I found a ~1.5in long crack in my Bravo 3 lower housing near the prop shaft opening. This area does not look like it needs to be sealed and the crack may not be an issue but I don't want it to grow. Has anyone ever had their housing cracks weld repaired?

Not cracks but I had significant cavitation burn filled in and half of the water inlet filled on my Imco lower. Cast aluminum can be welded by a good welder. They would have to notch the crack and fill it in. If it's not near a seal it won't need to be disassembled, just keep the heat local with wet rags.

Yes,,it can be Tig welded

Thank you, both! I'll let you know how it goes.

I have had one done years ago. Had a marina set the boat in the water in the spring. They moved it to a slip by hand lining it. The drive was all of the way up & it was hitting the concrete wall behind it in the slip. Broke a large section off. Took the drive off, they had to disassemble it to repair the housing. Never had another issue with it.

My first boat 35 years ago I stored boat outside and left drive all the way up. Snow and rain and cold weather crack. Marina took lower apart clamped it then put it back together and sent out to be welded. Never had a problem after that. Expensive learning experience for a 20 year old 😀

Wow thats interesting. I was trying to figure out how it would get a crack in this spot as it doesn't seem like it would be under much load during operation.

I talked to a local weld shop that says they will do it for about $50. I'm going to try to take the empty housing to them this week.