Figures my first "technical" post would be a newb question like this, but I screwed up and put the "rolled up towel" between the tach/pump gear and the primary gear, and not the primary driven gear, because silly me removed the clutch first and....  So I crushed the boss for the tack and pump gear, and it's in pieces and probably difficult to weld.  Can I get by with an Ebay replacement case, or do I need a "set" of cases?  And is Ebay the place to by these?  I do apologize if this has been covered.  I spent awhile searching, and saw some opinions and then some fixes, and figured the dumbest question is the one not asked.  I feel pretty sick about this stupid mistake. Case # AT1 101731   Dave 

I know what I would do Dave. I won’t admit it on this forum. But it starts with JB- and I’ve fixed so many things with it from motorcycles to dishwashers.

I would go to a machine shop and see if they could tig weld it

Years ago I used a product called Marine Tex to rebuild metal parts on an old outboard engine, including internal areas that had corroded away, and the broken shroud around the propeller. It was super tough, did not fail, and really does dry hard, but you can work it. You can drill and sand it very well. Considering that nylon gear axle is captive between two bosses, I don't think you have to worry too much. After all, it'll never get nearly as much stress as you put on it by putting the rag between the gears.

www.amazon.com/Marine-Might-Repair-Ounce...id=1648158951&sr=8-4

Next time, just hold that gear with a rag or wearing a heavy glove, and take it off with an impact wrench. The first time I put a strap wrench on it, but I took it off and put it back on again, and just used the rag to hold it with my hand to take it off the second time. Live and learn though, we ALL make these kind of mistakes.

 By the way, I was just remembering how I used it... if you use this or something like it, you can create sort of a mold out of either painter's tape or cardboard or both, then once it's dried, then you can finish it off. You could actually turn this into a fun project (trying to look at the bright side).

Thanks folks.  I don't like to use epoxy like this, because if it fails, I am rebuilding the entire engine again.  LOL, I am familiar with Marine Tek as well, from my boating days.  It is tenacious stuff!  

A friend called a guy he knows, who said that it is Okay to mix case halves.  I assumed it was because I've done it with the Hodaka ACE cases, but I guess I'm a bit intimidated by this bit of Oriental Wizardry.  (Remember THAT ad campaign?)

So while I source a replacement case, I went ahead and did the JB Weld option.  This is the slow curing "high temp" version.  I turned down a bit of DOM to match the outer diameter of the boss, and split it to fit over the main gear boss.  Clamped it six ways to Christmas, using the DOM bit as a band clamp to spread the pressure.  It's going to have to be really peachy in there when I check tomorrow morning, for me to go with it, but we'll see.  Thanks again for the input!  It's nice to not be alone in a vast wasteland of (Oriental Wizardry?)      

Here is a TIG weld repair to a DT3 crankcase sprocket cover mounting boss.

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Me being tight on money i'd just have the tach on to make it look original & carry on. Could have the cable & the piece it screws onto--no-one will know haha [Except Us--umm]. Welcome too.