I would still be concerned about the overall integrity of the piece. You
could have the best welds in the world and it won't do much good if the
metal around it is weakened/cracked. You might just set yourself up to go
through the whole experience again.
That's two big heavy chunks of metal held together in the middle by the four
bolts on that housing.
I think I'd can it and find myself a good used unit that was in one piece-
in this case I think the devil you don't know might be better than the one
you do know.

Cya,
Robert

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Scott Daniel - Turbovans
Sent: Thursday, June 03, 2010 12:15 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: 2.1L engine failure - Update #2

hmmmm...
I would say it will take very careful expert welding to get the bell housing
repaired and dimensions still perfect on it - on a vanagon auto trans bell
housing - which is not a separate bell housing - see below.

welding cast iron ...
I had an expert welder freind weld a 1.6 TD block one time.
First we heated it in a charcoal fire for several  hours,
he arc welded it with nickle rod I think,
then we buried in it clean sand overnight for slow coooling,
then I had to get the flywheel end of the block resurfaced by a maching
shop. It was fine after that, and that engine ran for a long time...that
incideent was one of 3 or 4 near death events that engine went through even
! ..lol.

My point is welding cast iron has to be done right.

The auto trans bell housing is not a separate bell housing.
it's the main body of  the auto trans.
I have one here at my shop, with just one small piece broken out of the
corner of one of those 'windows' around the torque converter area ..
if anyone wants to do a whole trans number using this one,  I would sell it.
Would want the buyer to see pictures in advance.

but ...unless you have small cracks, that can be addressed with everything
assembled...
welding on a vanagon auto trans cast iron bell housing is a 'whole rebuild
the trans' type of job.

Good welders don't weld on assembled oily things,.
they weld on bone dry clean bare metal castings.

Scott
www.turbovans.com

----- Original Message -----
From: "Frank Condelli" <RAlanen@AOL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Thursday, June 03, 2010 3:01 AM
Subject: Re: 2.1L engine failure - Update #2

> In a message dated 02/06/2010 1:43:54 P.M. Eastern Daylight Time,
> LISTSERV@GERRY.VANAGON.COM writes:
>
>        Jack, actually that's a  very common problem.  That flex plate VW
> used is too weak.  The only  option is to find a good used one, inspect it
> carefully to see that there are no  cracks beginning around the hub.  The
> bell
> housing should be easily  repaired by any welder who can weld cast iron,
> not a big problem.
>
>
>
>>>>>The mechanic pulled apart the motor / trans on our  friends 90 Westy
> 2.1,
> discovered that the "flex plate"/ Fly wheel
> blew  up!  Basically ruptured and caused everything to stop abruptly...
> auto
> trans bell-housing
> cracked in 5 places, and needs a new Flex Plate.  (anyone have a source
> for
> this?).
>
> Motor still turns, haven't tried  to start it.
>
> They are quoting big bucks to change auto trans or weld  bell housing, if
> trans is OK.
>
> What could have caused the flex plate  to break-up?
>
> Any suggestions on a course of  action?<<<<<<<
>
>
>
>
>
> Cheers,
>
> Frank  Condelli
> Almonte, Ontario, Canada
> '87 Westy & Lionel Trains (_Collection for sale_
> (http://frankcondelli.com/trainsal.htm) )
> _Frank Condelli &  Associates_ (http://frankcondelli.com/busindex.html)  -
> Vanagon/Vanagon Westfalia Service in the Ottawa Valley
> _Vanagon Stainless Steel Exhaust  Systems_
> (http://frankcondelli.com/exhaust.htm)
> _BusFusion_ (http://www.busfusion.com/)  a VW Camper  camping event,
> Almonte, ON, June 10 ~ 13,  2010