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  1. #1

    Default Block Welding Question on 2.5L Chevy Engine

    i just bought a used 2.5L engine out of a 91 S10 to put in my 1985 S10 because the engine started mixing water and oil together.

    Well anyway i bought this other engine with less then a 100,000 miles on it and i got to cleaning it up today and found the block had about a 5 to 6 crack in it.

    It is right under the 3 freeze out plugs on the left hand side.

    Well my question is can i take a stick welder or a wire feeder welder and weld it the block where it won't leak coolant out?

    I had a few mechanic guys tell me that i can do it and then had a few tell me it wouldn't hold and bust back loose with a bigger hole.

    I'm a pretty good welder and i think i can do it but i really like to know if i can do it or not before i try.

  2. #2


    If the block is cast iron your not going to be welding with a wire welder.Cast iron welding requires a skilled stick welder. You need to heat the area 1st then weld. Then will it hold maybe maybe not. Time for a new block man.

  3. #3


    yeah i got rid of that engine and working on a other one. i'm putting main bearings and new gaskets on it when i get the block back for the shop after having it checked out good.
    Proud Member Of Anderson County Coon Club

    Keep them Treed Boys

    Own and Drive a 1985 Chevy S10 2.5L 4 Speed

  4. #4


    You can use a wire feed if you use stainless wire, just remember to heat it before you weld and then ping it when you are done. If you use stick there is some really good nickel rod unless it is aluminum then use TIG.
    Ford has a better idea! Drive a GM!

    07 GMC Sierra Classic
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    68 Camaro (blown)
    2011 Ford F550 V10
    I don't own this truck, I just drive it!

  5. #5


    yeah i was using the gas with the stainless wire but it still didn't hold worth a nothing. so i got rid of it to other guy that needed a few parts to get his engine going.

  6. #6


    Did you grind it out first and clean it well?

  7. #7


    yes that was the first thing i did. and it just didn't hold like i thought it would so i got rid of it.

  8. #8


    I used to weld a lot of cast and when I first started doing it I had a few that failed. Most of the cast that I weled was on big pumps, the nickel rod worked the best but I used the the wire feed a lot.

  9. #9


    oh i c well i'll write this down and remember it next time in case i get a other block that is cracked.

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