Where in the cover is it? Is it in a structural location?

If it's just a crack or in a non-critical location, using a strong epoxy should be acceptable. There's quite a few epoxies out there with yield strengths significantly higher than cast aluminum.

Alternatively you could probably weld or braze the cover.

 

Tiny hole just in front of the bolt to the crank position sensor. it is not in a structual area. do you have a recommendation for an epoxy?

 

Tensile strength of JB weld is roughly 4ksi, and cast aluminum will probably be in the 20-30ksi range depending on what alloy they used.

I would generally check the packaging of the epoxy and try to find something with a 15+ksi tensile strength.

Truth be told JB weld will probably do the trick, but if you want to maintain the same strength you'll need something a little stronger.

 

I would not do anything other then weld it all it takes is one mistake with the JB weld and that chunk falls inside your timing cover reeking havoc and destroying your motor.

I did the exact same thing as you, that part is pretty thin where you have to grind, and its a common mistake. Take it off and have it welded the right way!!

 

I did the exact same thing. I had quick steel on mine for a while and it worked fine. while the engine was removed i took it into work and hit it with a weld before i powder coated it

 

I agree welding would be best but honestly I just want to get the car to the tuners. It has been parked all year waiting for a new transmission and then a pile of other parts for the blower upgrade. I would like to drive it for a couple weeks before it gets parked for the winter.

 

Jb weld if in a safe location, no pressure in your timing cover

 

JB weld is some tough ****. I would not hesitate to use it. Especially if you can get to the inside and apply some there too.
I have seen and even fixed timing covers on ISB cummins motors that have cracks fixed using JB weld. (caused by a locating dowel pin falling out and wedging between a timing gear and case causing it to crack)

 

Keep in mind the front timing cover on an ISB5.9/6BT is stamped sheet metal which is far more forgiving to cracks and holes than cast aluminum. Also there are no components mounted to the front of the timing cover.

Bottom line is JB weld will work, but it won't be nearly as strong as from the factory. Whether this is an acceptable risk or not is up to you since the timing cover is not a critical component, and failure would not be disabling.

I'd hunt around for some stronger epoxy, or see if there's someone who can weld/braze it for cheap.

There's definitely epoxy out there. I forget where we got it for formula SAE, but we actually used it to attach a composite part to an aluminum one because the aluminum would actually fail long before the epoxy.

 

Thanks guys, I yanked the cover off tonight. I will have it welded up tomorrow. For the peace of mind it's worth it.