Thanks for the input and ideas.
The mechanic at the lawnmower shop I trust said the main problem when the rod breaks is extra aluminum is somehow deposited onto the crankshaft. He said often the new rod won't fit around the crankshaft unless the crank is re-machined. Way out of my league if that has happened.
Thanks guys!
I have run into many times over the years and unless the crank is scored or severely out of round it does not need re-machined because of the aluminum deposits. Of course the overall condition of the engine is important also. Inspect everything inside the engine for damage. Be sure to inspect anything that was contacted by the rod or is in the path of the rod. This is especially important with camshafts and governors. You may find that the cost of parts is going to exceed reasonable costs over a replacement. If there is a chunk missing from the bottom of the cylinder wall It often will be fine once you de-burr the edges. As a general rule, if the area missing is below the ring travel area, still has the area to support the piston at the sides of the skirt thrust area and no cracks are radiating up into the ring working area you'll be fine. If it looks good thus far, here is how you do it......
First off before condemning the crank make sure it is a viable candidate. is the overall condition ok? (seal surfaces decent, shaft not bent or torn up?) if those areas are OK, now you remove the aluminum. First off, using care, try to flake off as much as possible. I use a piece of hard aluminum plate as a scraper. Then you need to dissolve the remaining aluminum. If your lucky and have nearby a shop that uses caustic solution hot tanking (many have gone away from this style) you can ask them to toss the crank in overnight and let is soak. (the solution you want is the type that says "Do not immerse aluminum in solution") this will dissolve the soft metal and once rinsed off you can wipe the remaining metal off the journal with a rag. Then you can toss it in again for another soak to ensure the pores of the journal are cleaned if you want. If you cannot find such a place you can make your own solution using Lye "WARNING, LYE is extremely hazardous and harmful. Use extreme care and safety equipment to protect your self!! see the wiki article..
http://en.wikipedia.org/wiki/Lye ) Now I will tell you it is not going to erupt or explode when you put the crank in but you definitely want to have water to rinse off and flush handy in case you spill any and you want to be sure you do this in a place that is safe and has good ventilation. I use LYE I purchase locally from a supplier, that I mix in a heavy duty tub. Remember, add LYE to water, never water to LYE! (splashing hazard is why) I have saved many cranks this way. Once the metal is wiped off the crank, you can lightly polish it and clean with brake clean then break out the micrometer.
BTW, there is no need to polish the crank into visual perfection, some discoloration is going to be normal considering what happened, just as long as the surface is not able to grab a fingernail and has no visible high spots or broad nicks. Tiny nicks I have had no problems from over the years as long as they are small, not raised and are out of the main thrust surface of the journal. If you find you crank is 1-2 thousandths undersize/out of round that is not necessarily a bad thing. On our racing engines (Briggs, Tecumseh, Kohler) we ran the rod journal clearances loose and heavy oil (SAE 50) to prevent scoring and overheating the rod journal. Especially on our Briggs 130232 engines which we supercharged (that's another story from many years ago)
Oh, and if by chance a hole gets popped in the side of the block those are easy to deal with most of the time, but that also is another story