolences. Still trying to figure out how that happened, given your input. If it ain't one thing it's two. Hang in there. (IMG:style_emoticons/default/beerchug.gif)
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Spoke
post Aug 10 2019, 09:51 AM
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What a bummer. How did this happen since it you were only fitting parts?

I have a cleaned 2L case if you're interested.
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ChrisFoley
post Aug 10 2019, 10:45 AM
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I would repair it if it was mine.
Careful build-up with TIG, no use trying to weld the broken bit back on. Then hand grind/file/scrape until a custom made gauge pin barely fit through the bore - always being careful to not cut into the remaining original bore surface nearby.
I wouldn't use a reamer - too much chance of removing material from the other case half.
1 hour for the weld process and another 3-4 hours of hand work.
Tedious, but doable and worth it to recover the investment.
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dr914@autoatlanta.com
post Aug 10 2019, 11:00 AM
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yes it can be welded and align bored, c&j welding HERE does beautiful work, then Goza machine shop has all of the align bore equipment, there is hope mike!


QUOTE(Mblizzard @ Aug 9 2019, 04:32 PM) *

Ok so some of you may know I am doing the build of my life.

Put the case together for checking fit all went fine everything turned great. Disassembled and found this break in the case at the cam.

I have a massive amount of money in this case and it is opened for my 102s.

Anyone think of if and where I can get this repaired quickly?
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Porschef
post Aug 10 2019, 01:17 PM
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QUOTE(ChrisFoley @ Aug 10 2019, 12:45 PM) *

I would repair it if it was mine.
Careful build-up with TIG, no use trying to weld the broken bit back on. Then hand grind/file/scrape until a custom made gauge pin barely fit through the bore - always being careful to not cut into the remaining original bore surface nearby.
I wouldn't use a reamer - too much chance of removing material from the other case half.
1 hour for the weld process and another 3-4 hours of hand work.
Tedious, but doable and worth it to recover the investment.




Wow

(IMG:style_emoticons/default/pray.gif) (IMG:style_emoticons/default/pray.gif)



Sorry to see this, you must be heartbroken. (IMG:style_emoticons/default/sad.gif)
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Superhawk996
post Aug 10 2019, 02:02 PM
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(IMG:style_emoticons/default/popcorn[1].gif)

I see the back and forth on this thread and it is interesting for sure. I want to reiterate again how heartbreaking this is and I feel your pain.

I've been lucky enough to see things from many perspectives in my career.

I've been involved with a race program with corporate funding at the highest professional levels and I can say without a shadow of doubt that I've seen extremely expensive race parts scrapped for minor flaws that are seemingly insignificant. . . Just to be absolutely sure that we had the best chance of winning a race.

I've also been involved in SCCA club racing and have crewed on teams that were run on nothing more than a desire to be there. Each crew member funding their own way. I've seen wrecked cars and motors rebuilt overnight with little more than bailing wire and duct tape in order to compete the next day. I completely understand Chris' perspective that it could be saved. It absolutely could.

The toughest decision is to decide which end of that continuum you are going to be on.

None of us can decide that. It is a deeply personal question dependent on the end goal, time, money, and resources at hand.

I wish you the best in this tough decision. I am so sorry to see you go though this. (IMG:style_emoticons/default/sad.gif)



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