July 8th 2013:
Block is clean, and we have to realise that it is cracked twice. .
August 15th:
Cracks closed, engine ready for the machine shop.
See details below.
July 8th 2013
In cleaning the block we followed the following procedure:
1. Manual removal of deposits.
2. Steam and high pressure cleaning
3. Washing in Diesel.
4. Removal of rust with a wire brush in an handhold grinder and a air pressure needle scaler.
After that the cracks were obvious, see pictures. We try to locate who is able to weld the cracks. We definietely want to reuse the block due to the matching numbers.
The measurement of the cylinder bore showed, that oversize pistons of 0,08 inches should be enough. The measurement was performed with an inside micrometer in the following manner:
Each cylinder was measured in the top, middle and bottom area. In each of these areas there were three measurements in a relation of 120 degrees to the next measurement. Each of these measurements was performed thre times on three different days. The measurement precision was 0,001 inches. See table below.
The valve and timing covers were treated as the block, a broken oil pan screw was removed from the timing cover. The oil return pipe ist finished, it is bent but useable.
The oil filler tube misses all the inserts and has been elongated. This is not original, but is the history of the car. We reuse the tube.
Cylinder 1 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | 0,064 | 0,002 | 0,001 | 0,067 | |
Top | 3,939 | 3,939 | 3,940 | 0,063 | 0,063 | 0,064 | |||||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Middle | 3,939 | 3,939 | 3,940 | 0,063 | 0,063 | 0,064 | |||||
Middle | 3,938 | 3,940 | 3,940 | 0,062 | 0,064 | 0,064 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,938 | 0,060 | 0,061 | 0,062 | |||||
Cylinder 2 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,940 | 3,938 | 0,063 | 0,064 | 0,062 | 0,064 | 0,002 | 0,001 | 0,067 | |
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Top | 3,937 | 3,938 | 3,938 | 0,061 | 0,062 | 0,062 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Middle | 3,939 | 3,940 | 3,939 | 0,063 | 0,064 | 0,063 | |||||
Middle | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Bottom | 3,936 | 3,936 | 3,937 | 0,060 | 0,060 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Cylinder 3 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | 0,064 | 0,002 | 0,001 | 0,067 | |
Top | 3,938 | 3,940 | 3,939 | 0,062 | 0,064 | 0,063 | |||||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Middle | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Bottom | 3,936 | 3,937 | 3,935 | 0,060 | 0,061 | 0,059 | |||||
Bottom | 3,936 | 3,936 | 3,937 | 0,060 | 0,060 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,936 | 0,060 | 0,061 | 0,060 | |||||
Cylinder 4 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,942 | 3,943 | 0,063 | 0,066 | 0,067 | 0,067 | 0,002 | 0,001 | 0,070 | |
Top | 3,940 | 3,941 | 3,939 | 0,064 | 0,065 | 0,063 | |||||
Top | 3,941 | 3,942 | 3,939 | 0,065 | 0,066 | 0,063 | |||||
Middle | 3,940 | 3,941 | 3,942 | 0,064 | 0,065 | 0,066 | |||||
Middle | 3,939 | 3,941 | 3,941 | 0,063 | 0,065 | 0,065 | |||||
Middle | 3,939 | 3,942 | 3,939 | 0,063 | 0,066 | 0,063 | |||||
Bottom | 3,938 | 3,937 | 3,937 | 0,062 | 0,061 | 0,061 | |||||
Bottom | 3,937 | 3,937 | 3,939 | 0,061 | 0,061 | 0,063 | |||||
Bottom | 3,937 | 3,937 | 3,938 | 0,061 | 0,061 | 0,062 |
Cylinder 1 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | 0,064 | 0,002 | 0,001 | 0,067 | |
Top | 3,939 | 3,939 | 3,940 | 0,063 | 0,063 | 0,064 | |||||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Middle | 3,939 | 3,939 | 3,940 | 0,063 | 0,063 | 0,064 | |||||
Middle | 3,938 | 3,940 | 3,940 | 0,062 | 0,064 | 0,064 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,938 | 0,060 | 0,061 | 0,062 | |||||
Cylinder 2 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,940 | 3,938 | 0,063 | 0,064 | 0,062 | 0,064 | 0,002 | 0,001 | 0,067 | |
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Top | 3,937 | 3,938 | 3,938 | 0,061 | 0,062 | 0,062 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Middle | 3,939 | 3,940 | 3,939 | 0,063 | 0,064 | 0,063 | |||||
Middle | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Bottom | 3,936 | 3,936 | 3,937 | 0,060 | 0,060 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,937 | 0,060 | 0,061 | 0,061 | |||||
Cylinder 3 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | 0,064 | 0,002 | 0,001 | 0,067 | |
Top | 3,938 | 3,940 | 3,939 | 0,062 | 0,064 | 0,063 | |||||
Top | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Middle | 3,939 | 3,939 | 3,939 | 0,063 | 0,063 | 0,063 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Middle | 3,938 | 3,939 | 3,939 | 0,062 | 0,063 | 0,063 | |||||
Bottom | 3,936 | 3,937 | 3,935 | 0,060 | 0,061 | 0,059 | |||||
Bottom | 3,936 | 3,936 | 3,937 | 0,060 | 0,060 | 0,061 | |||||
Bottom | 3,936 | 3,937 | 3,936 | 0,060 | 0,061 | 0,060 | |||||
Cylinder 4 | Measurement Nr. | Difference to standard bore (3,786) | 3,876 | ||||||||
1 | 2 | 3 | 1 | 2 | 3 | Max. Difference | Piston Fit | Measurement precision | Min Piston Diameter | ||
Top | 3,939 | 3,942 | 3,943 | 0,063 | 0,066 | 0,067 | 0,067 | 0,002 | 0,001 | 0,070 | |
Top | 3,940 | 3,941 | 3,939 | 0,064 | 0,065 | 0,063 | |||||
Top | 3,941 | 3,942 | 3,939 | 0,065 | 0,066 | 0,063 | |||||
Middle | 3,940 | 3,941 | 3,942 | 0,064 | 0,065 | 0,066 | |||||
Middle | 3,939 | 3,941 | 3,941 | 0,063 | 0,065 | 0,065 | |||||
Middle | 3,939 | 3,942 | 3,939 | 0,063 | 0,066 | 0,063 | |||||
Bottom | 3,938 | 3,937 | 3,937 | 0,062 | 0,061 | 0,061 | |||||
Bottom | 3,937 | 3,937 | 3,939 | 0,061 | 0,061 | 0,063 | |||||
Bottom | 3,937 | 3,937 | 3,938 | 0,061 | 0,061 | 0,062 |
August 15th:
Cracks have been closed with JB weld, as many experts recommended this and gave advice, not to weld the cracks in the water jacket. We opened the cracks a little in a V-shape and closed the cracks with JB weld. We will see, whether this works out.
The block is primed and ready for cylinder boring (oversize 0,08) and resurfacing of block and head (The head shows deep marks of what ever the reason for this may be) and for poring the bearings.
The engine bolts have been cleaned. The oil dip stick has been replated (zink), pulley (ebay, used) an ratchet nur blasted and painted.