In article , F.
Hayek wrote:

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

It could be done, and accurately, but would take a bit of skill.
The welding be be easiest if the bell housing was relatively new so it
didn't have a decode of oil saturated into the porous surface of the
casting.

The jig that aligned the 2 surfaces would be critically important.
The welding would take some time as it couldn't be done too fast
without cracks forming around the weld area.

I though these adpater bell housings were already available off the
shelf for a few $100.