Have a 4g63 in a 04 evo in my shop. Balance shaft delete shaft came out of the oil pump and the big end of the shaft got hit by the crank once into the wall of the block in the balanceshaft journal of the block.

it made about a 1" x 1" square hole through the block. When the shaft fell out and did that, we had pulled oil pan, saw it came out, so we switched to a stub shaft, put it all back together an started it up. ran fine for about 5 mins idling to warm up until we noticed so much smoke from under the turbo, and finally saw the hole in the block.

dumb question... but is it possible to patch/repair the hole? My shops neighbor is a custom welding company, he took a look and said he could patch it up with some kind of steel that would mate to the cast iron well.

Is this something that could be done to salvage the block? this was a brandnew stock rebuild motor with not even 1 mile on it. Car had warmed up to go seat the rings, and heard 1 pop noise while driving and we killed the motor quick enough. everything else internally is perfect, car still runs even with the hole.... just wondering if it is something that is possible to fix and keep the motor or do i need to yank it and swap a whole block again.

i know a new block is the correct route but just wondering if somehow its salvagable and can still be used since this car has balance shaft delete and nothing else really spins or put pressure in that area aside from crankcase pressure.

Thanks... just figured id throw out some odd scenario to see if its possible. I have access to a few highly trained welders and machine shops if it is possible.

 

It has been twenty years since I was in the heavy equipment business but even back then there were some industrial products that would patch that hole and not even require welding. Find the right industrial supplier and he will fix you up.

 

The block can be welded no problem.

 

I have seen JB-Weld on a block, so yeah. Weld it!

 

lol well it'd ad least be welded by a professional to make sure. tho... if you cant duct it... **** it.

ill wait to see some more replies here and see what kind of consensous it comes out with. maybe we can get by without doing a whole new bottom end.

 

nothing ventured nothing gained

 

This is what we are looking at right now.

 

as a certified welder, tell him to go stupid slow because the block will expand at a different rate then the pistons because heat is being applied outside of the block as opposed to being run where the heat comes from the inside.

it would be best to take out the pistons and crank then weld the block and put it all together again. and if your going to do all that work then replacing the block makes more sense.

 

even on that section thats not really near the cylinder walls?

 

if whoever is doin it has welded cast before he will know what to do .

 

in my opinion you would at the very least need to brake cleaner/degrease the inside of the block near the weld so it does not out gas. Not sure if you can do that with the oil pan in place, seems like a large enough area to get a cloth soaked in cleaner in there to rub it down. I am no certified or professional welder ..... amateur at best lol.

 

Might just be me, but I would never weld my block =/

 

Pans coming off tonight or tomorrow morning to inspect and clean up.

had a few people stop by that said it should be okay. Got another buddy thats a boilermaker welder thats going to come by with all his gear to tackle it.

 

Weld it. What have you got to loose?

 

^mmmmmm well if everything else is in good shape quite a bit. i would go with a new block, but thats just me. if you do weld it post pics and let us know if it works out