My concern with utilizing the "MIG" or even "Stick" welding is the deposited filler material increases the localized volume of molten material which then in turn will transfer greater sums of heat into the aluminum.  The weld bead would result in greater pull and shrinkage and 'is' ideal for removal of tougher bearing races in ferrous housings, but I just don't want this greater time exposure of high heat to the aluminum.   

     And I will expedite the ambient air cooling process with compressed air discharge upon the surface on the completion of each torch run.   

     Also be sure your "grounding cable" is in direct contact with the sleeve you're sparking to.   

     Scott.

      Yes, that would fall under the "very repairable" heading. 

      But I gotta say, though that actually is a charge that 'should' be levied considering what actually is involved for a truly "proper" repair, it's just that I've gotta up my prices for work done!   

      Scott.

Although the man's advice and wisdom is beneficial . . . . . .

      Perhaps presented a tad excessive on the hyperbole in attempting to make points, that maybe haven't been established yet.   

      But of course, the greater the concerns the better the business (unless you manage to scare the customer off!); but then, it is a "promotional" video subject, right?   

I would never use an Eagle crank on an FE. 

      +1      Particularly those "cast steel" examples!   

      Scott.

     

would there be any benefit to dowelling the girdle to the pan rail at several points around it?

      The entire challenge is the attempt to make whatever it might be that your trying to incorporate into the original structure "to be as one" with it.  The problem becomes with the physical invasion into the original structure not engineered for such and the redirecting of stress loads to areas not intended for such, in the attempt to accomplish this; so in reality this effort often results in only weakening it. And then often the add-on structure still isn't sufficiently integrated anyway; as here for example, do you really think that the fastening intended for the retention of the oil pan are truly sufficient in their new responsibility of trying to arrest movement that has overcome other more significant engineering?   

      So the next thought might be: Where were you planning to remove metal from the block in the effort to make it stronger?   

      Scott.

And yet, after 7 years, the engine still runs perfectly fine. 

      Although you may "feel" that it runs "perfectly fine", the point was that it obviously isn't running as well as it could!   

      But then, that may just be "good enough"!   

      Scott.

     

Not everything has to be perfect. This sort of thing was commonplace years ago, and under the right circumstances, there's nothing wrong with it.

       Your are absolutely correct, everything doesn't have to perfect, but do realize otherwise, it is something less than!   

       And I did present the statement that suggested that one really needs to have the parts in hand and actually looking at them in order to determine what state they might be in, which then can be weighed against that of one's own level of acceptance might be.  But I think when inquired upon and we are attempting to outline the processes to be followed, we probably should be suggesting as close to "proper" as possible and then allow the individual to temper this to their own abilities and liking.     

      Scott.

      P.S. Just a note, this to "aid you" on "your effort":  Now I'm not there . . . . . . but of perhaps less than ideal, it looks like on the intake valve the seat contact surface "runs off" valve face, both intake & exhaust seating surfaces appear "sorta wide" not to mention "bad transitioning" with "no back-cut" on the valves nor additional angles "defining" the seat face angle in the cylinder heads.  Now there may be additional "concerns", but like I said, I'm not there and this is just what I noticed in glancing at your photos.   

   

       Just note that although it 'is' generally the intention to create equal air flow within the intake, runner to runner, this in itself, for a number of reasons, doesn't guarantee that the fuel (original inquiry) will be distributed accordingly.   
       Scott.

The valves are already ground and I plan on doing a slight lap . . . . .

      Now I'm not there, I don't have the parts in my hand, looking at them, but generally I would be of the impression that 'if' the valve faces were worn to the point of necessitating a "refacing" process, then the corresponding seating surfaces in the head are really going to need more resultant effect than that which "lapping" would be able to provide.   

      Scott.