If you hadn't of ground it out already I would have used lock and stitch method. Now that you have ground I would pick Belzona as the next best, But first drill and tap a 1/16 or 1/8 NPT hole at each end of crack and locktite a pipe plug in, and grind it off flush. Google Belzona cast iron crack repair. I have used it a lot at work and as long as you have repair area prepped the way they say it is amazing how well it sticks. If you are bent on welding it then still drill a small hole at each end of crack, but not all the way thru to stop crack from propagating farther. Make sure joint is clean and well prepared ( picture looks like you have it grooved out fairly well) Run torch over joint to warm but not heat. Just after you shut torch off you need to be able to put your hand on for a second and not get burnt so I am going to say 200 degrees F or so. This also helps to burn out any crap in root of joint that your wire brush does not get out. I have also washed down with brake cleaner before but depends on if there is crap in joint. Your 55% nickel sounds like the right rod, run it as low as you can but still get a good wetting/fusion action. If you have not welded grey cast iron before you may want to practice on another old piece? I would start welding progression from the ends of crack towards the center. Weld a short bead maybe 1/2 to 3/4 inch max. Have a chipping hammer that is well worn/rounded on the end and peen the weld and surrounding cast to relieve the stresses induced by the welding.( peen it a lot, all around the heat affected zone on the weld itself and an inch or so each side of weld. you wont peen it too much) Before putting another short bead down make sure cooled to a point where you can put your bare hand on weld zone without getting burnt. When you have completed joint peen it all around until you think you have done enough than do it some more. There is probably a pile of info on you tube etc. on welding engine blocks. At the end of the day you do need to be a decent welder to do this so not knowing your experience level I cant comment on whether you will be successful?
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