2.3L ('02-'11) 2004 ranger 2.3 water pump leak-ish

[KornTruck2]

So i found the problem. They ran stop leak i think and erroded the engines cooling passages. Just when i think it cant get any worse, i get a hair brained idea for repair

 

[KornTruck2]

I went as far as to make a clay casting of the damage, made lets call it, an internal plug. I made a few molds and eventually was able to plaster cast my plug with aluminum. I made a bridge of sorts to hold the plug into place. It works of course…

 

[KornTruck2]

At this point, i got it running enough to drive it while i prep it for a fusion 2.5 swap with a turbo. Whyyyyy not…

 

[KornTruck2]

I found a huge hole in the block

 

[SenorNoob]

That looks like it just rotted.

 

[KornTruck2]

That looks like it just rotted.

I first thought it was the wrong coolant, until i ripped it apart and found the other coolant passages were fine. I think the water pump just sent schrapnil into that cavity. As i pulled coolant hoses off, all of them had rusty muck lined u