Been a little while since I've updated. In the meantime, I've been pretty busy getting things ready for re-assembly. Also had to fit some whitetail hunting in there too! Anyway, I've been putting things back on the engine in the last couple days.
To re-cap, I pulled the engine down to the short block because of a coolant leak somewhere. I figured that since my intake was going to be coming off anyway, I might as well pull the heads and have the valves done.
One of my employees is a "boat guy." Used to race offshore, has three boats (including two go-fasts). His engine builder is also his best friend. So, he offered his guy up to do my heads. I told him there was at least on broken bolt, I wanted the valves done, and to "clean them up". In my mind, that meant look them over and fix what was wrong. I guess I should have been more specific. He Degreased them, ground the valves and replaced the seals and one guide. Didn't do anything with the exhaust manifold mounting surface...or fix the 4 other bolt holes that were screwed up (he did fix the one I told him to). Not sure why he didn't mention it before he gave them back to me. Seems like he should have. A couple days later, my employee said the builder noticed the surface was garbage and the other holes were wonky, and was going to fix it, but then thought since it was assembled before he got it, he didn't want to "fix" it and make it not go back together. I guess that makes sense...but it left me with heads that I didn't feel right about putting back on the engine.
I have access to a full machine shop at work and the guys that work in there are a little lacking in work right now, so I had one of them take a couple hours and mill the manifold surface and install thread inserts into the screwed-up holes. Being the boss has a couple advantages!
Anyway, some pictures...
Here are the heads as they came off the coach and after they were returned to me from the engine builder...
Majorly screwed up mounting holes. I figure someone has been trying to fix exhaust leaks on my girl for a while. Removing the manifolds broke some bolts and they played amateur hour fixing it. The drilled and tapped holes were off center and crooked.
This has been leaking exhaust for a while! I've never seen such an eroded surface.
This is how my heads look now. Took about 15 thousandths to clean up one head, the other (pictured above) took considerably more...like 45 thousandths! The picture on the right is the head from above. That dark spot is the only place it didn't clean up. I got some high heat JB weld and filled it, then filed it back flat. I also shot a quick coat of Dupicolor Engine Paint, Corporate Blue on them. I don't really expect it to last, but we'll see. Looks nice for now.
Why go through all this? I ALSO bought new manifolds from Cinnabar. I didn't want to have $500 dollars worth of new manifolds on the coach and still be fighting manifold leaks. For reference, here are said manifolds. They are VERY nice and look nearly identical to the originals. Only difference I could see is in the markings. It makes sense that they are the same. Cinnabar said they use the original patterns to cast their reproductions. They did a nice job of finishing too. Machining marks are nice and uniform, they removed most of the casting flash, and there isn't anything left internally to interfere with the flow.
So, with my freshly machined mounting surfaces, brand new manifolds and Lenzi's Copper Gaskets, I should have a tight, leak free exhaust.
That covers exhaust...My last post was about the intake being cracked. I ended up buying a brand new Edelbrock intake manifold, Number 2711. One of differences between the 455 and the 403 is the deck height. The 403 is considerably shorter, which means the intake doesn't have to be "concave" as Jim Bounds puts it. The standard performer intake from Edelbrock is only about 0.25" taller than my factory manifold, and only in the back. It was kind of expensive though. Not sure why...as you can buy a SBC intake for about 150 bucks. The Olds one is $400'ish. Still WAY cheaper than the super-special, custom aluminum one that the 455 requires.
Shiny Aluminum Goodness
With all my parts now in hand, I started putting the top end back together this weekend. Got the heads on yesterday after finishing my Honey-Do list. Had more time today, since I did all the honey-do stuff yesterday. Took my time during assembly to make sure everything was clean and in good shape. The rockers are showing some wear at the pivots, so I may look into replacing those. I installed Dick Paterson's exhaust crossover block off plates and intake manifold gasket, and got the intake installed and the first step torque done. I'll torque to the full 45 ft-lbs after the RTV cures so I don't squish it all out. I also need to get another 1/4" pipe plug for the manifold.
With a good push this Thanksgiving weekend, I hope to have her fully assembled and running again. I know my dad would appreciate it, as its taking the room in his barn where he would normally park his truck to keep the frost and snow off it!
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