7.3L powerstroke block

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ok I was given a free '97 Ford f250 with a powerstroke, that had low compression in cyl 6. so I diagnose that it needs a new block.  I ordered a goo used short block off of ebay. and they did a crappy job of crating it.  (they wrapped it in two cardboard boxes and threw it on a wooden crate with some rope to hold it on.  The fork lift forks at some point had knicked the top  deck of the block in 3 different spots,  all smaller than 1/2 dime size.  and one of these is right on the edge of a cylinder, so I dint think the head gasket would seal.  What would be the best way to weld it  (cast iron) and could it be done with my 100 amp wire feed?  flux core, solid wire?Thanks in advance and sorry it was so long.
Reply:No recourse with the seller?  No inspection before accepting shipment?I think a repair is left in the hands of an EXPERIENCED block welder, and he will almost certainly use a TIG for the ultimate control between heat and filler.What caused the low compression on the first motor's #6?
Reply:I do not have the time to deal with this through the other companies as I need my work truck up and running.  The previous engine went south on number 6 cylinder because a ring got a little bent out of shape, and ended up tearing into the cylinder wall beyond boring it out to a larger size.  so instead I bought something I might be able to sell a few parts from in the future (ie extra crankshaft, camshaft gears, etc..) to make up for the cost of the short block, and basically have a new engine when all is said and done.
Reply:Originally Posted by mr2turbo7... ended up tearing into the cylinder wall beyond boring it out to a larger size...
Reply:Last I checked, it was about $90 bucks a hole to have a block sleeved.  That seems pretty reasonable to me.
Reply:Run a flat file over the deck lightly and see just how bad it is. Compare different brand head gaskets. Maybe the nicked areas are not so bad or critical. You may be able to gently peen down a "ridge".If your a gambler, and you think the fire ring will have some crush,  build up the nick with copper paste and run it.I once repaired a high hour 3306 Cat that had the block burned out badly between two cylinders. Dressed up the damage and shimmed with copper sheet. It ran for a few thousand more hours without head seal problems.  But... You could probably change three of those Cat industrial  heads in less time than one Power Stroke.Good LuckLast edited by denrep; 09-22-2007 at 09:01 PM.
Reply:mr2~I have a fair bit of experience with the 7.3 Power Stroke...it's actually a large part of my business.I would tear down the engine with no compression on #6...and either have that one cylinder bored over....020 & 030 pistons are readily available...and on an otherwise 'stock' engine, the larger piston/bore will have little bearing on engine balance...that will probably be the least expensive of your options.a hone on the other 7 cyl's...(maybe new rings)...and call it good.---if it was one of 'our' engines...I would absolutely have it sleeved, and then bored/honed back to match whichever piston size you choose.We've built a few dozen hi-performance 7.3's for customers around the country...but haven't had to weld on any (7.3) blocks.We recently did a twin(compound) turbo 2007, 5.9 Cummins, which had a headgasket failure (despite headstuds), and the gasket failure allowed the combustion to jump between cyl's 1&2...which eroded both the block and head...and eventually burned off a valve...we sent that block & head out to be welded (as it had only 10k miles on it), and other than the valve being missing...the cyl bores were fine.Though the machine shop we (previously) used had great confidence in their ability to weld it up, and then re deck the surface...in the end, it was not acceptable, so a new head and block were acquired...IF you attempt to (or have it) welded, a nickel filler MAY be soft enough so that once the deck is surfaced, the welded area will not make the cutter skip across the filled areas.and we usually pay about $80 per hole to have sleeves installed...If you will be keeping that truck/engine for the foreseeable future...you will most likely need (at a minimum) new exhaust valves installed in the heads...take care~Davewww.swampsdiesel.comMillermatic 251Syncro 200