Here is my risk splitting 2 cents ....

Pull out any chunks of rock or broken aluminum you can reach.  

Spray it clean with brake parts cleaner, sand it with VERY COARSE wet or dry sandpaper (Lowes sells the stuff as super duper woodworking sandpaper), spray it clean and totally oil free with break parts cleaner, mop it up so it dries totally grease and oil free.

Mix up some fresh JB WELD metal repair paste (the kind that can be ground, machined or tapped) and fill in the hole not pressing too much up inside the cases beyond a little bit you worked in on purpose around the broken lip edge to make sure it has an inside ledge to keep it from being pushed out by piston "huff" and circulating oil forces.  

As soon as this "coat the edges good" gets stiff enough to support another layer stick a piece of screening to it and push the screening in and get it bound firmly  to the coat the edges stuff.  Now quickly mix another layer sorta large and go a goodly distance out around the outside embeddding more screen to provide some mechanical strength which gets greater as the layers of embedded screening get layered on.  

See if you have some aluminum screen that you have laying around (or buy some from Lowes) and add that to your second & third layer to lend the necessary physical strength.   Each new layer of screen should be a little bit bigger than the last one so it bonds to a new fresh clean area of sanded case.  

Build up the screening and JB up until you have something as strong or stronger than the case used to be ....

If that first over the hole JB/mesh layer won't stay still and in place properly, use saran wrap and some duct tape to hold it in place until it sets up, then peel off the saran wrap and roughen the surface a bit with the coarse sandpaper before the next layer goes on.  

Once it sets up for 1 full day after the last layer, then put you some oil in the crankcase and ride that engine until it dies, meanwhile looking for that mythical "good used engine" that everyone else is looking for.

This path is cheap, quick and gives you all the use you would get out of that engine in whatever shape it is in from the oil loss.

Might last for years ..... might die tomorrow --- but it allows you to find out for less than $10 and a day or so spent fiddlin' wid it.



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BTW, which case has the hole in it?   I am assuming a crank case half (worst case) instead of a side cover.

Having been thru a few hard times in life, I can say this...
I have never been thru a long, painful trial that I didnt learn something about myself or life in general,, this whole trip is a school & testing ground for souls,, its not always comfortable, Ive never grown while things were all rosy,, only thru trials have I seen personal, spiritual growth. Enjoy the ride.. even when its bumpy.

Justin, I agree, it just seems like I been in the basement for a long time. Oh wait--it was rosy for about 2 weeks while I had some $$, but then right back to the basement. Hard to see the light at the end of the 10 mile long tunnel.

Oldfeller--There is different kinds of JB Weld? I have some JB Weld--black and red tubes--is there a specific different kind that is grindable/machinable?

No it doesn't say machinable on the tube itself....maybe on the package it comes in?
The hole is right on the bottom front--right side. It's about bb sized, but there is some cracking around it too. All told--maybe 2 pea's next to each other.

If the package doesn't say machinable do NOT use it on an engine. Regular JB Weld works great as body filler. Sticks a whole lot better than Bondo type "muds" do.  It also will "work" to a much smoother initial surface, so less sanding is needed. You can use the same screen trick to build up the dented frame tube.

justin_o_guy2 wrote on 06/25/11 at 07:02:51:

He didn't use a torch... he used a honkin' great big soldering iron (no flame or spark-no boom). Possibly the oil would hurt the heat.

If it was mine, Id have some Devcon 5 minute epoxy on board if I was gonna get too far from home, & some oil,

Devcon 5 minute epoxy. Where at you get this stuff?