PeachParts Mercedes-Benz Forum - welding a cracked IP

PeachParts Mercedes-Benz Forum (http://www.peachparts.com/shopforum/)

- Diesel Discussion (http://www.peachparts.com/shopforum/diesel-discussion/)

- - welding a cracked IP (http://www.peachparts.com/shopforum/diesel-discussion/104906-welding-cracked-ip.html)

pberku,

Thanks for the link. Looks like a common problem. Unfortuanately the link and the links off of it did not show a picture or describe anything in detail. Also nothing about fixing a hole in the IP. Can i clean the hole to prep for epoxy with brake cleaner and will that damage anything if it gets into the IP?

Does anyone know a link that shows or describes the fabricated frame that is used in lieu of the broken part off the IP?

If not I'll just clean the hole as best as possible and proceed as I described in post #11:
"Above and slightly to the rear of the IP idle bolt mount is a bolt that is threaded through a gusset on the IP. It is not doing anything. Will try to fabricate a simple piece of steel that will mount to it. The fabricarted steel piece will be made to reach over to exactly where the idle bolt should be located. Hard to describe without a picture but it looks doable. All this to avoid putting stress on the patch."

What he said....

Quote:

Originally Posted by pberku

Its an easy 20 Min do it yourself fix.
Just follow the thread below
http://www.peachparts.com/shopforum/diesel-discussion/40470-idle-adjustment-screw-up.html
Phil

My objection was attempting to weld it.
The weld stress, contamination, teardown/reassembly and calibration cost is higher than a rebuilt injection pump.

Quote:

Originally Posted by erubin

pberku, Thanks for the link. Looks like a common problem. Unfortunately the link and the links off of it did not show a picture or describe anything in detail. Also nothing about fixing a hole in the IP. Can i clean the hole to prep for epoxy with brake cleaner and will that damage anything if it gets into the IP? Does anyone know a link that shows or describes the fabricated frame that is used in lieu of the broken part off the IP?If not I'll just clean the hole as best as possible and proceed as I described in post #11: "Above and slightly to the rear of the IP idle bolt mount is a bolt that is threaded through a gusset on the IP. It is not doing anything. Will try to fabricate a simple piece of steel that will mount to it. The fabricated steel piece will be made to reach over to exactly where the idle bolt should be located. Hard to describe without a picture but it looks doable. All this to avoid putting stress on the patch."

As I asked in the thread that "pberku" refers to, PICTURES would be very helpful, before - during and after would be best.
Can you take pictures of the injection pump hole "please"?
Trace ammounts of brake clean will not harm, volume will.

Quote:

Originally Posted by leathermang

But remember, we are suggesting you get a used one .....

and send the old one to Greg........... :D

20kmiles later the epoxy plug patch and sheet metal plate for holding the idle screw is working fine.

Quote:

Originally Posted by erubin

The picture shows the idle screw with a chunk of the injector pump's cast aluminum case. There is now an approximately 1/2" gaping hole into the IP's internals. The idle screw (and hence the hole) is in the real case of the IP. That is the case without all the injection lines. Now i know the case can be welded once i get the pump off and the hole cleaned, but are there internals such as seals, orings, ball bearings, etc that would be damaged by the heat generated from the welding. If yes, can the internals be removed before welding without needing specialty IP rebuilding and measuring equipment. At the very least I should seperate the front case from the rear case. BTW, a rebuilt IP is too expensive for the budget and a used one is too risky. I believe this IP is fine except for the hole.

I thought about using JB weld but there is stress on this part from the trottle hitting the idle screw. Furetheremore getting epoxy in the crack will make it much more difficult to weld the aluminum because of contamination.

gonna be near az anytime soon? 20 bucks but it doest have a shutoff valve or alda

Thanks for the IP offer. For now it's holding. If that changes will explore replacemnt. The epoxy is not stressed by the idle screw since the epoxy only seals the case. The idle screw is held in place with a fabricated heavy gage sheetmetal bracket that is mounted to a nearby bolt as described in an earlier part of this post.