Exhaust Port Hole Patching

Over the holidays, we found a friend, Ken, who has the skill, equipment, and willing to help us.  Reviewing the trouble, Ken thinks it is possible to TIG weld the aluminium if it is cleaned really well.  So, after some scrubbing and washing the port, we got it cleaned and ready.  (This also make for a good picture to see the hole into the cylinder's water jacket.)

With everything set I load the motor into the back of Daws headed to Ken's.  After some test runs, Ken got going welding to close the hole.

It started well, as Ken laid down some welds in front of the hole.  As he moved back problems started.  The edges were thin and the heat needed to weld would vaporize the aluminum.  This made the hole bigger, and more material was needed to be laid down to fill the ever enlarging hole.  As he worked, I could do nothing.   At first I listened and could hear the weld arc ebb and flow.  This got me anxious, so I began to pace like an expectant parent.  After an interminable period of time (really about 20 minutes) Ken announced he had finished.

To test this patch we devised a pressure test.  The coolant return line was tapped off, a cap with a valve stem was placed on the coolant feed line.  I then used a bike pump and Ken would look and listen to see if the patch held.  After some amusing start that only jury rigging brings, we found the patch was leaking.  So, Ken went at it with the welder again to see if he could fix it.  This time the welding did not go well.  The pneumatic test had pushed enough containment into the patch that the second attempt to weld did not stick and mostly balled up.  After a lot of effort, little could be done.  So, with a brief Hail Mary test, it was determined that the patch will not work.

sigh...

Thank you Ken for your efforts, sorry I did not give you much to work with.

Alrighty then, on to plan B.

Sears Pointless 2017 Work Checklist

Work Checklist for Sears Pointless 2017
Electrical Systems			Status
		Items	300z		Type D	Comments
	1	Power disconnect switch	Done		Done	Test
	2	Dashboard / Gages	Done		Done
	3	Alternator light	Done		Done
	4	Descuzzify wires	Done		Done
	5	Main power battery hookups	Done		Done
	6	Traqmate				Check D
	7	Battery charged
	8	Check charging system
	9	Check ECU error codes
	10	Switch for the cooling seat	Done		Done	Not Needed
	11	Start button
	12	Cooling fan			Done	Z- Mount thermocouple
	13	Idiot light system	Done		Done
	14	Racer Connect System - Car
	15	Racer Connect System - Pit
Engine and Drivetrain
		Items	300z		Type D	Comments
	1	Engine compress test	Done		Done	Z-  1-170, 2-170, 3-170-, 4-170,   5-170, 6-160 D1-175, 2-180, 3-180, 4-180
	2	Spark plug	Done		Done
	3	Replace oil filter				D - Install new filter housing
	4	Replace engine oil				Need 18 quarts for the race
	5	Check transmission oil			Done
	6	Check differential oil			Done
	7	Check clutch fluid
	8	Inspect timing belt
	9	Inspect water and alt belt
	10	Check air box
	11	Check and add water to radiator
	12	Check and add water to overflow
	13	Inspect throttle cable
	14	Oil cooler and lines inspection				D- Need Replacement
	15	Run engine to temperature
	16	Radiator	Done		Done
	17	Radiator screen	Done		Done

Suspension and Brakes
		Items	300z		Type D	Comments
	1	Check strut and tighten
	2	Inspection ball joint
	3	Check wheel bearings
	4	Front and rear sway bar mount	Done
	5	Check rear and front bushing
	6	Check rotors	Done		Done
	7	Check brake pads	Done		Done
	8	Bleed brake lines
	9	Alignment
	10	Tires and rims				Have tire need to mount
	11	Check tire pressures				Z – 29 f 28 r D – 28 f/r
	12	Strut tower support
	13	Springs and Perch Inspection
	14	Brake Bias	Done		Done	D – Acquire and add
	15	Brake Cooling	Done
Safety Systems
		Items	300z		Type D	Comments
	1	Check fire extinguisher
	2	Fire suppression system	Done			Install
	3	Check seat
	4	Check back rest
	5	Check seat harness
	6	Check mirrors	Done			D- Needs to be replaced
	7	Roll bar pad
	8	Check tow hitch				Make sure they are labeled
	9	Cover remaining glass
	10	Secure roll cage	Done		Done
	11	Arm restraints / driver net	Done		Done
	12	Fire wall inspection
	13	Battery disconnect outside	Done		Done
	14	Main battery secured
	15	Rear fire wall
	16	Windshield
	17	Fuel system and vent line	Done		Done
Chassis
		Items	300z		Type D	Comments
	1	Wipers				Most likely not needed.
	2	Front skirt
	3	Rear diffuser	Done
	4	Rear spoiler
	5	Door Latch Inspection	Done		Done
	6	Door Panel Repair	Done		Done
	7	Fender repair	Done
	8	Front and rear bumpers
	9	Jack points	Done		Done

Décor
		Items				Comments
	1	Car number				Need 12 x 11x17 label
	2	Team logo				Review
	3	VLE logo				Inspect
	4	Paint				Touch Up
	5	Team Logo for Padlock				Print