Re: Mercruiser oil pan
We. A bunch of old race boaters, never have pan problems. Even when cut apart & added baffels are brazed in or made into deeper or more shallow pans for a dry sump engine.
If you weld ?? Now you are at risk of having rust outs along the weld lines. Just to many variables to control at those high heats to prevent leaks. Wrong rod & flux for what you are welding causes chemical changes to the metal.
Biggest problems are ALWAYS stiff, thin gaskets. We coat both sides of a thick rubbery gasket. I also wire wheel ALL the bolt threads & rinse in Acetone to remore oils. Then lightcoat the threads with RTV by GE. Never a drop leaks. We DO NOT EVER cause the bolts to deform around the bolt holes. If a new person does, we redo it correctly. That means pull the pan & flatten the holes area.
Thick in our case, is a 1/16" thick OPEN CELLED gasket, that compresses to about .010".
Rich