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View Full Version : Repairing your damaged alloy sump (for the interim)


Preen59
19-03-2011, 03:13 PM
First up, Mods, i didn't know where to put this, so here it is. Place it where you like...


So.. Last night i'm driving along, going to pick a friend up from the Pub.. At the last second I see a concrete block in the middle of the road. I didn't have time to avoid it and BANG!! (sump) ....... BANG (rear axle).... OH ****, this isn't good.

By the time i'd pulled up there was already a slick behind me. I looked underneath and the sump was busted, oil dripping out. I thought bugger it, i'll see if i can get home before the oil light comes on! haha.. I made it 2 blocks.

(Sorry for the ****ty phone pics)

http://i280.photobucket.com/albums/kk182/preen59/IMG00073-20110319-0055.jpg


So.. I grabbed my jacket out of the back and started on the long walk home..


Tilt trayed it to the shop this morning and put it on the hoist to assess the damage.

A quick wash with carby cleaner to see what we were up against..

http://i280.photobucket.com/albums/kk182/preen59/IMG00075-20110319-1149.jpg

Oil pump was undamaged (Thank christ/god/allah/your homeopath)

http://i280.photobucket.com/albums/kk182/preen59/IMG00078-20110319-1235.jpg

So.... grab that stick of Knead It! (Awesome ****, we use it to bog alloy vacuum form moulds at work)

First up a damn good clean with carby cleaner to remove all the oil residue etc. Then we tried our best to straighten it up without busting it further using a hammer and a block of wood.

Using the bits that were broken out we carefully glued them back it with knead it (it's a bit like sticky plasticine before it sets). I had to make a couple of little sections to fill the gap out of some 3mm alloy, but nothing too drastic. Once one side sets, you can fill the other side and push it right in hard to make sure it fills and seals properly.

http://i280.photobucket.com/albums/kk182/preen59/IMG00079-20110319-1307.jpg

Once it sets, clean the sealing faces, put some sealant on the sump and put the sump back on..

http://i280.photobucket.com/albums/kk182/preen59/IMG00080-20110319-1348.jpg


Fill it with oil and go nuts!


I must stress that, although knead it is damn good stuff and will most likely seal for a VERY long time, I am only using this as an interim measure.

I have a fully baffled, windaged fabricated alloy sump leaving INA Engineering on Monday (With Corey's oil cooler kit, actually!). I'll chuck up some pics when it turns up and I fit it. :)

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc3/21972_330013624991_294598024991_4919297_5019616_n. jpg



If you want more info on doing this, hit me up.. But I must stress that it's not a job for the faint hearted. :)

Cheers guys!
Preen59
20-03-2011, 12:23 PM
Correction.. Issam was nice enough to send me a bog standard sump for the cost of the postage, pending pics to make sure the ones he has are the same as mine. No fabbed sump for the Caddy.. But we've got something else in mind later on... ;)
Preen59
20-03-2011, 05:10 PM
Knead It is holding up so far. A slight weep, but that's all. I'll just keep an eye on it. Not bad considering the state or affairs it was in to begin with! :)
schoona
20-03-2011, 05:18 PM
Thats some pretty serious damage!
Looks like good gear that knead it...
Transporter
20-03-2011, 05:32 PM
That was a one big whole in it. You've done a good job with that sump.
The Kneed it is a good stuff. I also use this with a very good results. You probably know it, but others might be interested.

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/20110320_003-1.jpg
Preen59
20-03-2011, 05:35 PM
Thats some pretty serious damage!
Looks like good gear that knead it...

Yeah its pretty good stuff! Wish i hadn't had to do it though..

Still going to drive the Caddy to Sydney next weekend if it doesn't get any worse.. Haha. :D
Preen59
20-03-2011, 05:37 PM
That was a one big whole in it. You've done a good job with that sump.
The Kneed it is a good stuff. I also use this with a very good results. You probably know it, but others might be interested.

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/20110320_003-1.jpg

Cheers, mate. It didn't take too long to do either. In a situation where you only have a crack it works even better.

Never heard of Q-Bond. Might do some research on this stuff.. :)
Transporter
20-03-2011, 05:38 PM
I moved the thread to the Caddy section, so the thread doesn't get lost. Other option would be to Restoration and Projects thread if you like. :)
Preen59
20-03-2011, 05:54 PM
I moved the thread to the Caddy section, so the thread doesn't get lost. Other option would be to Restoration and Projects thread if you like. :)

Where ever is fine with me, mate. I only put the info up to help others. It sort of doesn't fit "properly" in any particular section.


Maybe here is a time to suggest a "How to" section for most general repairs or similar??
Transporter
20-03-2011, 06:00 PM
Where ever is fine with me, mate. I only put the info up to help others. It sort of doesn't fit "properly" in any particular section.


Maybe here is a time to suggest a "How to" section for most general repairs or similar??

Yes, it is a good idea.
schoona
20-03-2011, 06:09 PM
Yes, it is a good idea.

You really don't want to know his other ideas hahahaha
kaanage
22-03-2011, 11:46 AM
The biggest problem with this stuff is finding it holding things together on a 2nd hand vehicle that you just bought.....
Preen59
23-03-2011, 01:29 AM
The biggest problem with this stuff is finding it holding things together on a 2nd hand vehicle that you just bought.....

Hahaha.. I do know what you mean there..

Don't worry, I have 2 sumps coming currently somewhere between here and Canada.. As soon as they arrive i'll be putting a fresh one on and crushing the busted one for scrap. :)
GoLfMan
24-03-2011, 05:09 PM
knead it works real well. Used it on a machine engine cover once. Smell's reaalll funky though
My sump got busted a coupla days after this... ahh well I'll keep it, weld up the hole and re-enforce it while I'm there
Preen59
24-03-2011, 06:08 PM
knead it works real well. Used it on a machine engine cover once. Smell's reaalll funky though
My sump got busted a coupla days after this... ahh well I'll keep it, weld up the hole and re-enforce it while I'm there

I've got 3 sumps coming if you need one... Cheap cheap too.

Let me know if you need (heh, or "knead" :P) one dude.
Silver dub
24-03-2011, 06:17 PM
dam thats bad luck preeny (and Josh).

Did it do any damage to the rear axle?
GoLfMan
24-03-2011, 06:39 PM
I've got 3 sumps coming if you need one... Cheap cheap too.

Let me know if you need (heh, or "knead" :P) one dude.

Sadly too late man. I need my car for uni so I had to get a new one. :(
Preen59
24-03-2011, 10:21 PM
dam thats bad luck preeny (and Josh).

Did it do any damage to the rear axle?

It's all good, dude. Fixed for now. Heck, i'm driving it to Sydney in the morning! hahaha.

The block clipped the shackle bolts on the trailing arm and burred the end up on one of them, but that's about it. Thankfully it didn't kick up and bust a fuel line or anything.. :)


Sadly too late man. I need my car for uni so I had to get a new one. :(

All good dude. :)
Preen59
16-04-2011, 06:19 PM
Fitted my new sump today.

FYI, the US spec sumps aren't the same. Although, i have a feeling this is an FSI sump.. So it might be that the FSI sumps are different to the TDI sumps.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/216545_10150164496803007_686043006_6502595_7752645 _n.jpg

It doesn't have the little ears on the back side for the windage tray.. So i had to trim the windage tray down to fit. Nothing a few minutes with a hacksaw and a file couldn't sort out though. :)
Lams
18-04-2011, 01:49 PM
hey preeny does yours have the fuel cooler sitting under the driver as well?
Greg Roles
18-04-2011, 02:29 PM
I think we chould call the new section the "MacGyver" one. Preen sure did him proud with this effort!

Without metal reinforced epoxies, I'd be lost!

Nice handyword MacPreenster!
Preen59
18-04-2011, 09:53 PM
I'll get some pics up of the sump after doing about 1000km (incl. a trip to sydney!!) like that! haha


hey preeny does yours have the fuel cooler sitting under the driver as well?

Yeah mate it does. Got a couple of marks in it too. :(
Lams
19-04-2011, 01:46 PM
not the wisest place to put it... mine takes a beating too. Not sure if it's on the new one. I imagine it wouldn't take much to rip that off and have diesel going everywhere, then a smoker lights it up, Die Hard style
Transporter
16-06-2011, 08:49 AM
How did you go with that sump Preene? :)
Preen59
16-06-2011, 09:17 AM
How did you go with that sump Preene? :)

Held up no probs! I have a new sump on now. Sam from INA sent me a couple of used ones for free, because he's a top bloke. :)

The knead it stayed in place and only wept a bit. I'd do the same thing again if I was in the same position.
gldgti
17-06-2011, 05:44 PM
i fixed my fuel tank with knead it once on my old mk1 and the repair is still there working fine....

on a side note, speaking of macguyver - We had a full complement of 5 in mum and dads mercedez 240D last year (badly worn shocks). Went over a big bump where there was also a lump in the road and bang, the sump hit the road. Pouring rain. Anyway, we pulled over and dad and I get out and peer under the car, we can see the oil coming out about as fast as it would if you undid the sump plug. So we run to the boot, find an old juice bottle, cut it open and start catching the oil. Then we start looking for something to repair the sump with... all we can find is some old 3.5mm vacuum hose, some bandaids, chewing gum, electrical tape. So, once all the oil had leaked out, we suffed the most part of the hole with rubber from the vacuum hose, kneaded some chewing gum into the gaps, covered it with a pultice of bandaids and then wrapped electrical tape all the way around the engine to hold it all in place. We put about 2L of oil back in it and drove 25km's back home :-)

I think luck was on our side that day :-)