At the same time I did this:



I also did this:




however whilst replacing the sump in a French campsite with the car precariously balanced on a scissor jack I didn't spot it and blamed the resulting oil leak below the sight case on the sump gasket being re-used too many times.


Repair options:

1) Proper weld - heard it might be a pain as the cast aluminium is tricky to weld
2) Those sticks you see at shows that you use with a gas torch - i.e. www.durafix.co.uk (any cheaper better places to buy - they are approx £25 for 5 sticks from there)
3) Bodgetastic chemical metal.

It's not the best place for damage as it's affecting the mating face of the sump.

The case is being removed anyway as I have a gearbox issue.

Which would be the best way to repair - anyone else done similar recently?

Any decent welder should be able to TIG that up in a jiffy. I've had cast alloy parts welded (e.g. bellhousings) with no problems.

"... with the car precariously balanced on a scissor jack..."



Wasn't precarious enough to prevent the rest of us pissing off to do this...



PS... weld then file the face, if the rest of the engine/box is OK as discussed elswhere.

The casing material will weld up really, really nicely, anyone with a TIG and some patience should be able to sort it out. It's only the rather poor sump material on some engines (GSXR's for example) that gets a bit marginal on welding quality, I just see slag rise to the surface of the weld pool and then spatter.