Water leak at top of head

[Flatlander]

This is embarrassing, my first complete rebuild of a power head and I missed something obvious. The starboard deck is completely flat except where the top of the head meets the block at the water passage.. It looks like someone may have tried to remove an old head gasket an took to much aluminum off the block. There is about a .010 gap between the head an the block. Using just a new stock head gasket caused it to leak pretty bad. Then I tried using a little blue gasket sealer around that area but it still looks like a sprinkler when it's running (it is better though). The motor is complete and runs great, just leaks! Please tell me there is a way to fix this without tearing the whole motor apart. Live and learn!
Thanks

[Flatlander]

Been doing some searching and it looks like Three Bond 1194 might work. Has anybody had any experience with this stuff?

[johnboy 88 vegas]

Permatex 1 or 2 (hardening or non hardening) are my favorites when it comes to a water leak.

[Bruster]

Remove the cylinder head and carefully repair the scratch with a little JB Weld. Let it cure and carefully file it smooth. Reassemble. 3 Bond is great stuff, but you need to make the JB Weld repair first.


This is embarrassing, my first complete rebuild of a power head and I missed something obvious. The starboard deck is completely flat except where the top of the head meets the block at the water passage.. It looks like someone may have tried to remove an old head gasket an took to much aluminum off the block. There is about a .010 gap between the head an the block. Using just a new stock head gasket caused it to leak pretty bad. Then I tried using a little blue gasket sealer around that area but it still looks like a sprinkler when it's running (it is better though). The motor is complete and runs great, just leaks! Please tell me there is a way to fix this without tearing the whole motor apart. Live and learn!
Thanks

[Flatlander]

Thanks, I was thinking about using JB weld or PC-7 epoxy but the problem is it is not just a scratch or gouge. The block actually tapers away from the head at the top water passage. That means I would need to lay a thin layer of epoxy and sand until level with the deck. That is why I was looking for a rubbery type sealer first. Do you think a thin layer of epoxy will adhere well?

[rock]

Bruce is correct. I would use Belzona if you had it available. JB Weld on steriods. You have to build up area in order to seal the water jacket. Clean area well and strike it off with a good straight edge. Let it cure then shave it down.
Rock

[Flatlander]

Never heard of Belzona, where do you get it? Thanks for your help. I have had good luck with PC-7 on nose cones. Do you know how it compares to JB or Belzona?

[Flatlander]

I just went to Belzona's web site. Your right, they make some cool stuff! Looks like they make a product to repair just about anything.

[Bruster]

I glued an exhaust manifold freeze crack with JB Weld when the guy wanted a cheap quick fix. That was years ago and it is still going strong. Any of the above products will peremently fix your problem.

[Flatlander]

Thanks guys! You saved me again. I have JB Weld at home and will work on it tonight. Have to admit, that Belonza epoxy is intriguing though. By the way , I got the motor mounts and they are very nicely done.
Thanks

[Bruster]

Happy to help 2X!

[HP]

JB Weld........:iagree:
Seen it used on all-out race cars......it works :thumbsup:

[rock]

Belzona is used to fix castings on Caterpillar tractors and used to face turbines. It is by far the most expensive epoxy I have heard of but to be recognized by Cat and others for their extreme situations it is probably worth it. Back in the eighties a Merc dealer friend of mine wanted to use Belzona to epoxy studs into the floor for a motor stand. Drilled holes and installed studs. To be sure they lined up they put the stand in place but did not nut it down. The next day the stand could not be removed. They had glued it to the floor.
Rock

[richcraft]

I bought a 225 Ocean Runner to rebuild. Pulled the heads off and found salt corrosion/pitting on the deck of the block. I cleaned it well with a wire wheel and aluminum cleaner, washed it off with soap & water, blew dry with compressed air and applied JB Weld. Before the weld set I put a layer of wax paper over the entire deck area and bolted the head back on with all 20 bolts per head. This seamed to force the JB into the low spots. I let it sit for 24 hours pulled the head off, peeled the wax paper off and with a little filing and block sanding it was like new.

Just a thought.