I recently tore apart my S5 TII engine and was prepping it for bridgeporting tonite. I was cleaning it up and removing the original water seals. I saw the water jacket galley was actually eaten away in 2 spots on the front iron. The first was about an inch long and the second portion that was eaten away is just under half an inch. The inch long missing chunk is on a straight portion of the galley and the half inch portion is on the bottum radius toward the oil pan. I showed a metallurgy/welding/machining guy that I work for and told me he could fix it, no problem at all. He said he would take it and throw in a filler weld either by tigging it or with a high nickel content arc welding rod. Then the weld would be ground or milled down to the surface of the iron. To finish it off we would run several overlapping passes with a 1/8 end mill to carve the new water jacket galley, while keeping the same width of the original. Has anybody ever repaired a water jacket galley like this? Does it sound like it will work? I will take pictures of the whole process if I decied to try it out.

 

Worth a shot if he isn't really charging you. What is the worst that can happen? You end up with an iron you couldn't use anyway?

And yes... lots of pics! Hope it works for you.