Contour Enthusiasts Group Archives Forums Modifications 3.0L Duratec 3L rebuild/install for a college class NEED HELP!

Yeah ouch.

However, since the bearings are inserts and provide the surface for the crank journal, I don't think it would be that much of a problem to fix. I can think of two ways:
Welding is an option but the negatives are how weak would it make the metal around the gash from the heat of the weld? And that metal needs to be strong.
Metal-epoxy filler would be a good bet as that stuff has been used to repair engine blocks literally thousands of times to good results, but some people are inherently against it because it is a high density plastic/metal matrix. Still, a plastic metal matrix can be extremely tough and since nothing is riding against it that is what I'd do in this case if you don't want another block.
Oh, 3rd option would be have it machined down and install a machined steel insert that restores it to stock functionality. Big $ there and you would need a really capable machine shop.