Abby’s Guide > Outdoor Power Equipment (Lawn Mowers, Snow Blowers, Chain Saws and more) > Discussions > Cracked aluminum crankcase repair options?

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GtWtNorth

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Cracked aluminum crankcase repair options?
Original Message Nov 21, 2012 9:50 pm

I picked up a nice clean 3000 watt generator from CL with a small crack in the bottom of the crankcase that allows the oil to drain out slowly (fell off the back of a pickup). Any one have any suggestions/experience for repairs other than welding? I'm hoping maybe Devcon, JB weld or some metal epoxy?
The motor is a clone, Lifan 168F2 196 cc and parts seem to be quite rare. The manufacturer will ship a replacement crankcase for $62.00 + transport, which is probably close to what I would pay to have it welded.
Thanks

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jrtrebor

Location: Michigan - 3 hours north of Chicago on the lake
Joined: Feb 10, 2010
Points: 539

Re: Cracked aluminum crankcase repair options?
Reply #15 Nov 25, 2012 5:55 pm

From the photos there is nothing left strength wise.
There is only one rib left and even that one has a crack by the bolt hole.
Boy, I wouldn't even consider trying any kind of fix other than having it welded.
Any welder that really knows what he's doing and how to mig or tig weld could fix that.
Then I would also as someone suggested redo the mounting.
If it were me I would mount the engine to a piece of 3/16" plate steel.
Bolt the engine to the plate using the other two currently unused mounting holes
Then remount the engine with the plate attached onto the shock mounts studs.

I've worked on a couple of generators that were mounted like that.
Found it easier to loosen up the shock mounts from the frame as well (all four).
Makes it easier to get them all lined up correctly with the engine mount holes.
If you get them turned even a little off line the shock mounts won't sit correctly
under the engine. In other words the stud coming off the shock mount won't
be vertical. It will be leaning one way or the other.

jtclays

Joined: Aug 7, 2011
Points: 16

Re: Cracked aluminum crankcase repair options?
Reply #16 Nov 27, 2012 7:54 pm

$62 in a heartbeat for me if I was going to use /count on it for service. Flipping it?,........... JB Weld and see ya later.

niper99

Location: London Ont
Joined: Dec 2, 2007
Points: 354

Re: Cracked aluminum crankcase repair options?
Reply #17 Nov 28, 2012 12:43 am

ONLY option i would do is to braze it with aluminum... u can not mig or tig it because the block becomes inpreganted with oil... ive brazed many many blocks (espically tecumseh with thrown rods) that are still holding up to this day...

jtclays

Joined: Aug 7, 2011
Points: 16

Re: Cracked aluminum crankcase repair options?
Reply #18 Nov 28, 2012 1:58 pm

Niper, Not to be rude, but would you be able to braze this for a customer for less than the $62 crankcase replacement?

GtWtNorth

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Re: Cracked aluminum crankcase repair options?
Reply #19 Nov 28, 2012 4:34 pm

Thanks for all the help. I got the crankcase open & on first inspection there does not seem to be any cracking on the inside, so it may be going out the drain hole then through the cracks there. I'll try to find a way to test that theory.
My intention was to flip this unit, so I'll probably try lots of JB then bolt a plate to the bottom of the crankcase to prevent the cracks from traveling further & weakening that bad corner. By the way, the supports at the other end broke off completely (by that's a fairly easy repair) so these things are not very robust for use around a construction site.

Cheers

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hirschallan

If it aint broke don't fix it !!

Location: Northern Hills of NY
Joined: Aug 25, 2005
Points: 327

Re: Cracked aluminum crankcase repair options?
Reply #20 Nov 28, 2012 5:13 pm

GtWtNorth wrote:

By the way, the supports at the other end broke off completely (by that's a fairly easy repair) so these things are not very robust for use around a construction site.

Cheers

These ope aren't meant to be dropped off the back of a truck either.

GtWtNorth

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Re: Cracked aluminum crankcase repair options?
Reply #21 Nov 30, 2012 3:29 pm

It seems like I was lucky after all. I filled the cracked oil drain hole with JB weld and buttered up the drain plug before screwing it in. Nnow that it's hardened, the leaking seems to be stopped(knock on wood). The cracking is limited to the corner base area & didn't propagate through the case.

So I'll close her up & fill with oil to confirm. Let you know how it goes.

Cheers

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mkd55

Location: wisconsin
Joined: Dec 16, 2005
Points: 155

Re: Cracked aluminum crankcase repair options?
Reply #22 Nov 30, 2012 3:53 pm

gtwt! you also could jb weld all the wells(valleys) where the cracks are visible in the pics. i filled the whole cavity adjacent to the drain plug casting.

Bill_H

Location: Maine
Joined: Jan 12, 2008
Points: 354

Re: Cracked aluminum crankcase repair options?
Reply #23 Nov 30, 2012 9:28 pm

I would just Alumiweld it. Should be a lot stronger.

Who the hell let all the morning people run things?

GtWtNorth

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Re: Cracked aluminum crankcase repair options?
Reply #24 Nov 30, 2012 9:44 pm

mkd55, - I may still fill those cavities for the extra support.

Bill_H, I looked at the Alumiweld for a long time but the feedback I've seen doesn't give me a warm feeling. Plus I only have a propane torch so it would take a while to heat such a large mass, if it was possible. Plus I am too lazy to strip it right down to the casting so I'd be worried about how the heat would affect the other components, bearings & gaskets.

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