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Ok guys i have a case that is cracked by where the oil cooler mounts to the case at the area in which the fan shroud overlaps the boss the oil cooler sits on. I guess the fan shroud rubbed off about a 1/16th and it was enough for the oil pressure to start weeping through and making my engine bay terrible.
Is this possible to weld and if so are there tricks to making the welding smoother such as using heat to stress relief the case? Is there a possible issue with igniting the mag? Should i build a purge box filled with argon?
Its a fairly fresh 1600DP with an AS21 dual relief case.

thanks, Knox

Just weld. Worst probl;em is oil contamination. Tt its happened before and will again. lay a piece of rod over the crack and weld it to the case. There is less chance of oil contaminating your weld.

I'm sorry to say, your case is a gonner. There will be a lot more BIGGER cracks inside the case. Since there's no stress on the tab for the cooler, a crack there is just the end of much larger cracks you can't see. Don't waste any time on this case. Get another.

i' ve seen many cases with that kind of external crack.it does not starts from the inside like many other cracks that happens on overheated cases.
i' ve seen them welded and working, but it is not a 100% success.

a reasonable thing is to have it welded then having a tube pressed in

i agree that it is better to replace the case. i've thrown away many of that in this conditions.