Hole in engine block...repair or scrap?

Drgyver · 12-01-2016, 09:08 PM

Hey all,
Just picked up a 2003 Ezgo Workhorse 1200 cheap. Guy I bought from had no info on damage just saw a hole in side of crankcase and was told to "get rid of cart". Cart has 1200 hours on it. Been tearing it down and removed engine in anticipation of clone swap. While turning clutch/crankshaft by hand, can hear valves releasing and can see crank turning through hole. Can I just have case hole welded/patched? Has anyone ever done this? Hole is about the size of a quarter. Wondering if the chunk is in engine or blew out. Opinions?

meimk · 12-01-2016, 09:15 PM

If you open that up I'm sure you'll find the broken remains of what ever it was that blasted the hole in that block. Theoretically it could be repaired, but would probably end up cost far more than you proposed clone swap.

FluxCapacitor · 12-01-2016, 10:34 PM

Welding cast aluminum can be very difficult and would likely result in crud inside the motor. You would be better off trying to seal it up with JB weld...if by some MIRACLE that hole was not a result of major engine failure AND there isn't major damage or debris inside the motor.

Quite frankly I would be VERY surprised if that motor works out with a simple JB Weld patch. Also, I would have to open that up and have a look inside before trying to run it.

Please keep us updated.

Drgyver · 12-01-2016, 10:45 PM

Thanks for the replies guys. I was thinking the same things and never really tore an engine apart before...I am, however, comfortable doing any of the needed fabrication to do the clone swap. I guess I could try to open this one up for learning experience, if nothing else!

meimk · 12-02-2016, 10:08 AM

I would say: open it up! It's free. It's educational. It might even give you a decent story about when "(fill in the blank) broke apart and blew a hole clean through the block".

Drgyver · 12-02-2016, 10:20 AM

Well I removed oil filter and a little water and very dirty oil flowed forth

Along with this:

Looks like the rod was the culprit of the hole after all!

Oh well, back to plan A, off to HF. Just got a coupon in the latest flyer for $299 so figured that was a sign

May just tear this apart for a winter project/learning experience.

MILLERTIME · 12-03-2016, 01:43 AM

You can braze aluminum, I get my rods at Harbor Freight.
https://www.youtube.com/watch?v=CCycms8wVC4

MILLERTIME · 12-03-2016, 01:46 AM

A trailer I made for my RC boat.

Shepard · 12-03-2016, 09:18 AM

Your going in the right direction heading to HF. Skip the JB Weld -- its not truly oil resistant. Gas destroys it - oil will eventually leak its way through. Open up your old engine to learn from it. With the rod cap broken off as the picture shows -- the rod most likely destroyed the cam slapping into it. If it were some antique you might want to try welding up the block. In the long run you'll have more into attempts to fix it then its worth. Go Predator or better yet go VRX 460.

raydhd · 12-03-2016, 09:46 AM

You are at the point where the decision should be made "what is my end goal for this cart ? ". If it is just to drive around at stock speed the stock clone is the answer. BUT as Shepard points out if more speed is the goal the vegascarts VRX 460 is the answer. All sorted all built good for 6000 rpms. Along with that just adding speed equipment to a stock clone will cost as much or more than the VRX 460, but will have the weaker 7 bolt engine block versus the much stronger 10 bolt VC unit. It all depends on what you want out of the cart.

12-01-2016, 09:15 PM	#2
meimk Gone Wild Join Date: Jun 2011 Location: Northern Indiana Posts: 2,823	Re: Hole in engine block...repair or scrap? If you open that up I'm sure you'll find the broken remains of what ever it was that blasted the hole in that block. Theoretically it could be repaired, but would probably end up cost far more than you proposed clone swap.

12-01-2016, 10:34 PM	#3
FluxCapacitor Gone Wild Join Date: Sep 2016 Location: New Jersey Posts: 227	Re: Hole in engine block...repair or scrap? Welding cast aluminum can be very difficult and would likely result in crud inside the motor. You would be better off trying to seal it up with JB weld...if by some MIRACLE that hole was not a result of major engine failure AND there isn't major damage or debris inside the motor. Quite frankly I would be VERY surprised if that motor works out with a simple JB Weld patch. Also, I would have to open that up and have a look inside before trying to run it. Please keep us updated.

12-01-2016, 10:45 PM	#4
Drgyver Not Yet Wild Join Date: Nov 2016 Location: Ct Posts: 21	Re: Hole in engine block...repair or scrap? Thanks for the replies guys. I was thinking the same things and never really tore an engine apart before...I am, however, comfortable doing any of the needed fabrication to do the clone swap. I guess I could try to open this one up for learning experience, if nothing else!

12-02-2016, 10:08 AM	#5
meimk Gone Wild Join Date: Jun 2011 Location: Northern Indiana Posts: 2,823	Re: Hole in engine block...repair or scrap? I would say: open it up! It's free. It's educational. It might even give you a decent story about when "(fill in the blank) broke apart and blew a hole clean through the block".

12-03-2016, 01:43 AM	#7
MILLERTIME Gone Wild Join Date: Feb 2009 Location: Sanger, Ca. Posts: 1,689	Re: Hole in engine block...repair or scrap? You can braze aluminum, I get my rods at Harbor Freight. https://www.youtube.com/watch?v=CCycms8wVC4

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

12-03-2016, 09:18 AM	#9
Shepard Crazy Ole Man Join Date: Jan 2016 Location: Owego NY Posts: 2,758	Re: Hole in engine block...repair or scrap? Your going in the right direction heading to HF. Skip the JB Weld -- its not truly oil resistant. Gas destroys it - oil will eventually leak its way through. Open up your old engine to learn from it. With the rod cap broken off as the picture shows -- the rod most likely destroyed the cam slapping into it. If it were some antique you might want to try welding up the block. In the long run you'll have more into attempts to fix it then its worth. Go Predator or better yet go VRX 460.

12-03-2016, 09:46 AM	#10
raydhd VC 460 CLONE GONE WILD Join Date: Oct 2014 Location: Ray BY The Bay NJ Posts: 10,633	Re: Hole in engine block...repair or scrap? You are at the point where the decision should be made "what is my end goal for this cart ? ". If it is just to drive around at stock speed the stock clone is the answer. BUT as Shepard points out if more speed is the goal the vegascarts VRX 460 is the answer. All sorted all built good for 6000 rpms. Along with that just adding speed equipment to a stock clone will cost as much or more than the VRX 460, but will have the weaker 7 bolt engine block versus the much stronger 10 bolt VC unit. It all depends on what you want out of the cart.

Similar Threads
Thread	Forum
Small hole in battery case,repair?	Electric EZGO
Stripped Bolt Hole Repair	Gas Harley Davidson
Stripped Bolt Hole Repair	Gas Club Car
repair large hole in plastic	Body and Paint
Hole repair/fill	Body and Paint