The hole on the left was drilled and tapped .450 deep and the hole on the right is .750 when we tightend the bolt down on the left wich was to long it broke the peice off. Those holes are to hold the lifter tray down. We figured out that there is .500 of material still left until you would drill into the oil tube, What would you do in this situation? Please help. Thanks.http://www.uploadimages.com/myalbum/9591

 

Maybe you could braze it back together.

 

If you haven't fixed it yet here is what I would do: Drill the threads out of the broken piece and it becomes a spacer that will mate perfectly with the uneven part of the block. Drill the block about 7/16" deep and use a bottoming tap to thread it. Put a stud in the threaded hole that will bottom in the hole. Put the "spacer" on the stud with a layer of green loctite on the face and bore and dial it until it mates. Attach the spider with flat washer, lockwasher, and nut. The loctite will hold the spacer and stud in place if it is removed at a later date.

 

This will sound crazy, but JB weld it. I've done some amazing things with that stuff in the past.

 

I agree, except forget the "JB" part of that.

Just weld it with a high nickel filler material - Either rod or MIG wire. Of course, there will have to be some disassembly before and cleanup after the weld. Mating the parts back into proper position, covering up all the exposed drainbacks and components, then welding it right in place would probably be fastest, almost be the easiest, and certainly be the most robust repair. Pre-heating the area should be no problem, since there should be no risk of damage of any of the surrounding components. It shouldn't take a lot of pre- or post-heating to keep the casting stable, since that is not a high stress area of the casting - The end walls are a lot more critical. If you have a torch with a rosebud tip and even a small MIG, it will probably take longer to prepare the area and clean up afterward than repair it.

If there is only 0.500 below the bolt boss before you strike oil, that's only going to be four full threads even with a bottoming tap. That may not be enough strength to prevent thread failure and further damage.

You could drill through, stud the hole as Supervisor42 suggested, and seal the stud threads with PST. You'd have to be careful about the depth of the stud in the oil gallery so it didn't become an oil restriction to the front mains, and there will have to be serious cleanup after drilling chips into the oil gallery (like pulling all the plugs and hot-tanking the block).

Using a repair epoxy in an oil area of the casting will take a lot more cleanup and prepataion than for welding or brazing, and may not result in a very good bond given the type of break.

 

This is what we did we drilled down .310 or so, the hole is the same depth as the other two and we red loctited a stud in and used the broken peice as a spacer and jb welded it on then put the nut on top to hold the tray down. We had about 4 threads catch on the stud after bottom tapping the hole. The boss originally broke because the bottom of the hole was filled with loctite from when I had the motor built.