Weld crankcase or epoxy?

[kinger]

Well I found my WP leak and its not the seal its the fricken mounting stud for the waterpump housing, apparently its a factory freak and the bolt was mis threaded into the mouting stud that is part of the crank case that the water pump housing attaches to and its cracked. At 26psi I can get a few drops of coolant. Looks like I need to repair this case or get a new one which is a lot of freaking money that I don't want to put into a 03.

What the verdict on TIG welding the outside then filling the hole with epoxy and re-drilling/tapping for the bolt, think that would hold up? If I go through with my big project I want at least 10,000 miles before I have to mess with this sled again. I'm worried that the epoxy would leak into the water jacket and partially plug it and I would over heat the damn thing on the 1 st ride next year. I don't have any pictures of the problem it was the diagnosis from the dealer and they feel confident they can repair it with the epoxy, maybe I'm being paranoid but it feels like a band aid fix. Doing it right and replacing the case seems like it opens up a can of worms also.

Thoughts? They quoted me 8 hours to R&R the engine and fix plus all new waterpump equipment from the housing out. Tempted to try to pull the engine myslef and take it to them for the repair then install it myself. Not sure if I am up for it yet but feeling around for opinons. Thanks!

 

[flainx]

If they have someone who knows how to TIG weld, you should have no problems. It will be just as strong as original. Epoxy isn't the first thing I would use to make new threads but that might be the only option. I would try a Helicoil first. The problem is they might not be able to get one in there. As long as the bolt isn't a main mounting bolt you should be just fine. I don't think there is a lot of weight on the bolt.
8 hours is pretty good if they have to remove the engine, fix the problem then replace everything. It would probably take a normal guy 3 times as long.

 

[BURMAD69]

Seal it up with JB weld, Or at least use it to secure the heli-coil

 

[doc 4 stroke]

i have a updated motor for sale 05 pistons and rings 1500.oo can plus shipping