Metal spray is the common answer, had them done in the past without any issues but there are now companies out there that are welding them and re grinding, not had one done myself but it's a quite popular alternative.
A friend who is a top race engine builder said to me buzz it up with the tig straighten it with V blocks and a press, dial gauge and get it ground then crack tested.he did say they do crack somthimes, I said to him do you think I could do it, he said its a easy fix
I was thinking of pre heating the crank in the oven, not sure what rod to use , I would be confident if I could have it xrayed aftet, I want to run it at 10,000 rpm
Hey tommy. I had a triumph trident (one from the 60's not the new ones) crankshaft that had the same problem you have, a knackered big end journal. I looked into doing what you are going to do but decided against it. The problem as i see it is going to be distortion. To the best of my knowledge anyone who welds up cranks clamps them in a massive fixture to stop the distortion and has them stress relieved afterwards. I have a link below , which while motorcycle related is still pretty much the same thing.