How to Repair a Cracked Engine Block

A #crackedengineblock in a vehicle is not uncommon and certainly does not mean the end of the engine's lifespan. There are various methods of repairing cracked engine blocks: from welding and brazing, to cold metal stitching. In this short video, you will learn how to repair a cracked engine block using Belzona in less than an hour. www.belzona.com/engines
Cracked engine blocks can lead to problems such as leaking cooling water so for that reason they need to be repaired. Belzona offers a solution that does not require hot work or specialist tools and is proven to provide a long-lasting alternative to costly replacement.
Materials Used:
To repair this cracked engine block, we used #Belzona1111 (Super Metal), Belzona 9111 (Cleaner/Degreaser), Belzona 9341 (Reinforcement Tape) along with a few tools from our machine shop. For more information, please visit www.belzona.com/1111.
Read more about this repair on our Blog: blog.belzona.com/how-to-repai...
How-To Guide:
Step 1: Before starting work on the repair, make sure the damaged area is thoroughly cleaned and free of grease, oil and dirt. We recommend the use of Belzona 9111 and a stiff bristle brush to remove all the surface contaminants.
Step 2: Terminate all cracks by drilling holes along the length of the cracks and at both ends. This helps to prevent crack propagation.
Step 3: Insert studs into holes and using a grinder, cut all the studs flush with the casing.
Step 4: ‘Vee’ out all the cracks with a hand-held machine fitted with a cutting disc and roughen the entire repair area to ensure excellent adhesion of the Belzona repair material.
Step 5: Once again, clean and degrease the repair area and apply masking tape to the area to be repaired.
Step 6: Measure and cut a piece of Belzona 9341 to the size of the masked off repair area.
Step 7: Mix the appropriate amount of Belzona 1111 making sure to achieve a uniform material (Learn more about mixing and applying Belzona 1111 (Super Metal) here: belzona.com/ViewFile.aspx?id=5...)
Step 8: Apply a thin layer of Belzona 1111 to the prepared surfaces pressing firmly with a stiff bristled brush to ensure full contact with the surface.
Step 9: Wet out the Belzona 9341 with the mixed Belzona material and bed it down over the crack into the layer of Belzona already applied using an applicator.
Step 10: Apply another layer of Belzona material to create a buildup of approximately 1/8th inch (3mm) over the entire area.
Step 11: Remove the masking tape and leave the repair to cure. After the product is fully cured, the engine is ready to be put back to service!
To find your local Belzona products and services supplier please visit: www.belzona.com/en/about/disfi...
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[@travisc3571]

THIS PRODUCT WORKS! I used carb cleaner and starting fluid to clean my surface. I then dipped the bolt in 3 in 1 oil, placed it in the hole. Mixed Belzona per specs, and packed it around the stud and put more than needed. I then smoothed it out with my gloves dipped in carb cleaner. This allowed me to smooth it out nicely. I did this on a 302 block that cracked by the water pump.

[@caseycasey5778]

What does it cost?

[@travisc3571]

@@caseycasey5778 I paid $350 for 1 kilo, but I could have gotten away with a can that was about $175. I really didn't know what to expect but it really works.

[@caseycasey5778]

@@travisc3571 how long has it held up

[@CholbePilot]

@@travisc3571 350 for glue and you have to buy cleaner and studs yourself? Thats crazy!

[@travisc3571]

@@CholbePilot huh? My block was broken so no repairs could be done. It’s still working.

[@summitcastle3694]

Research this company. They do amazing things using chemical bonding. I was fortunate enough to have met the owner. Very knowledgeable people. This was invented for military use.

[@belzona]

Thank you for your comment! Belzona 1111 can be used in any type of industry. Here is more information on this epoxy-based product: www.belzona.com/en/products/1000/1111.aspx

[@kevinbusby734]

Summit Castle where can i purchase the 2kg kit?

[@belzona]

@@kevinbusby734 You can find a local Belzona supplier using this link: www.belzona.com/en/about/disfinder.aspx. Best regards, Belzona Team

[@DrBill-zv5dx]

Excellent video, thanks Belz

[@chemstrsafariks.r.o.6976]

Really nice video of whole process of renovation.

[@belzona]

Thank you for your feedback!

[@lux1469]

We're going to need 16x the detail

[@danpower-JP]

Hey Internet Historian brought me here too

[@thefarmlifeinhd]

then wire brush the slag

[@JalopyTechnology]

Back in the 1970's I drove a Freightliner that had a hole in the block repaired with fibreglass and epoxy... never leaked and the engine ran that way for tens of thousands of miles.

[@DrBill-zv5dx]

Rick Schlabowske My father Machinist, mechanic and finally a marine Engineer. repaired a hole in my 1973 Chevellle 351 engine block with JB Weld . Never a problem after. .

[@cuzz63]

@@DrBill-zv5dx chevy didnt make a 351 in 73...you mean a 350

[@TOMBSTONESTAN]

Nice quick vid. This is how I like them, no faffing about and straight to the job. 👍

[@half_r_mk5]

They should have tested the engine run to see how the seal worked.

[@shawntincher2212]

It’s really interesting and educational learning it’s showing you how to fix crack engine take steps on how to where you’ll need drill the holes on where it’s repaired

[@connersnow298]

Awesome vid and edits and filming

[@tatewinters5565]

Very cool. Would 100$ cover the cost of fixing a cracked engine block? Thanks!

[@YoungHeartedSoul]

Wish you guys sold your product in the USA in smaller quantities. I tried getting in touch with corporate via email several times and no one ever answered my emails. I spoke to a loca belzona distributor but he said the smallest amount sold is quite a lot and all I needed was a small amount to repair a rotted piece of cast iron on an engine water pump outlet. Would be perfect if you sold it in sticks like JB Weld does. I gave up trying to contact you guys and will try welding the area with Muggy weld 77 rods.

[@Syedansarb]

Good

[@bchipper3932]

And how long would this patch last

[@DaytonCarCare]

I think I'd probably just buy a good used replacement motor or block. I once had an Audi TT 1.8t with a failed piston. I just purchased another good used block with pistons from a VW Jetta (same block) for only $150. Swapped the cylinder head and everything else over from the TT engine. Ran great after that.

[@travisc3571]

I used this on a broken water jacket on my 302 Ford engine. Hopefully it will work. 🤞

[@StarAsinine76]

It’s been three months… did it work or not

[@travisc3571]

@@StarAsinine76 still going strong! I’m sold on this product.

[@shawntincher2212]

To know what your doing your going to practice lot on learning knowing to do this kind of stuff you gotta pay attention focus on what your doing if your focus listen to your boss they’re not gonna wanna keep at your job it’s very important to pay attention at your job if your really close attention and take advice from other showing how to do it properly

[@spicky2966]

could you sandblast the area instead to avoid the chemicals...

[@BrokenLifeCycle]

What's the advantage of this over the tried and true metalock and stitching?

[@belzona]

Thank you for the question! We are showing another way of repairing a cracked engine block. Using an epoxy composite like Belzona 1111 does not require any hot work, but will maintain the integrity of the engine and provide corrosion protection. Repairing cracked engine blocks using epoxies is another proven method. Please feel free to let us know should you have any other questions. Best regards, Belzona Team

[@chlyon]

I heard brazing works well too low heat , may not work in this exact situation but for broken off lugs etc

[@dangates3022]

i had a 79 ford bronco 30 gallon fuel tank. the whole bottom of tank had pin holes on the entire bottom surface when i removed the skid plate it was rotted away from the two metals contacting each other. i ground all the rust and loose debris on the tank, smeared a liberal coating of belzona let sit for 24 hours. people were saying when you put the skid plate back on it will smoosh the plat to the tank, and crack the repair. i was concerned. it never leaked again till i sold the truck years later!

[@belzona]

Thanks for sharing your experience of using Belzona products, Dan!

[@WaterBearOfficial]

will this hold up to engine coolant?

[@PAKfromFYCB]

did not work for me on CAT3126.

[@WaterBearOfficial]

@@PAKfromFYCB thanks!

[@bradtodd3639]

I used this to try to seal one of the infamous "shifted casting" #53 Cummins/Dodge diesel blocks that cracked, and was leaking coolant. I made the weld repair with Muggyweld rods which leaked immediately - contrary to their "testimonials" and the owner's advice! I then prepped and applied this very expensive crap to try to seal any coolant leaks. The Belzona engineer gave me wrong prep instructions (wrong size of sandblasting compound) and the Belzona failed and leaked. Ground all the Belzona off, tried more Muggyweld, then sealed it again with Belzona. Belzona provided 1/2 of the material to re-do the job, and the engineer even came out to watch and instruct. It held for less than a year, then failed again! I control the "leaks" with Fiberlock cooling system sealant and will be replacing the block some time in the future. I read all their glowing testimonials (both Muggyweld and Belzona) that suckered me to spend hundreds and hundreds of dollars on these failed attempts to repair. Save your money - Muggyweld cast iron rods don't work on engine blocks that heat cycle. Belzona is over-priced snake-oil epoxy that cracks and delaminates even with an engineer-supervised application. In addition, I had a new, unused container left over (sealed/never opened). This was very expensive. Went to try it for another (different) kind of project and found it had hardened! Belzona informed me that there is a fairly short shelf life (which is NOT printed anywhere on the container or conspicuously in the instructions!), and since I couldn't locate my original receipt, they would not be replacing the (very obviously new, unopened) container, nor give any kind of credit! Very strange snake-oil company marketing overpriced epoxy!

[@carterslade477]

Whoa Todd-DeJaVue...Me and my 53 block are there...have applied the Balona twice with same results- STILL LEAKS. I have the Muggyweld sticks waiting in the wings but like you, am convinced the only way to END this nightmare is a new block-Engine only has 150,00-Fucking Dodges...

[@shanerorko8076]

The block needs to be stripped and placed in an oven then either brazed or eutecticaly spray welded. You have to groove all the cracks out. There's a lot of prep work for the repair work to be done properly.

[@ricardocuellar2100]

Withstands high engine temperatures ? Can someone tell me?

[@randyleadholm]

60°C (140°F) immersed, 200°C (392°F) dry - www.belzona.com/en/products/1000/1111.aspx

[@dogdog4173]

Would that hold an engine getting 28 psi ?

[@BobSmith-mc7uq]

NO. Limit is 26PSI

[@calongoodlie1647]

How much hp and compression has this been tested out to?

[@belzona]

Hello! All test data for Belzona 1111 - the product used for this repair - is in this document: www.belzona.com/viewfile.aspx?id=52299

[@randywl8925]

This repair has what relationship to HP? He's repairing a coolant leak issue in a block. Better question is, what is the rating on your radiator cap. I'm better than 16 lbs or less. The flesh and a high quality block saver might work just fine. A block sealer might even be better after doing the girl on tap method shown in this video is simply to keep the crack from getting wider and the crack itself flexing though it would be a minimal amount.

[@calongoodlie1647]

@@randywl8925 idk product application tolerances maybe 🧘🏾‍♂️

[@randywl8925]

@@calongoodlie1647 there are some pretty damn good epoxies out there and they wouldn't hold the pressure from combustion however if you stabilize the block like they did with those screws so it couldn't take back and forth, JB weld might work just fine. The two drilled and tapped holes at the front and back of the crack would stop the crack you just need to stop the pressure coming out of a minuscule crack. A good block sealer alone might do that that might cost you 80 bucks. I'm taking a couple hundred bucks for their product and 80 bucks for a block sealer would be much cheaper and probably as good as buying a new or even a rebuilt engine. Either way, to do the repair you'd have to remove the engine to gain access to drill and tap so it would be a messy process regardless.

[@chade74]

Can you use this on a engine still a truck. Have no way of taking it out. Thanks

[@belzona]

Thank you for your question! The repair shown in the video is an example of best practice. We understand that in the field it is not always practical or possible to dismantle equipment. We always recommend that you should follow the manufacturer's product Instructions for Use (www.belzona.com/viewfile.aspx?id=51037) and attempt to perform the repair following as closely to the best practice and procedure as possible. Some changes may have to be made in procedure due to access and/or available equipment. A clean, dry, firm substrate that is prepared as good as possible should be the minimum required before applying the product. If you need any further assistance, feel free to reach out to a Belzona representative in your area: www.belzona.com/en/about/disfinder.aspx. Best regards, Belzona Team.

[@sirkokrisz]

Will this work on aluminum engines too?

[@phantomofdetubez2376]

sirkokrisz it should, just use tig if your welding

[@bulelanizilwa1746]

Mine has a hole in the engine block. Can it be fixed?

[@belzona]

Hello and thank you for your question! Our product might work, however, we recommend that you speak with a Belzona representative in your area to discuss the problem you are experiencing with the engine. You can find one using this link: www.belzona.com/en/about/disfinder.aspx or respond back to this message and let us know which country and city you are located in. Thank you!

[@travisc3571]

It looks like Belzona.

[@codecircle423]

Yeah, I'm never going to fix a cracked block this way. I'll do it properly. With a plasma cutter, and i'll weld the holes shut properly. I'd not put that stuff on there until I'm long after done bonding the damaged metal with fresh material.

[@MrCbell57]

You just used $140 dollars with if Belzona!

[@rickybailey7123]

Looks like J&B weld that was mixed up

[@brookewoody8620]

Has anyone tried this with success?

[@jkrlozjherdez2924]

I try to contact them for a quote and never call me back...

[@PAKfromFYCB]

i did not have success with this product and followed this procedure exactly. it was a cat3126 tho so of course the entire corner of the block would have popped off if the head was removed

[@tontonperez3544]

how much the cost of this set

[@belzona]

Hello! Thank you for your interest! Please contact your local Belzona representative to request pricing: www.belzona.com/en/about/disfinder.aspx

[@motorised1]

have any of the experts here ever properly welded cast iron

[@johnhosler6636]

The honest verdict on welding cast is this' you will never sleep well if you know its welded' its just one of them things it might hold 1000 years or split 2 minutes after it heats up. If you have nothing to lose weld that shit but just take every day as a blessing when it holds

[@chrismc410]

@@johnhosler6636 which is why a lot won't bother fixing a crack and instead replace the block with a new one or suitable and inspected used one

[@atomjordan]

One way is to use an oven. Take the block out, slowly heat in oven, weld, slowly cool in oven. Use temp sticks throughout the process to make sure your block stays within your desired temperature range (depends on metal). Heat + patience + temp sticks + tig welder = 🥳

[@shanerorko8076]

The only form of welding that should ever be done on cast is eutectic spray welding. Brazing is another good option. I've tried mig brazing but it melts too much of the parent material before you can get it to wet in. The trick is you don't want fusion on cast you want mechanical joints which is why brazing and spray welding work so well because they don't melt the parent material and cause fusion.

[@robertstanley1056]

This is like putting fix a flat in your tire. Yes it may work for the very short term but will cause you a big headache when you have to fix it the right way. Do it the right way first save yourself time and money. Lock and stitch or welded or a combo of both.

[@christopherwilkinson3128]

insert video of right way, or link to video xox

[@chrismc410]

Or a new or suitable used block.

[@MrSpankyxiv]

Unless you've used this product I don't think you can pass it off as the "wrong way"... on my farm I've barely ever resorted to welding after finding this product. Although I'm sure the manufacturer won't mention it due to saftey reasons this product works amazingly well in the worst conditions. Dirt, dust, grease rust, etc. It just bonds it anyways...yes clean first for best results.

[@sclapsclap177]

Why the drilled hole and the inserting bolts?

[@d4rkhound388]

reinforcement + it removes the "ends" of the cracks thus less chance of it cracking.

[@romyenglish]

I don't know man. They are all patch job. Welding is best

[@chrisdoyle7081]

I know, why the bolts making more openings, maybe to stop a crack from traveling? I used Permatex cold weld on my IH block 25 years ago and still holding. I think it has really now just rusted closed for good now.. not one drip. But need to clean engine and rough it up well. Chris

[@omcdude64]

@@romyenglish You cannot weld a iron engine block.

[@atomjordan]

@@omcdude64 lolz

[@mobilechief]

Weld the dam thing, I would never trust that puddy

[@sclapsclap177]

t Mann - if the engine is out. i would too

[@d4rkhound388]

On newer engines i agree but on older cast iron engines, if you welded them without taking precautions you could crack them BADLY...

[@romyenglish]

I used JB weld on a trctor. It hold for a while but then started leaking again

[@TheMrMattola]

heat and cast do not mix well, the weld would just separate from the cast and weld area + the heat will cause the cast to crack further. this should be metal stitched for a proper repair.

[@joshuaszeto]

@@TheMrMattola actually I'm interested too. I just inherited yet another goddamn 4age Bluetop and wanted to experiment with this one. I want to somehow attach strengthening ribs along the sides of the block. Maybe make it as strong or stronger than the 4agze block.

[@kman-gq9lc]

the music is unnecessary

[@kscotthoy]

That's a lot of fucking around. I'd have run a bead after the V groove had been made, five minutes with a stick welder and done.

[@jessilooney2444]

just use jb weld shit works good

[@timwhiting6854]

JB Weld was invented for these kind of repairs. It was originally designed to repair cracks in flathead engines.

[@tylercurtiss1351]

Drilling those holes made it weaker. Weld and then apply a thick larger area of puddy.

[@atomjordan]

And why is that? Do you know whats involved in properly welding cast iron?

[@molinelligarage1004]

Drilling and tapping holes in the block and threading in studs with a tapered hole actually brings the crack closer together and strengthens the block ...welding is possible but super hard with cast iron....tons of pre heat treatment needs to be done and can cause the crack to spread further

[@taxicamel]

It's too bad that when people who do not know what they are talking about make silly statements, ....there may be SOME people will actually believe them. A crack ....literally ANY crack in any material ...needs to be stopped from propagating. Propagating means "GROWING" longer. There is only one sure way of doing this. Drilling a hole at the ends of the crack. What this is doing is eliminating the "stress concentration" that exists at the one tiny point at the crack end. A hole eliminates this "stress concentration point" and spreads the stress out uniformly such that the crack can no longer grow. The other holes are to make sure the cast walls to not flex back and forth differently and wear on each other over time. But for those people who believe clowns like Tyler when they make their silly comments ....go ahead and weld .....and enjoy the potential myriad of micro cracks that the welding will cause if not done by someone who knows of all the problems when welding cast iron and can tell IF welding is feasible or not. .

[@bulgingbattery2050]

If your demolition derby car engine is damaged beyond repair, you can have the engine block melted down into molten metal, and then reforged back into shape. THIS ENGINE DON'T QUIT!

[@azeissler1987]

Looks like JB Weld

[@danoldsbb4558]

Good video music sucks

[@noelleonard2498]

How ridiculous 😆😆