2003 Sportster XL883C.

There was an oil leak near the oil switch and after cleaning it up, I discovered this. The mount is once piece with the engine, there's no replacement part for this.

I'm afraid I'm out of options... thoughts?

 

Over tightened oil pressure switch. I'd clean it up real good and use some Permatex Ultra Black on it. Probably won't stop it but may slow it down enough to make it tolerable. A good welder could fix it, LOT of work stripping it down, but doable.

 

Welding an aluminum casting requires some pretty incredible skills and methods if it's ever going to hold together.

 

Theoretically it only needs to be welded on the inside, doesn't it? And it doesn't need to be pretty

 

That looks cracked straight thru, oil will still come thru the hole where the sensor is screwed in. Would need to be filled, drilled and tapped.

 

It definitely can be welded by a skilled person. Doing it while the motor is still in the frame may be an issue, but anything is possible. You need to go to an old school Indy shop, a place that welds up old Knuck and Pan cases regularly. They will be able to tell you how to go about fixing that crack. But you may need to pull the motor, good luck.

 

Considering that the surface with the crack in it is a sealing surface, the chances of getting it welded properly, without pits, or other imperfections and remain flat and smooth are slim and none.
even accomplished welders I’ve known that have extensive experience welding aluminum would be hard pressed to get that spot done right.
Other methods should be pursued, IMHO.

 

I researched and this may be the way to go. I do have a friend who's a welder so we'll see what he says first.

If I decide to go with Permatex Ultra Black, I'd cover the whole thing even inside. On the sealing surface it will have to be filed down flush. The oil switch itself - I'll cover it's threads with this stuff and screw it. It would be a pain in the azz to replace if it needed, but how often do you need to replace an oil switch...

 

I not sure silicone or pookie will hold up here.

This guy is a bad ***, but it is weldable.

 

[QUOTE=Rusty Springs;20988445]I not sure silicone or pookie will hold up here.
This guy is a bad ***, but it is weldable QUOTE]
Exactly what Architect said. Some handy guys out there that have superior skills that us garage welders have.