Thursday morning went out to start up the old 6.2 (now 243,500 miles on the clock). All was usual until I hit the key and the starter made a loud bang and the whirling sound of the bendix missing the flywheel. Had to go to work so jumped in the '68 and went.
Got out a few minutes ago to inspect the starter and found the solenoid completly snapped off the rest of the housing. Started loosening bolts to take starter out and the outer side of the block's mounting lobe fell out and hit me in the forehead. Is this a fixable thing?(not my forehead) or am I needing to replace the block?
Really bummed out about this.:(

This has been known to happen, although it isn't nearly as common as the starter mounting bolts snapping off...

I would say that you could probably get that repaired (no, not your forehead... you'll have to talk to a doctor about that one ):h ). I would say it could probably be welded into place. The only problem would be that the welder wouldn't go all the way in, and then the part won't be as strong as it was... To correct for that, I would have a piece of metal welded across from the broken part to the block. The hope would be that it would reinforce it enough that it would hold. From there, make sure that the front starter bracket is solidly in place and that you use the proper mounting bolts for the starter.

I never heard of the solenoid snapping off... Wonder why that would happen?

I've never had the chance to use Mangus580's favorite smilie, but in this case it applies:

:nopics:

Forgot to mention in the original post, the inboard starter bolt (nearest the oil pan) was missing. Front bracket still in place, that may take some of the wonder out of why the solenoid snapped.
I dont know how to get pics posted here, but I added a few pics of the starter , and the broken lobe at the link below, in "The Diesel" folder. Not high quality pics, but enough to give you the idea.
BTW, "The Bus" folder is my latest accquisition, a 1988 also with a 6.2 "J"/400thm.
www.picturetrail.com/yachtcare

I would think a good welder could v-grind that and weld it into place solidly. It's thin enough it should be no problem at all for somebody good with a welder and a grinder. You'll have to drill and tap the hole out again, of course. Do make sure that once it is done you install BOTH of the bolts ANd the front bracket... This could probably have been avoided entirely.

By the way, I really like your trucks. The dually is real nice looking. The Apache is what I always wanted (EXACTLY what I wanted - I wanted the early one with the ovals in the hood)... My truck was what I got. Oh well.

Nice bus...