Hi Steve,
Sounds like we have similar situations. freeze crack in mine may be as long as 13 inches... I have magnaflux red dye penetrant on the way to get a better idea of where the crack starts and stops. I will probably expand the red dye detection to a larger area and check further given what you have found with additional cracks. I came to the same conclusion as you: Welding concerns me unless you tear the engine apart and have a professional furnace weld. I am sure people make cold welds work but seems hit or miss. A solder approach or something like castalloy looks interesting for this type of fix, but opinions differ as to the durability of this fix. I am down to Belzona 1111 or the Stitch-n-Lock product from Calif. Stiching looks like the proper way to do this, but 13 inches of repair will cost me about $600, and that's doing it myself. The other concern with stitching is thickness of the metal... You need minimum 3/16" thick, and of course degree of corrosion on the inside of the jacket is unknown until you start drilling... On the other hand, the Belzona 1111 looks like good stuff used in demanding commercial applications, but I think not quite as good a fix. I did find the Belzona 1111 in 1kg size for around $100... Do a google search.