Corvette aluminum block cracked

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I have to tig weld/repair on a newer ZO-6 Corvette block and am not sure of the exact metal composition. It is aluminum of course but it is busted in a criticle area so I need to get the exact filler for tig. Not the old standby rods if at all possible.Anybody know what it is?Links to a racing forum may be a help.Miller Dynasty 700Miller 350P with Aluma-pro push-pullMiller 280 Dynasty with expansion card Dynasty 200 DXMigMax 215 Enuff power and hand tools to create one of anything..... but mass produce nothing!!!
Reply:i believe that block has steel sleeves cast in as piston walls..very tricky.. good luck
Reply:Buy another block, charge the guy for it because the labor and rate on a repair like this is worth the price of a block. If the smallest thing happens afterward, he's going to come back to you on it anyway and you will end up paying for a new one anyway.Oh the things that can go wrong welding on a block like this.  Its one thing to weld up a crack on the outside of an old diesel tractor block but another to start messing with a 0 tolerance high bred animal like this one.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Define "critical area".If its anywhere near the mains, don't waste your time.  You could weld and sleeve if it were a cylinder issue, but even then...LS7 motors are 319-T5 aluminum, as are the LS2's.  Not sure about older generations of the LSx motors.
Reply:Fusion King,  See the reply on the Miller board for your answer.
Reply:Originally Posted by makoman1860Fusion King,  See the reply on the Miller board for your answer.
Reply:Originally Posted by lugweldBuy another block, charge the guy for it because the labor and rate on a repair like this is worth the price of a block. If the smallest thing happens afterward, he's going to come back to you on it anyway and you will end up paying for a new one anyway.Oh the things that can go wrong welding on a block like this.  Its one thing to weld up a crack on the outside of an old diesel tractor block but another to start messing with a 0 tolerance high bred animal like this one.
Reply:Originally Posted by FusionKingI appreciate your input but disagree....if I started using that line off thinking I may as well just go get a job working for the man. People bring me this sorta stuff fairly regular because sometimes I'm at the end of the line as far as they are concerned.People have been welding blocks for many many years.The price is about $3500 and I wouldn't charge quite that much
Reply:Fusion King,Good luck on this one.You mentioned that the crack occured in a "critical" area.  That sorta indicates to me that the failure was due to stress rather than a manufacturing/casting defect.While you're right in your comments about blocks being welded all the time, I don't think you'll find many welding aluminum blocks with a 200A tig.  You've got a great big ol 250lb (or thereabouts) heat sink sitting there looking at you.  Even with a bunch of preheat, I think you're looking at needing everything a Dynasty 350 can produce.Without seeing photos I'm afraid I can't give any more advice.  You did mention that a new block was $3,500.  Who's going to pay the install/removal fees if the block fails again after being welded.While I admire your tenacity, I gotta say I think this is one I would leave to a "specialist" who does this type work on a regular basis.Let us know how things turn out.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Yea i left out a few details because I ran out of time this morningI thought I might have to weld this but my brother will prolly do it himself ...it is 100 or so miles away.  He has a machine shop and another shop had tried to press a sleeve with too much interference and busted the block. He thought he would not have time to do it. It has cracks in two cylinders. Sorry no pics. Thanks for the replies. More details on Miller BTW. 4145 is the correct filler according to Alcotecs welding engineerP.S. Sundown III... sorry you think I am stupid enuff to attempt to weld a block with a air-cooled torch on a 200 Dynasty I do believe my Airco could easily handle it though Not to mention I owned an automotive machine shop for a decade. Some of us do understand how things work despite we are on the internet. I just wanted to get a quick answer by using the forums instead of answering someone elses question for once.Out of 2 forums Supe gave me the info i needed (thanks)Miller Dynasty 700Miller 350P with Aluma-pro push-pullMiller 280 Dynasty with expansion card Dynasty 200 DXMigMax 215 Enuff power and hand tools to create one of anything..... but mass produce nothing!!!
Reply:Next time they should warm the block in an oven and stick the liners in the freezer for an hour or two before installation.My son knows a guy at K-Tech (guys that build the ALMS Corvette motors) to see if he or someone there can offer anything.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55Next time they should warm the block in an oven and stick the liners in the freezer for an hour or two before installation.My son knows a guy at K-Tech (guys that build the ALMS Corvette motors) to see if he or someone there can offer anything.
Reply:Originally Posted by duaneb55Next time they should warm the block in an oven and stick the liners in the freezer for an hour or two before installation.My son knows a guy at K-Tech (guys that build the ALMS Corvette motors) to see if he or someone there can offer anything.