[Trak Ratt]

Originally Posted by markwemple

What and asshole for a neighbor. My community doesn't have one of those...

yes it does

[smdubovsky]

dropped the motor a little and used a mirror & borescope to look around. I could SWEAR I see the open end of the hose way back near the flywheel using the scope. I tried from underneath near the trans and can't see or feel it though. Even if I do see it, there is no way Im going to be able to repair it so either I have to take a bunch of stuff off the front/top of the motor or the motor has to come down & out Makes a couple hr expansion tank problem seem minor.

Dorki drop?

(Heres to hoping the fellow coming to see the boxster this wk hauls it off)

[smdubovsky]

Found it! "Coerced" the alternator off after a good lunch (and a nap) and it was staring me in the face.

Now how to fix it. The elbow appears to be bonded in originally. Wonder if I can rebond w/ something or should just replace the whole piece. Appears to be part 996.106.039.73 (#15) in PET. $200 from pelican and special order (so who knows how long it would take to get!)

[Lucky]

Two words: J-B Weld.

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Actually, I'm not sure J-B Weld is the right answer, but I'm confident with the right epoxy for the application you can repair that.

[markwemple]

Don't think jb weld would do the job. Not sure what epoxy would.

[smdubovsky]

Im sure there is suitable epoxy for aluminum. We glued suspension pcs on the solar car back in college. The stuff was AMAZING in shear, so Im sure in 15 yrs later there are even better ones. Finding something suitable is what would worry me.

Though, current plan is to pull it out (if possible) and maybe try to weld it. I've gotten all the bolts out, but can't get the large hose off yet. Ran out of daylight. Hopefully it won't be too hard to wiggle out once thats off. I'll clean it up and decide what to do then. Gluing it sure would have been faster though...

[markwemple]

Tig sounds like a better idea than epoxy, although what about the adhesives that they use for radiators etc.

[Vicegrip]

Originally Posted by markwemple

Tig sounds like a better idea than epoxy, although what about the adhesives that they use for radiators etc.

Tig would require a large tear down and clean of the metals and might introduce heat related issues down the road. Aston Martin uses "glue" to build the frames and bodies in the modern cars. I looked one over that was in a head on wreck and the metal was mashed, torn and folded up all over the place but the adhesive joints were intact. I don't know its properties with regards to heat and coolant exposure but I would trust it in a properly designed joint.

How was this fitting set initially? interference fit, adhesive?

[smdubovsky]

Orig appears to use an adhesive w/ a healthy clearance (not even remotely press fit.)

Agreed tig requires a teardown and cleaning. But a proper bond would require the same level of cleaning. Im still trying to get it out. I've got the harld bolts out, now just down to a stubborn hose that won't pop loose. If it won't come easily, then the decision is made for me

My only problem w/ epoxy is what kind. Im sure the factory/supplier did plenty of testing on whatever they used originally to survive thermal cycling and coolant. It can't get too hard or will crack due to expansion. At first glance it appears there was incomplete bonding (looks like a big spot missing on one side, but maybe that bit of glue was left inside the mating end.)

My problem w/ tigging is what alloys. Its a thick casting and a thin extruded elbow. IME, the casting will probably weld fine. Who knows what the extrusion is out of - likely 6 series but could very well be one of the others. Both ends are O-ringed, so heat distortion shouldn't be as big a problem. I can lap the one end back to square. In searching 6spd, some shops have welded in fittings to prevent recurrence.

Decisions, decisions...

[HoodPin]

Originally Posted by smdubovsky

...... In searching 6spd, some shops have welded in fittings to prevent recurrence.

Decisions, decisions...

IMHO, unless long term ownership is not contemplated, that sounds like the better repair alternative. Unfortunately, it doesn't sound like an easy one.