Front half has odd wear from sealing ring. What to do?

[LakeFever]

I got another 2.5 and it was rebuilt once by someone sloppy so it didn’t last long. The front half has one land for the sealing ring that is kind of wallowed out. It’s worn in a concave shape instead of the usual flat trench. Is this repairable or useable or what say you all? See pics


545036 545037

[Merc 2.5]

Wrap a socket with sand paper and try flatten it out

[LakeFever]

I was thinking something like this. I wondered about welding it and machining it but that doesn’t seem worthwhile. Ideally I would like to bolt the front half to the block and somehow lap the surfaces down smooth again so I can keep things concentric. I’m not sure what tooling has been dreamt up for this or if there is a hone specifically for such a task?

[Chaz]

The 3.0L motors are bad about digging the end of the sealing ring in the soft aluminum. I weld the trench up and made a drum (one for a 2.5 and 3.0) that sits in one register while sanding the other. Then i can flip it over and dress the other side. The paper is strips cut from old 6x48 belt sander paper. It sits in a .050 deep recess I cut in the drum. works like a champ ... :thumbsup:

http://i.imgur.com/HwWdgh6l.jpg (https://imgur.com/HwWdgh6)

http://i.imgur.com/MXxTsPRl.jpg (https://imgur.com/MXxTsPR)

http://i.imgur.com/Z865LOGl.jpg (https://imgur.com/Z865LOG)

[WaterZebra]

The 3.0L motors are bad about digging the end of the sealing ring in the soft aluminum. I weld the trench up and made a drum (one for a 2.5 and 3.0) that sits in one register while sanding the other. Then i can flip it over and dress the other side. The paper is strips cut from old 6x48 belt sander paper. It sits in a .050 deep recess I cut in the drum. works like a champ ... :thumbsup:

http://i.imgur.com/HwWdgh6l.jpg (https://imgur.com/HwWdgh6)

http://i.imgur.com/MXxTsPRl.jpg (https://imgur.com/MXxTsPR)

http://i.imgur.com/Z865LOGl.jpg (https://imgur.com/Z865LOG)

Geez! Another example why S&F needs a SPECIAL TOOLS section!!

[LakeFever]

Need a tool? Make a tool. The golden rule of a tool room. Bummer I got no lathe. Thanks Chaz that’s interesting