Crack in engine block, repairable?

[Topbuzz]

I have a crack around one of the sump bolt holes on my engine block on my C20LET engine. I used a 8v sump gasket as it made the job a lot easier but didn?t take into consideration about using shorter sump bolts. So doing the original 16v sump bolts up one at a time, the last one, up to torque and then ?snap?.

Thought at first the thread had gone but in fact a small segment of the cast iron block has cracked and it broke out towards the flywheel. It has not gone into the sump area. So no oil can get out of there, but because the bolt hole is only half there, I can?t do the bolt up 100% so it?s not tight enough. Hence oil is slowing dripping out.

I wonder if anyone has repaired a cast iron block before? I?ve tried liquid metal and a helicoil, which seemed to do the job at first, but the segment, broke away eventually. Can you weld cast iron? Or can you braze it?

See pic below, its not very clear (focus not very good) but you can make out, near the 5 end cap, the sump bolt hole and the 2 hair line cracks that grow from out of it.

http://www.topbuzz1.carenthusiasts.co.uk/project/engine_failure/day53_02.jpg

Here?s a close up view.
http://www.topbuzz1.carenthusiasts.co.uk/project/engine_failure/day53_03.jpg

And here?s me inserting a helicoil in, but didn?t work :(
http://www.topbuzz1.carenthusiasts.co.uk/project/engine_failure/day53_06.jpg

[C-S_Cormac]

If you use plenty of instant gasget wen replacing the sump i shouldnt see a problem!

Cormac

[LiD0N]

i used the 8v baffle on my 20xe and didnt realise u had to use shorter bolts.. luckily i only snapped the head of the bolt and didnt damage the block..

[Topbuzz]

If you use plenty of instant gasget wen replacing the sump i shouldnt see a problem!

That may or may not work. I would still be concered about that bit of broken metal segment which is VERY close to my lighend flywheel. The metal segment dosn't move much either, so I don't know how far it goes up the block.


luckily i only snapped the head of the bolt and didnt damage the block..

There is also an issue with the amount of crap up the threaed hole and the tolerance (deepth) of the hole when it was drilled at manucature. I think I was luck and had a shallow hole, plus a long 16v sump bolt and the think decided to crack.