Broke off chuck of the case

[IXL2Relax]

How about creating an external aluminum strap/brace that runs long enough to get past each break point. Drill holes in the middle of the brace to weld thru to attach it to the top of the broken piece, as well as welding at each end past the break point. That in addition to rewelding the actual breaks.

It's hard to believe that section just broke off... I would have expected some downward pressure on the starter that overstessed that part of the case.


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[Napawineguy]

The problem im having right now, is that the starter is not sitting right because of whats going on there, so when the solinoid pops out its barley contacting the gear and breaking the tips of the gear off, i ended up with a bunch of tny ends in my oil when i drained it

[brucstoudt]

this makes me think the repair was done with the motor still in the frame?poor access limited space poor alignment warping from the weld = what you have there.personally i would have myself attempted it that way,no foul there i'm an AWS certified welder so i've seen alot of unusual situations.only this seems to have less than satisfactory results.

[Tomcatt]

Originally Posted by Napawineguy

The problem im having right now, is that the starter is not sitting right because of whats going on there, so when the solinoid pops out its barley contacting the gear and breaking the tips of the gear off...

And breaking the case. You need to fix the starter issue first or you'll keep breaking the case repair.