Main Cap

One of the things I inherited with this engine was a broken main cap.  The previous owner had made a replacement, but it was larger and not original. 

When I was discussing getting the block cut for a rear main seal with my machinist, I mentioned this and he said that he could probably get it welded and make it like new.  The first thing he did was make a jig to hold the two pieces in their correct relationship and sent it out to be welded.

Then he cleaned up the excess weld and line bored the cap.  Here is is with the bearing in place checking for the proper clearance.

The final step was to recut the oil groove on the inside of the cap.

Once everything was done, the only way to detect which cap had been repaired was to see which one is cleaner.

In case you can't tell, it is number 2, second from the far end.