How do I weld this? Engine block.

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I have a John Deere 4 cyl diesel that threw a rod.  Bought a machine knowing the engine was bad.  To repair the damage I now need to apply some filler to the block.  Bottom of the sleeve where the O-ring seal between the block and sleeve, has some chips out of the grooves.  It is a little too much to fill in with JB weld. What i need to accomplish is build in the groove that the rod made, without filling in the machined groove that the O-ring needs to seal.  My plan is to fill the machined groove in with some carbon from gouging rods, use pencil tig torch to reach the area and use ??? stainless filler rod to deposit filler.  I have a huge selection of filler.  What to use ? im thinking 308-309 maby?  I will need to grind down any high spots and any small pits can be filled in with JB.  The largest chip to fill in is @ 3/8 " wide and 1/8" deep.  These are small deposits, just little to large for JB alone.  Please realize when I say JB I will really be using Belzona  (http://www.belzona.com/en/products/1000/1311.aspx). I have used this before and  it is the  only product recommended by Caterpillar for this type of repair.  Anyone please chime in.Last edited by Daring1968; 04-08-2014 at 10:12 PM.Reason: Forgot to add picsLincoln MK 250, Syncrowayve 351, Cutmaster 151, SA 250D, bobcat 225  and want more.4 Daughters, 6 cats, 1 dog, 1 wife and don't want anymore.
Reply:Well the way I see it...The welding is the easy part....The machining is another story....You're not going to just weld here and there and call it a day...This will get involved.....zap!Last edited by zapster; 04-08-2014 at 10:39 PM.I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:For cast TIG welding 316L is best.
Reply:it's an O-ring seal, all i need is a dab to fill the larger part of the missing material.  any deposits above surface I can take down with die grinder.  I'm concerned about how filling the groove with carbon will work.. I have tested this theory and on flat plate with groove cut in it. It works pdg.  Flys out as soon as you touch it with grinder. BTY a new block is$700.  To line bore and cut grove is 600.  Hoping to save block.  Just need a dab in 2 PLACES.Lincoln MK 250, Syncrowayve 351, Cutmaster 151, SA 250D, bobcat 225  and want more.4 Daughters, 6 cats, 1 dog, 1 wife and don't want anymore.
Reply:Once you add the heat of welding its going to change in size/dimension . I would assume that even a small repair should have an effect, correct? If its a critical area, as it sounds to be, I would think it would all have to be squared away by a machinist, or someone really good with their mic sets.
Reply:Do you have a torch? You can braze it? That's a lot gentler on cast iron (assuming it cast iron not steel) heat wise and you can probably control it with carbon the same way. I know we use carbon blocks to dam flat spots when filling a ding. Here's a good video on brazing a cast repair:
Reply:Why can't you fix it with epoxy?
Reply:The pitted area is corrosion, rust, that area has little iron but a lot of carbon left behind. Makes it really tough to get anything to flow in. I'd try ni99. With enough epoxy it will probably seal. Best option would be to make sleeves, bore area out and install them, but if a block is 700 it wouldn't be cost effective.PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:I weld alot of cast iron , that is not the best place for welding . There is a fellow in SD in the old hub city  machine building that makes repair sleeves for almost any sleeve engine, I use them. With a cylinder boring bar , bore the block to fit the repair sleeve , put repair in bore , use driver plate to drive repair in place , and wahla you are ready to install engine sleeve.      georgeIdealarc 250 , sae 600 lincoln m/g, many torch sets,2 sub arc machines.   5 milling machines,6 lathes,planer , 3 surfacegrinders ,cyl grinder, automotive machine shop. http://www.georgemillermachine.com/ http://www.imageevent.com/gmachine
Reply:It is a diesel engine, the pic is with sleeves removed, area to weld is where 2 O-rings seal.  One to keep oil back and one to keep water out of oil. The rod flopped around in there a couple times before shutdown, that's why chips missing.  Epoxy can bridge the chips but the shape of it would be very weak, surface area vs bonding area to parent metal. As I said I only need to put a dab in there to give the epoxy something to hold on to.  I have fixed pitting due to electrolysis before and not had problems. The groove filling in is my major concern.  To bore that groove back in, the boring bar for that is more than most Mills would cost you.Lincoln MK 250, Syncrowayve 351, Cutmaster 151, SA 250D, bobcat 225  and want more.4 Daughters, 6 cats, 1 dog, 1 wife and don't want anymore.
Reply:The repairs that I am talking about have the oring grooves already in them .   georgeIdealarc 250 , sae 600 lincoln m/g, many torch sets,2 sub arc machines.   5 milling machines,6 lathes,planer , 3 surfacegrinders ,cyl grinder, automotive machine shop. http://www.georgemillermachine.com/ http://www.imageevent.com/gmachine
Reply:Gotcha.  Oversize the bore for cyinder, put grooves in sleeve, much easier. I can try this and if it fails then I just bore it all out anyway. I would like the name of this guy.  That never crossed my mind.Lincoln MK 250, Syncrowayve 351, Cutmaster 151, SA 250D, bobcat 225  and want more.4 Daughters, 6 cats, 1 dog, 1 wife and don't want anymore.
Reply:Daring ,      I have tried twice to answer your PM , looks like I don't know how. look in the web site  send me an email or call me.       georgeLast edited by george md; 04-17-2014 at 11:00 PM.Idealarc 250 , sae 600 lincoln m/g, many torch sets,2 sub arc machines.   5 milling machines,6 lathes,planer , 3 surfacegrinders ,cyl grinder, automotive machine shop. http://www.georgemillermachine.com/ http://www.imageevent.com/gmachine