"F. Hayek" wrote in message
...
Some 4x4 enthusiasts were discussing an engine swap that would use an
aluminum bellhousing that had a 1.00" section removed and the rear face
then welded back on and trued up on a milling machine. A jig was to be
used to keep the alignment of the front and rear faces in the proper
relationship.

My question regards the feasability of welding something like this. Can
an aluminum bellhousing welded like this be considered safe and strong
enough to use in a vehicle?

I am pretty sure parts like this are cast, machined and then heat
treated when they are produced by the original manufacturer. I guess I'm
concerned that major welding on this unit is not a good idea.

Fred

I don't doubt the strength, but I'd sure as hell question the ability to end
up with the pilot bearing in the crank concentric with the main bearing in
the trans. One that is not is likely to be the cause of premature clutch
failures, as well as bearing failures. Even if a fixture locates the
two halves properly, I can't imagine that the welding process would leave
them where they were desired. I would worry about that more than the
strength, especially if the welding is in the hands of a good weldor. Is
this a case of re-machining the bore of the bell housing , too?

Harold.