bjly92

Hey your 2 cents is valuable to a guy like me. I have not posted the minimum requirements to send a private message. Would you care to explain the costs to make this repair? Not sure if this is allowed in the forum but I can be emailed at binjimmyly@gmail.com

Hmm seems to be a lot of controversy, Pinning seemed like the safer way to go but I was also worried that if the pins dont hold then we just weakened the crack further, as mentioned in my original post I have only heard of this technique recently. Welding seems like the more permanent solution but I am worried about the heat. Does anyone know if it would be affective to stuff a wet rag or bag of ice in the cylinders while welding the aluminum to help keep them from warping? or would they just be more prone to warping because of the large temperature difference? I'd also like to take the time to thank everyone for helping me out with this. Of all the forums I have posted on this is the only community that has helped support me rather than come up with clever ways to tell me my block is junk.

Thanks, I'm not sure I can afford another machining job. I know halfass repairs are just that, I hope to find a decent solution for cheaper Do you think welding would affect the cylinder shape? It has a cast iron sleeve but I've spoken to welders and they tell me there's no way to control the amount of heat they put in. I was hoping they could just do multiple tacks and give it time to cool. Oh yes that's definitely why I decided to do the rebuild. The ignition systems can be swapped out for an automotive ignition system as well. It looks like the previous owner overheated the motor. Probably with lack of maintenance with the impeller. That's what probably caused the scoring in the cylinder and cracked block.

Hey so this is my first post on this forum. I have an interesting problem and I just need to help find a solution. I started my first engine rebuild project, I thought it would be fun and it was... until it wasnt. I am hoping to find some answers among a community that has experience dealing with rare engine blocks where rebuild is the only option, because i have spent so much money on this block already and at this point I just want to make it work. Now let me explain. This aluminum block is on an outboard motor, yes its for a boat. I tried with the boating community but they only gave me answers which I already know. I needed to think out the box, hopefully someone here has dealt with a block deemed unsavable and somehow saved it. It is a 1971 Chrysler 105HP 2 stroke inline 4. The engine ran, ok... I knew something was wrong so I took the head off and saw that cylinder 2 had some pretty deep scratches. I inspected the other cylinders and they were fine. Prior to this I did do a compression check and cylinder 2 was off by about 10 PSI. I thought a rebuild was something I was willing to challenge myself to do. So I took it apart and sent it to the machine shop to see if it was savable. The machinist took a look and said it was worth the rebuild and he would disassemble the rest of the motor and get it done for me (this was my mistake) I waited weeks past the deadline and finally got the block back along with the new parts. All together it cost me $1800 CAD. After I paid the machinist told me they found 2 cracks in the cylinder but it was fine because it was on the exhaust stroke and it would still run, they could resleeve but it wasnt worth it. I took it home to inspect it further now that everything was cleaned up and I found everything to be quite concerning. There were 2 cracks in the sleeve right under the exhaust ports in cylinders 2&3. it cracked all the way through to the aluminum block. On the exhaust side of the block I found 2 more hair line cracks... Now if I had known this from the start I would have never proceeded, but now all the money has been spent and I just want to put it back together. All I want to do is run it until it dies, I dont live near the ocean and on top of this I will have a trolling motor and I will be able to get back to shore. it is not a safety concern. This engine did run with these cracks and some deep scratches in the cylinder so I'm actually pretty confident if I slap it back together with these damages it will run, the cracks are under the exhaust port facing the crank, the compression side of the cylinder is undamaged and thats probably why the engine ran fine. I just want to try and squeeze a couple extra seasons out of it until I can afford a new motor since this one bled me dry. I know the engine block is junk, I know it wont last as long, I know that if I saw the cracks I should have spent the money on another motor, and finally I know this is not an antique automobile. I just need some help. What can I do to make the most out of this shitty situation? I have gone to a welding shop and they agreed to weld, but I am concerned the heat will warp the cylinders and make everything trash. I've seen crazy things like epoxy repairs online... but Im not sure how well that will hold against the exhaust the of the engine. Finally I've heard of some old school engine rebuilders using cold stitches, but I have not heard about that until a couple days ago. Anyone with some knowledge would be greatly appreciated... and once again sorry for posting on this forum with a boat question.