Professional Cylinder Block Prep
We hand pick out each of our engine block cores, inspect for any imperfections and flaws. We then closely check the cylinder bores, main bore saddles, cam bearing bores, and engine block decks for signs of stress or excessive wear. Then we inspect all of the engine blocks bolt threads to insure the integrity.
Each block then gets degreased and seasoned for our machining processes in our temperature controlled bake oven. Our system is a slow up in temperature and a slow cool down procedure so the engine components are not stressed and features a unique seasoning process as well. The blocks then get shot peened and stress relieved to relax the metal before any of our machining processes begin and to remove any of the external impurities.
We closely inspect the blasted block core for any previously hidden imperfections. The blocks then get completely magnafluxed to check for any cracks in any area of the block core. If a crack is found in the casting then it gets set aside for repair or will get deemed unusable. If core shift is present then we will sonic test the block to insure the integrity is present for the intended purpose of the engine build.
If the engine is a stroker combination we will then set up and dial in the engine block for stroker clearance. We determine radial core shift imperfections and set our tolerance according to the connecting rod and crankshaft stroke combination. The block is then cut out on our vertical mill using our custom cutters for precise stroker radial clearance and is measured and confirmed using our own custom measuring equipment.
The main caps and usable block hardware gets shot peened and stress relieved, magnafluxed to check for any cracks, inspected for any imperfections and measured for cap twist. We side dress all of the main caps to ensure proper main cap cutting alignment, deburr the main caps, and precision cut the caps to prep them for the main bore align hone process. The deck height of the block gets thoroughly measured and documented to insure adequate material exists to get removed so we will get a nice clean finish for our target deck height. All of the engine block surfaces get prepped and removed of any burrs. All bolt threads are prepped. Engine block is then cleaned of any small debris.
We now move into the main bore preparation. We deburr and remove any imperfections in the main cap block register, remove any twist, and straighten any register height inconsistencies. The register gets fine file finished and chamfered and the main bolt threads are measured and confirmed of their integrity and cleaned. The cut main caps are installed in their correct order and then the main cap fasteners are appropriately lubricated and installed. The main caps are then tightened in the main block register to eliminate any cap walk and/or cap twist. The main caps are then torqued to the correct indicated specification in the correct sequence. This same designed sequence will be used upon engine assembly to insure the same stress factors are being applied to the block so the finish product is true to the finished machined block. The main caps are torqued in place during all of the engine block machining processes so the engine block will be stressesd in the as run condition.
The main bores then are accurately and precisely align honed to properly correct the main bearing alignment, correct the out of round condition, and to finish each main bore size to the correct specification with exacting tolerances and zero taper. Engine block is then removed of any excess machining oil. Centered off the new main bore centerline the block is then equal and parallel decked to the exact deck height target and the deck angles corrected. The end rails of the block is machined to the proper end rail height and equaled. We then center bore all of the block cylinders in the correct alignment and angle to ensure the bores are true and correct to the engine block profile. We leave adequate material for our honing process.
All of the oil passages get drilled and cleaned to remove any imperfections. If applicable, we perform all engine oil modifications to provide better engine oiling for the engines intended purpose.
We then will precision hone the cylinder bores using our torque plate to simulate the stress on the block from the head being torqued on and in place. A very specific torque sequence procedure is used and this same sequence is used during our engine assembly to insure the cylinder bores are correct and true as they are in the machine process. We hone our cylinders using our tried and true specific sequence with our Sunnen CK-10 hone machine. Our procedure is not a fast one, we take time to get the finish that our customer requires, and there are many different stone sequences with several cool down sets depending on the material we are working with. We have years of perfecting the hone finish procedures. Our cylinders are finished to exacting tolerances of cylinder taper and roundness. The cylinders are finished with our ever-changing up to date cylinder finish process for instant ring seal and reduced ring drag providing excellent seal and better power and torque. RA finish is then tested and documented.
We modify the lifter bores with a small lifter bore groove on the leading side of the bore three quarter of the way up from the bottom. This insures added and direct lubrication between the cam lobes and the lifters, which is critical for camshaft reliability. Then we ream and hone finish each lifter bore.
Then the engine blocks are machined for screw in oil galley plugs, main caps are removed, and the block goes through our hot bath wash. Every inch of the block is scrubbed and all oil galleys are thoroughly and repeatedly brushed out. Our cylinder bores are thourghly cleaned using our own tried and true method that insures all microscopic debris is completely removed and cleaned. Then all machined surfaces are lightly coated to prevent tarnish.
We then move to the painting process, the block gets taped off and painted to the customers requested engine color using our high temperature engine paint. After the paint is completely cured, we seal and install the core plugs, install all of the oil galley plugs, press in the camshaft bearings and insure the correct fit. Camshaft bearings are then polished. Final block cleanliness check is performed. The finished engine block is then installed onto an engine stand and moved into our clean assembly room.