hole in transfer case help!!!

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Ok so I have a large hole in my transfer case in a 01 dodge Cummins. The front shaft sheared the bolts and knocked a large chunk out of transfer case. Unfortunately its not on a flat surface and it has contour to it. I do not have all the pieces and I really need help thinking of how to fill this hole so I'm not dumping oil everywhere.. I have a precision rig 225 Lincoln and I'm decent at rig welding. The material is cast and maybe 1/4 inch thick..
Reply:how big is the hole ? cast as in iron or aluminum ?
Reply:No biggie. Clean it, clean it and then clean it again. Grind out all the cracks, then have at it. I fix them all the time at work, but this is the only pic I have off one I fixed for my friends race car last year. It had two holes the size of golf balls in it.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Grrr! New format sucks with a phone! Other pic.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:It is CAST ALUMINUM and probably as thick as in the pics above.. But unlike the pics above, it has a 90 degree curve to it where its broken and I'd say if I were to cut the edges and square it I'd have a 5 x 7 inch chunk pissing including the 90 degree bend.. And thank you for the quick responses!! I chose the right website!!
Reply:Take some pics. That should help. I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Use multiple pieces to form the correct contour?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:As far as pictures go, the hole is covered up with cut pop cans and held on with quik steel. So you wouldn't be able to see it. And cutting up pieces and forming it is my only option to repair, right? That's what I was thinking also but then where would I getscrsp cast or new cast aluminum at?? That's my main question as of now.So far great help, thanks!
Reply:You would use sheet material and could use multiple pieces or form a single piece depending on the required contour.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:It would have to come out anyway to fix it, so just pull it out and we'll help you go from there bud. Otherwise it's just a tennis game with words. If it's your daily driver and needs to be done ASAP, your in a pickle then. I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:WelderMIKE is the '' MAN''. I would trade it in on a CHEVY.
Reply:Its actually my wife's DD lol but I plan on doing it this weekend and it being done by Monday. And ya its diffinately gettin pulled out in not bout to o/h that (TIG o/h isn't on my cert card) haha and Duane are you saying to use plain non cast sheet aluminum?? If everyone thinks that would work with cast then its worth a shot
Reply:BD1, if it would of been a Chevy it wouldn't of had enough power to break the front drive shaft bolts off in the first place..lol jk not getting off topic, but anything but dodge is a good choice, I'm a ford guy#6.4 powerstroke
Reply:Originally Posted by stroker221Duane are you saying to use plain non cast sheet aluminum??
Reply:Ok any certain treated aluminum? What should I ask for when I go to get it?
Reply:I love this...Always a good time!You need to fill in the hole and need material..If it fits and it's aluminum use it.Even if it's all filler....zap!Last edited by zapster; 10-22-2013 at 09:21 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:might want to make sure all the bearing bosses are good and true when you pull it and not cracked  cause the Transfer case does allot more then just hold oil might be better off going to the junk yard and pulling a tcase and replacing from what you are saying sounds like you are missing a decent sized chunk of the case my guess would be the front output shaft bearing boss  is cracked to sh*tbut pics will tellLast edited by WeldorWes; 10-22-2013 at 09:30 PM.Miller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Its broke towards the front drivers side.. And these things are hard to find used around here, salvage yards can't get enough of them. And ok I just wasn't sure how regular aluminum would fuse with cast...
Reply:Originally Posted by stroker221Its actually my wife's DD lol but I plan on doing it this weekend and it being done by Monday. And ya its diffinately gettin pulled out in not bout to o/h that (TIG o/h isn't on my cert card) haha and Duane are you saying to use plain non cast sheet aluminum?? If everyone thinks that would work with cast then its worth a shot
Reply:Years ago I was in race car shop that had lots of engine blocks on racking by one wall. They were all "good" spares for the car they raced. Many of them lost a rod or two but just put a hole in the side of the block and didn't hit a water or oil jacket/journal. What they did was just cut out a chunk of metal, epoxy the back side and pop rivet it over the hole on the side of the block.That would be a quick easy way to patch a hole while still on the truck and in less than perfect conditions.If the case is off the truck and clean and ready for weld personally I would just make up (beat with hammer) a over sized patch for the hole and weld it on.
Reply:Ok but I personally don't think I can bend this 1/4 inch 6060 aluminum without snapping it.. If I heat it it will melt, if I put it in a vice and hammer it, it will snap. What are you guys thinkin as far as forming it easily and it being a material that's still weldable to cast aluminum? Thanks