Just to see what the fuss was about, I tried to weld a junk cylinder head, and when the weld cooled, it shattered like glass. If you use a cutting torch, I don't see how the molten edge of the cut wouldn't affect the metal in a negative way.

I’ve read these before, Good reads though. I have a few broken blocks I’ll work with first

I’ll cut the piece out with saw and grinder, no heat to affect the patch, basically a backer for the sleeve then flex seal it in the jacket. After welding of course

What is the red stuff, paint?

Yes, I painted the areas in question so the seller wouldn't claim that he couldn't see anything wrong with the block. Now looking back on it, I probably could have done something different but that's what I chose to do at the time.

How long ago was that, and if you mind me asking, what kind of money where y’all talking?

I looked back in my records and the day that went down in infamy was Jan 31, 2010. That's the day I picked up the block, looked at it and went "What.........?" Along with the damage in the photos, this block had a broken horn on the left rear of the block that had been repaired so badly it didn't contact the bellhousing face. As to price, I never knew the exact price. I had the original block to a Hemi car another individual owned and this block was part of a block swap. This garbage block was acquired by that individual from a third party who misrepresented it. The individual was a stand up guy and the deal eventually went through and the seller of the garbage block got his garbage back. I want to say we were talking in the neighborhood of $3000 for the replacement block at that time but I couldn't find that figure documented anywhere, just going from memory. Also IIRC the seller of that garbage block was in PA at that time. Hope this helps.

What would you think of one that’s cracked up in one the mains? Just for a street car no racing? Maybe can get for $15-1800

I personally have no opinion on that. I would comment though that the asking price for a wounded Hemi block seems to depend strongly on how bad the seller thinks the damage is. As to whether it is repairable, that is something that only a firm that welds cast iron can tell you. Years ago a shop in Williston, ND routinely welded cracks in diesel heads using a gas fired hotbox and cast iron rod. Perhaps you have access to that kind of firm, you'd just have to ask. As a note, I have a CH426 block that is windowed in two cylinders that I have been agonizing over for 20 years regarding which way to go. Sometimes it's not an easy decision. Good luck with your project.

Thanks for the input. I’ve never worried to try anything, if it works out it’s a great feeling, if not over the hill it will go. Everything is a learning experience.

I bought one many years ago before replacements were being made.

The guy gave it to me for scrap metal price of about $20. I included a set of stock rods and a pair of heads with giant holes in the combustion chambers.

I still have it but if I could find a shop to fix it for a semi reasonable price I might give it a go. I just wanted it for a show piece but it is now under a bench gathering dust.

You never know, like the difference between fixing a destroyed Hemi Daytona or a plain Jane /6 Charger. What’s the value after it’s done

I just repaired a couple of windows in a Hemi block. Used pieces cut from a junk 440 block, and welded it with an oxy-acetelene torch with brass rod. Been driving the car, and everything seems fine. I don't intend to push this one real hard, but it sounds real good.

My block has the windows in the bores right at the bottom. There is only about 3/16" of the block left at the bottom of one cylinder for a sleeve to seal to. That makes me nervous. If worse came to worse I could probably use Bars Leak but I hate that crap. I've thought about brazing a chunk of cast into the bottom of the bore to get a larger 'lip' for a sleeve but 1) I don't know how the brazing would stand up long term and 2) how the boring bar would handle the brass. Would you mind providing some details of what you did? Any pictures?

No pictures, but my damage wasn't too close to the bottom of the bore. Had a bit of a problem with some oil leakage around one of the cross bolts, but a bit of JBWeld fixed that.

I talked at length with the tech guy at Muggy Weld yesterday telling him my plan. He said what I’m doing is the right way and to take pics of the process. I asked about dissimilar metals and he said it’s only a patch, bandaid in a sense. Whereas welding with his rods is a permanent fix with proper procedure, heating and cooling. I’d advise watching his videos. Brazing is glueing and welding is fusion.

What about a waterjet? There might a company near you that can cut the piece you want bigger, then you can grind it down to the size you want. There are also some youtube videos of people making their own but I don't know if that would be strong enough to cut through a block.

Anyone ever try this?

Castaloy