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I realize this has nothing to do with the original question, but have you thought of applying a layer of machinist dye, (dykem blue) to the contact surfaces prior to assembly. Then during the next dis assembly, the wear points will be easily seen? Just a thought.

IMHO I agree with all that metengr says except for the build up part. It would probably be quicker to lay out 25 mm on 2 connecting piles and cut it off, dress it up, slip in the backing ring and weld it up. A lot less time under the hood.

Thank You all for the responses, I have read several times what hydtools linked to. The way metengr explained it is somewhat understandable. As my name implies, I have been welding for a long time. I am not a engineer (always a dream of mine) but I do have the ability to see things in my minds...

How was this issue finally resolved ??

Forgive my ignorance, I have been welding for to many decades. AWS 3g 4g 5g 6g certs so I know how to weld. My question is, How does the actual bead bond to the base metal? Simply phrased, I know every thing melts and fuses together. but at that microscopic edge of the puddle between molten...