Your simplest solution would be to grind a moderate bevel on the loose
piece, get it welded to the extent possible, and then caulk the whole seam
with 5200. Don't go hi tech. - Bill
wrote in message
...
My outboard, 20hp Honda, jumped off my transom yesterday and hit the
pavement at 20-25mph. No critical damage but knocked a gapping hole,
the size of a golf ball, in the cast aluminum lower pan, the one below
the power head, next to the tiller handle. Fortunately, I have the
knocked out piece and it fits back in the hole perfectly. My first
thought was to have it tig welded. But it's in a really tight place
and I doubt I'd get a good weld without removing the pan which means
taking the whole power head off. I could tack weld it but that'd leave
a crack that could leak splashing water, not to mention look kinda bad
(as if it doesn't look bad enough).
So now I'm thinking about just using epoxy to glue it in. Mind you,
it doesn't need to be terribly strong. On the other hand, I don't want
it to fall out by just jostling either.
Anybody ever tried epoxy to glue cast aluminum parts back together?
How well will it hold? And for how long?
Thanks in advance,
Phantman

"Bill Kreamer" wrote:
Your simplest solution would be to grind a moderate bevel on the loose
piece

Actually, all the jagged edges match up perfectly and the piece fits
back together like a jig saw puzzle. Held in place, you can barely see
the seam where it fits together. I was thinking it'd be better to glue
it back just the way it is. Am I wrong for a reason I'm unaware?

get it welded to the extent possible, and then caulk the whole seam
with 5200.

In fact, I'd received that very advice at the coffee shop this
morning. Except in reverse order. Stick it together with 5200 (I was
told it's a Urethane based product) to bond and seal it, then
tack/spot weld it where possible for added strength.

Don't go hi tech

..... uh.... I dunno Bill, around here, 3M 5200 IS high tech lol!

Thanks :-)

PhantMan