Anyone come across this before?

Hole in side of sump from Turbo Pipe rubbing.

According to service history, was repaired at 76k now 100k.

Going to try same repair with JB Weld

 New Sump if not successful.

2009, 1.9tdi pd engine.

I've never seen anything like it myself, but have you had the engine mounts all checked?

It's not the engine mounts, all ok. Turbo pipe was resting against sump and lettering on plastic pipe rubbing against sump, with running vibration. Probably slightly misaligned from new. Cable tied pipe back a couple of millimetres to give it clearance.