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[T3] Volkswagen Metallurgy 101


Okay, I need help from those in the know (in other words, a guess ain't
gonna
help me).

I have a very, very, VERY fine crack in my case.  It's so fine that it looks
like a very thin scratch in the case more than a crack.  Anyway, after
tearing
away the sheet metal and inspecting the oil cooler (because that's where I
had
thought the oil was coming from) and finding it [externally] dry I
discovered
this neat little crack.  Looking down on the engine at the top, rear-most #4
head stud where it enters the case is where the crack starts and it travels
up
and rearward (towards the generator).  The crack doesn't start *exactly* at
the
stud, maybe 5mm or so away, but it's length is about 1-inch.  And yes, after
thoroughly cleaning the area and then running the engine (ya know, the fan
really pushes the air!) I could see the oil seeping out of the crack like
blood
from a paper cut.  The oil is NOT being sprayed or squirted from any other
place, I KNOW this much.  The crack appears to be directly on the oil galley
that feeds the [stock] oil cooler.

So, I need to have this welded because I'll be damned if I'm gonna spring
for a
new case and all the work ($,$$$.$$) involved.  A good bead over the crack
should take care of it.  Can anyone tell me what type of welding will be
needed
(TIG, I'm assuming, but maybe MIG?) and the makeup of the case so the proper
filler material can be used.  The case is a late model T3 case.

Help.

   Toby Erkson
   air_cooled_nut@pobox.com  <-- Please use this address for email
   '72 VW Squareback 1.6L bored and stroked to 2.0L, Berg five-speed
   '75 Porsche 914 1.8L, ORPCA member
   Portland, Oregon, http://www.pobox.com/~toby_erkson/

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