I've posted a few questions about how to deal with a cracked block, and after successfully fixing the crack with JB-weld last week I thought I would post this so that you can all sleep again. For those of you who are even greener than I am I have even a few recommendations of my own, so that you can avoid some small difficulties I was not so prepared for.
Last Thursday I got a package in the mail, special delivery from an anonymous source in Minnesota, a package of JB weld. It seems that in this day and age sending JB weld internationally is a threat to national security, don't tell my dad. Anyway I was able to persuade this anonymous source to send the JB-weld please, and since I had been waiting so long when it finally came the repair went pretty quick. I used a lot of tricks I read on this site, drilled out the ends of the crack, hooked up a shop-vac to the radiator, heated the area, ground and vee-d the crack, cleaned with brake-clean, and applied the JB weld. So here are some things I would mention to you really inexperienced guys like me, the rest of you can just ignore this part.
1) JB weld is pretty runny as applied. Since the block was in place, I had to apply the stuff on the side, and even if it feels solid as mixed, it takes a good long time to harden and it will have time to ooze downwards. Someone recommended turning the block on its side, this is surely a good idea when possible. But when not possible, be prepared that it will run.
2) The shop vac was a good idea but it did pull the glue through the drilled holes. So I shut it off soon after I started applying the glue.
3)Drilling the ends of the crack is surely a good idea. Finding the ends of the crack on an older engine is not so easy. I did not find the ends of the crack on my first try. In hindsight I would recommend - before draining the coolant, cleaning off the block, grinding the suspected area and drying it (if possible) and then starting the engine again to try to really find the end of the crack.
4) Some folks recommended using 40 grit sandpaper to texture the patch once the JBweld has set up. I let it sit a couple of hours before trying this, and the goo was still too loose, the sandpaper tended to want to pull the glue off the block or at least thin it out. You might let the stuff sit at least 4 hours before texturing the patch. Someone else said not to touch the glue at all after applying it. Personally I now subscribe to this advice - I am more concerned about a good repair than a texture
Finally I can say that my repair seemed to work, at least I have been driving the truck for 2 days now, probably 30 miles so far at around 50 mph, and the repair is nice and dry. I also have found a spare 216 in Stockholm (not so far from me) which I would like to snatch up as a reserve - I like to be realistic about the quality of my work. But until I find the time to pull the motor, I hope this JB weld will keep me on the road.
Karl
