How do you repair a corroded clutch cover

I just pulled the water pump cover on the 85 500XC and noticed that the clutch cover was corroded pretty badly from water/ antifreeze. Does anyone make an aluminum replacement or have one from the recall upgrade? Can I grind out the corrosion and fill it in with a JB Weld type product and re machine the sealing groove? Is there a recommended type of coolant that is not as corrosive?

I havn't repaired any as I have not had any go bad on my watch. The one which I got which was repaired with some sort of epoxy stuff years ago looks lifted enough so it should be re done. I have one corroded one (an 88 so don't believe the part about recall update unless later than that) which is almost through in one spot. none of my corroded ones are into the sealing ring. Wouldn't it be best to just push the o ring into the uncured epoxy to make it's resting place? The 88 and probably 87 covers are changed a bit and I don't think they will work real well without the matching kick start pieces on the outside. They have sleeves in them and the shifter has two o rings on it not sure what year that started. Someone suggested the water the anti freze is mixed with should be de ionized but I think modern vehicles generally aren't all cast iron engines like when these things were new and most anti freeze should be good but feel free to read the label that is what the manual says to do. Though I have access to a milling machine I would just work the epoxy as it cured and use a good sharp wood chisel to make the surface flat. I could see making a plate (coat with perhaps dish detergent) with the three holes and a few thin shims so you squish it down real close to where you want it and shave it flat as it cured more.

fran

I repaired a clutch cover for my 85 400WRX that was corroded thru under the impellor. I repaired the case with JB Weld and also repaired the badly corroded seal seat by filling with JB weld and recutting on a Bridgeport mill. Used the impellor shaft thru a hole in the JB to pick up location, push the shaft down before boring. It has held oil, but need to check with coolant.

If things are ok with HVA Factory now, they make a WC clutch cover

thanks for the replies, currently it does not apper that the seal was leaking, Fran I may just set the seal and put the jb weld around as you suggested

i got a good fix! when i broke my case on my "new husky" 450 it broke all the way thru the outer and inner clutch cover, you need to get all corrision off of the cover clean is all ways good> 3m part # 8235, its a plastic repair but once it sets its rock hard! you can get at a automotive paint sup. but u need a applacator gun. stuff is great for striped out bolt holes too. will hold 60 foot pounds of torc if prepped right