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Old 10-02-2006, 12:30 AM
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modifying cast aluminium oil pan - questions

i have an engine swap ill be doing this winter, and to do it w/o moding the frame, ill have to modify the oil pan. the pan on the engine is a rear sump setup, but the car requires a front sump style pan

there are no aftermarket oil pans for the engine in question, i promise you that, so that leaves me one option, customizing a stock pan

what is required to properly clean a used cast aluminium oil pan so that it can be welded ?

would there be any problem with using aluminium plate to create a new sump ?

anything i should be aware of in general ?

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Old 10-02-2006, 05:43 AM
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Cast aluminum is a bear to weld. It depends on a lot of factors like quality of the cast aluminum to be welded, the experience level of the welder. Welding cast aluminum is very touchy, it is a fine line between material collapse and a good weld.

Vince
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Old 10-02-2006, 07:08 AM
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Can you weld aluminum? If not then you will have to take to a place that will be able to do it. Note here, don't go for the cheepest place as this pan will need to be EXTREMLY clean and mostly likely baked (around 450) to remove as much of the oil as possible. Even then if its a crap casting there could still be problems.
But yes it can be done as I have done work on a merc pan for a BBC and it welded fine.
Randall
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Old 10-02-2006, 08:12 AM
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I have tig welded a lot of the Briggs go kart engines. They are cheap cast. I would clean that pan with some kind of solvent. DO NOT SAND BLAST IT. Sand blasting only puts more dirt in the aluminum. Then bake it in and oven as hot as the oven will go, for several hours. I clean the area to be welded with a carbide burr to get to good clean material. Acetone works good to clean with. I would clean and bake several times. Then maybe it will be clean enough to get a good weld on it.
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Old 10-02-2006, 12:15 PM
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You can have a steel or aluminum pan fabbed up pretty easily from sheet metal. You just need to have a drawing of the pan rail and then the rest can be fabbed up.

If you're talking about either the LS1 or the GM vortec inline 4/5/6 motors, their cast pans are integral parts of the stiffness of the crankcase. They'll live fine in stock applications, but I don't feel good about removing all that stiffness if its already given to you.

Probably a lot easier to either fab up a sheet metal pan, or its pretty easy to modify the crossmember.
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Old 10-02-2006, 01:25 PM
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Tbucit - personaly, i cant currently weld aluminium, BUT i would be able to do all the cutting cleaning and mock up

RPMs- good tips. im nat the type of person to sandblast things that have to be welded for that very reason. if i mod this pan ill deffinantly bake the heck out of it

curtis73 - in this case, the pan is not a structural unit. Also, to modify the cross member i would have to move the entire crossmember forward at LEAST 4 inches.

if this was just a street / drag car, that wouldnt be a prob, but this is also going to be a road course / autocross car, and lengthing the wheel base would kill some cornering ability

i might try my hand at building it out of steel instead of modding the stock pan ... donno yet. figured id see what u guys had to say about working w/ the aluminium

and oh yea, i cant recess the firewall to fit the engine either, its against class rules to recesses the firewall for the block or heads.

this is my competition in my autocross class ... as you can tell, i need every edge i can get, lol





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