[rocky]

https://flic.kr/p/WVFGfS

Any help is appreciated. This is the 6th time I'm doing this job. The bolts for the fan belt tensioner mount keep breaking. I'm out of ideas. I have replaced everything. I've tried different grade bolts and even studs. I think the problem is with the metal surface you can see breaking away at the 2 bolt holes. If that's the case it will require a new engine as it is part of the block and not a cover. Any ideas or advice? The fan hub turns freely and is working properly. That's all this belt runs.

[trackbird]

It's a little "hillbilly", but I wonder about installing it with a skim coat of epoxy (or similar) to fill the voids in the metal. The goal is to create a "good" surface for it to interface to the block (and not to just "glue it on"). I wonder if it might stabilize the surfaces enough to show some improvement. I might also find bolts from ARP and send them pics of what you have going on. See if they have a fatigue resistant bolt that might do the trick? Possibly worth a phone call.