See full version: How to Repair a Cast Aluminum Crankcase
Use a degreaser and a wire brush to remove grease and dirt from the crankcase. Apply degreaser to both the inside and outside of the crankcase. This comes as a thick liquid you pour on and spread with a cloth. Scrub all surfaces you have applied the degreaser to. Pay particular attention to the areas where you will be applying heat as you repair the crankcase. Rub off the degreaser with a clean cloth, and rinse the crankcase thoroughly with soap and water.
Cut a piece of scrap aluminum to cover the hole. Do this by using “C” clamps to clamp a sheet of aluminum to a work table. Use a circular saw with a carbide blade to cut the aluminum so that you end up with a rectangle that will cover the hole in the crankcase and extend at least 1 inch beyond the hole on all sides. Rub a candle on the blade of the saw to help lubricate it, but do not melt the wax. The heat from sawing will melt it during cutting, lubricating the blade.
Apply liquid sealant. Car-repair sealant comes in a tube that you can apply to metal parts to stop leaks. Though it is often called a liquid, it comes as a paste. After the solder and the metal have cooled to room temperature, apply sealant to the inside seam by squeezing the tube as you run the tip along the seam you want to seal. It will form a tight seal to your metal seams on your crankcase repair job. [links]
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Unfortunately, I forgot to take a picture before I started to clean up someone else's FIRST attempt at welding this some time ago (which didn't hold at all). I think the culprit might be the guy below because it looked a whole lot like pigeon $hit!! haha here
It is my buddy's lower unit on a boat he just picked up. The engine has just been rebuilt and purrs like a kitten, but there is some damage to the lower unit that I have been elected by unanimous vote to try and repair.
Having said that, I might not do much better! I am working with a Millermatic 211 and a Spoolmate. Wish me luck!
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