[SkeezGod]

Hello everyone,

I've been trying to wrap my head around this issue and I'm taking my time with it so it can be done correctly for the next owner (not a fan of passing problems to others even though it was done to me)
So I went to attempt some repairs to my vehicle and found out the previous did quite some damage to the thermostat mounting points and I'm at a loss as far as what can be done.

Someone suggested maybe welding a stud to the spot and using that as a new mounting point so I want to know what you guys think? I mean since your the experts and all. I'm referring to the top left bolt. Is it salvagable with an skilled welder?

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[cj737]

You won't be welding a steel but to an aluminum casting The two metals don't weld.

You "can" use a TIG welder and carefully build up the area and then drill/tap a new hole. This is the "right" way to do it, but it takes skills that you probably don't possess based upon your first question.

It looks like the hole in the bottom right might have some ham-fisted damage too? If so, that needs to be drilled out, filled with a TIG, then re-drilled unless you can use a Timesert thread insert to save it.

These types of repairs are a pain in the butttttt. The original cast aluminum is now soaked and caked with grease, grime and God know's what, all of which make welding them a challenge even for the most skilled.

I think the original damage was done by the PO using too long of a screw and jammed it in there (possibly wrong screw/thread pitch too) and cracked that ear. Blind screw holes are notoriously subjected to PO nightmares.

[SkeezGod]

Yes it would have to go to a shop but I really would like to take it to a shop with an experienced welder. I don't have any welding skills whatsoever.

Trying to find the lesser evil before I'm forced to remove the cylinder head and install a new one which would be painful.

Now to find a good welder local that can complete this type of task.

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[Mike Westbrook]

From a mechanic your done needs to be replaced at best welding it up it still should be removed or other gaskets will be screwed up the only hope is if you can drill down and tap a spot for a skinny Allen bolt beside the damage use no gaskets but ultra black ( urethane base ) let it cure 24 hours and hope and pray

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[Louie1961]

I doubt anyone can or would weld it in place, then drill and tap it. You are going to have to pull the head one way or another.

[VA-Sawyer]

Where are you located?

[SkeezGod]

Yup that's what I'm thinking, I'd rather swap the engine than remove the head. I've never removed a head but I've swapped an engine a few times so I'm more comfortable with that. Ironically I drove this car for 6 months back and forth to Philly until I started having cooling issues which lead me to the thermostat which in turn lead me to this mess. I almost want to mount it the way the last owner did. Wasn't the best but it worked

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[SkeezGod]

Where are you located?

I'm located in Maryland not to far from VA or DC. Kinda in between

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[SkeezGod]

Never updated this but I ended up getting The car up and running with a little bit of ingenuity, prayer and jb weld. Been running like a champ ever since.

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[Lightning]

Handyman in Two Cans FTW!

[Olivero]

I was going to pipe in and say it's definetley doable. I don't doubt I could do it.

I've had to do similar repairs on cast iron, but that was a roof drain, in place, welding the broken pieces back together, drilling and re-tapping

I've done engine and oily welding before, it's doable, so if it comes up again, it CAN be done, just need to find a guy that's willing to go through the hassle, it's not easy by a long shot and it takes patience but it's doable.

[Poland308]

Sometimes a chemical weld is the answer.