The rain stopped for a couple minutes so I moved the generator to get a better pic. I think it shows the factory weld a little better. Q for the more experienced: If I were to strip it clean with a wire-brush on a grinder would I be making it more difficult to spot possible cracks?
I would mark it up so you can put it in place again,then grind down the weld that hold it together (its probably shitty too. Strip the "cap" and frame and ask a friend (if you dont want to do it yourself) to weld it all up again. If the material were worn out you should probobly have a crack in the material insted of a loose weld. So just go ahead and weld it all together again.
this is why i suggested the three small holes and dowel pins, if you do this, you can blast it, grind it, or anything else and the marks won't go away. everything needs to be super clean to inspect and ensure a quality weld. if the metal is taken down to a bare shiny state that's the best way to inspect it. putting the pins back in at three points triangulates the parts back into position. once they are welded the pins can be punched out and the small holes welded up.
Thanks for all the input, I just got some bad news regarding some welding help. A fellow hamber local to me will not be available till the new year... I was really hoping to drive the car down to San Diego xmas eve... Lost your method will certainly be employed, now I just need a skilled welder that is available at a tricky time of year. I originally planned on welding it myself but it has been close to 20 years since I have used a stick and I would need to spend a lot of time practicing before I felt confident to do this right especially considering the danger if done wrong. Any skilled welders in L.A. with schedule openings next day or two? or even after xmas?
I'm tempted John! You could be one of my long lost relatives... I lived all over western europe and never made it to Sweden where I've got a bunch of family, prob too much time in Rotterdam although I can't quite remember...