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I had the same problem - only satisfactory solution in my view is to weld it (see picture). This is a specialised process and I would recommend taking it to someone that has some knowledge of welding cast casings - the materials used are not always weld friendly. It will also be necessary to dress the gasket mating surface after welding to ensure this is flush with the rest of the casing - delicate but not impossible. Good luck!

Thanks. I just stopped by a local machine shop and they can do it easily they say.

Off again it goes.

Case is welded. Cost me $15

Had to do a little more cleanup work after the weld but I got it back together with no leaks. Charging like a champ now.

Fifteen bucks?? What a deal. you need to look after this friend !! Tig aluminum is a specialized process and not all will do it, especially on an oil soaked casting. Lucky you. I have tig equipment and was qualified in tig aluminum. I've welded oil soaked castings and it's no fun. The oil contaminates the weld, turns to carbon under heat and contaminates the tungsten electrode. It's quite the pain in the ass to weld. $15 ?? Wow !!

Yes I was shocked. He did it while I waited and it took about an hour total because, as you say, the oil soaked casting. It took several tries to get the weld to take but he got it in the end. Then he took some time to grind it down and shape it. Once I got it home I did some fine work with a dremel grinder to get the edges around the bolt hole just right so the bolt would sit flush. If it didn't it would either crack in a different spot or leak. It didn't so all is well.

Considering the shop charges $90 an hour I have no idea why he only charged me $15. However, I have used them for other unrelated work so maybe that was a factor.