Building AAZ motor; meet Harley

[JASGTi]

Seems they have a new Sheriff in Arturlow. Still thinks it sucks that it takes almost 12 months of messages and offing to volunteer to get anything done.

[CrazyAndy]

Yeah, but at least his enthusiasm will hopefully keep things in check.  And Lucky trimmed the spam!

Engine-wise, I think I'm just gonna bore her out to the next OS, 1mm.  The bores' sizing issues are really frustrating me, and there's still some porosity showing in #1's bore.  Thank goodness I know about a closer machinist now!

And BTW, did somebody on here offer to buy my 0.5mm OS pistons?  Because I have a PM to send.

[theman53]

what for money do you want for them???

[CrazyAndy]

PM sent!

[CrazyAndy]

Okay, sorry to big bump, but progress will hopefully be made in the next few weeks.  My new 1mm O.S. pistons are on the continent according to Myke, so I should get them within the next few days. Got the sealing surfaces on my exhaust manifold planed since the turbo flange had some light pitting, but still need to drill an EGT port.  I also pressed new wrist pin bushings into my rods.  I'll have to get them reamed to fit the pins, though.  Gonna see if the local machine shop can ream bearings; if not, anyone who know a good shop that does them let me know.  Also need to see if they can balance the rods and pistons.  Still need to find a good 45+ trim compressor housing and save enough up to send the turbo to Ohio for rebuilding.  And get reamable intermediate shaft bearings.  Maybe coat pistons as well.  List is getting smaller, and now that the pistons are near I need to kick back into project mode and get some mo' money.

Progress needs to happen . . . soon . . .

[CrazyAndy]

 . . . .and then my pistons showed up.



Thanks, Myke.  Next stop, Mr. machinist!

P.S.: Anyone out there know of a shop that reams wrist pin bearings, or bearings in general?  And whoever has an extra intermediate shaft woodruf key, holla at me!
P.P.S: Can you swaintech coat over that black crap?

[theman53]

Yes, No, Yes, but that black crap is basically what swaintech would be putting on.

[CrazyAndy]

NVM on coating then.  Less money to spend anyway.  Thanks for telling.

The bearing reaming is what I need to know right now anyway; asked the local machine shop and they looked at me like I mentioned a dark art. That and IS key.

[CrazyAndy]

So, finally got my block, rods, and pistons out to the new machinist, and this guy did in 10 days what should have been done by the other guy in 4 months:






Nice, right?  Here's a list of what was done:
-Block bored over another 0.5mm to accept the 1mm OS pistons
-Pistons balanced
-Rods balanced
-Wrist pin bushings reamed to fit new pins
-Pressed in new intermediate shaft bearings

The block is now 100 times better than last time.  Ring end gap comes within new spec in at 0.010", the piston pins fit with surgeons precision into the new bushings, and the intermediate shaft bearings are so tight they need oil to turn (and the IS glides effortlessly in the bearings while oiled).  So all the bottom end problems are solved, and I'm one head gasket away from calling it a long block.  All that's left are forced induction things like rebuilding/upgrading the turbo, and the AWIC setup.

Also bought some block plugs and woodruf keys at work, so don't need anything for the bottom end anymore.

If the turbo junk can be sorted by the end of next month, Mk1 Madness is a feasible option once more!

[RabbitJockey]

ported head and what not?

[CrazyAndy]

Of course; actually need to clean it up, put in new stem seals, and match port the manis also.  So a little more than what I thought.

[CrazyAndy]

Okay, getting close to reassembly of the short block, but now I have some quick questions before sticking everything back together:

1) Should I seal the piston oil jets with anything, or do they just fit in their bores well enough to seal themselves?  I an't remember how they were when taking them off.
2) The machinist removed the oil galley plugs to clean the block after the second re-boring; what should I seal them with?
3) Block coolant core plugs, what do THEY get sealed with?
4)Anyone got an AAZ metal dipstick part?
5)My block still has it's oil pump shaft bearing in it; should I knock it out and put a new one in it?  It doesn't feel bad.

Just kind of a case of pre-assembly jitters; if there's anything I need to know that isn't obvious before putting it all together, just point it out.  If fortune smiles on me then the short block should be completed before the end of next week.

[theman53]

Piston jets do require a sealant. I think I used an anaerobic type. In theory all of them should leak less than 1 main bearing, but some members on here have had oil pressure issues when they didn't seal them. One tore it down, sealed them, changed nothing else and oil pressure issues were gone. I think this is where I may break out the hylomar. You maybe able to coat it on all the things you listed and it seal fine. I won't say 100% it will work, but I do stuff like this with Hylomar and it works fine for me. Good luck.

[CrazyAndy]

Piston jets do require a sealant. I think I used an anaerobic type. In theory all of them should leak less than 1 main bearing, but some members on here have had oil pressure issues when they didn't seal them. One tore it down, sealed them, changed nothing else and oil pressure issues were gone. I think this is where I may break out the hylomar. You maybe able to coat it on all the things you listed and it seal fine. I won't say 100% it will work, but I do stuff like this with Hylomar and it works fine for me. Good luck.

Would you use the spray stuff or tube hylomar?

[theman53]

Most I would tube it. But if you can not waste much with the spray it is all the same stuff so you could spray it too. I really like that stuff.