my cosworth 2wd head is corroded/pitted where the thermostat housing buts up against it
im now using the 4wd thermostat housing on this so it only seals on an o-ring

my concern is this will leak, any ideas on a repair while the head is bolted on???

I was thinking of using a 2wd gasket but it doesn't have much of a mating surface on the 4wd stat housing?

 

A skim of chemical metal to fill in the pitting should work (as long as surfaces are mega clean beforehand).

Ultimately weld and skim will be required for a more permanent fix - but appreciate this isnt going to be do-able with the head in place.

 

exactly what I was thinking

 

Got this exact problem myself.

I've given my spare thermostat housing to my mate to fill in the recess where the o ring sits with weld and then skim it flat. Hopefully then I should be able to use a gasket.

 

Plenty of sealers about for all sorts of things.

Stat housing on my Isuzu 1.7td just bolts up dry to the iron block. ie no gasket, just sealer and it's a pretty shitty surface !

I'm amazed it doesnt leak ( well it did eventually but just needed to clean and re-seal it )

 

Tiger seal just fixed the tumble dryer door handle with it, only problem you'll have is removing it at a later date

 

Doubt tigerseal would be rated for engine temperatures though.

Plenty of Loctite sealants rated for high temperature and with good gap filling abilities.

http://www.loctite.co.uk/gasketing-9224.htm

 

Chemical metal will fill the pits just fine