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[Radar]

Can anyone recommend where to source the above / someone who can replace? Was about to put the undertray on this morning after an oil change the day before and the jack slipped cracking the oil sump pan (luckily axle stands saved me... unluckily the sump pan is cracked . 

Damaged area is at base of pan about 5 inches long with part of it "recessed up" from the force of the jack, so i'm guessing to repair would mean taking off sump and flattening from inside?

Any pointers appreciated.

[hotel21]

Guessing its a pressed steel pan?  If so, remove the pan and knock the dent carefully out from inside to regain shape but beware of cracking.  Heating with gas to light red softens the pressing, easing reshaping.

Afterwards have used a VERY strong light source (not the sun, obviously....) to see cracks/porosity and then brazed the holes/cracks.  Welding is doable but can cause further holes so brazing will suffice, given operating temperatures are relatively low.

[Radar]

Thanks for reply and its good to know that operating temperatures are relatively low.

Have been doing a bit more searching and pan removal is not straightforward.

- The pan is aluminium and as far as I can tell requires the suspension to come off and engine to be raised slightly which is beyond my capabilities.
- Was thinking of trying to press the cracked lip up a bit with a piece of wood and gently hammering, then using an epoxy repair putty (suitable up to 150c). Sump will be drained already and thinking to leave for 24hrs to let putty set properly. Then see how it goes for a while. The crack is at the bottom of pan which is not so susceptible to high pressure.

[albitz]

Alloy welding in situ sounds like your best bet. 

[Radar]

Thanks - will look into this Anyone know anyone in Berkshire area?

[05omegav6]

A new sump from...

http://www.mercman.net/

Together with...

http://www.hss.com/g/67715/Folding-Engine-Crane.html

Be done in no time

[Andy B]

Alloy welding in situ sounds like your best bet. 

Trouble with welding ally sumps is the fact that ally is porous and the oil soaks into the metal ..... it's not pleasant welding it & the oil doesn't help the weld 

I've done a few similar for work related & as a 'foreigners' 

[Radar]

Thanks will try the parts supplier - got to be honest I think lifting the engine myself will be a non starter.