Charlie Olsen's Project Plan
On December 16th Charlie reported that all parts of my Slant Six engine had been cleaned and inspected. He explains the processes the shop will perform on it.
"Your original crankshaft was reground, it's oil holes chamfered(1), and the shaft polished at [where?]. After cleaning the engine block and cylinder head in our steel shot machine, those parts get magnafluxed(2). That is a process to detect surface and slightly subsurface flaws in the iron parts. Then we bottom tap(3) all threaded holes to clear shot particles that may lodge in surface holes. We torque all main bearings and check and repair line bore as needed. Bore and honing of the block is to the smallest size that the bores will clean up; and to the size for which pistons are available. The cylinder head gets machined for new valve guides and positive valve seals. The guides are honed to finished size. Multi-angle valve seats are cut and the "deck", the top surface of the cylinder block, is milled to precise flatness. Valve stem heights are set, and valve springs set to correct load. Connecting rods all get resized. The complete assembly will be balanced. Pistons will be installed on rods, and all rods will be checked for straightness and twist. The block will then be cleaned for final assembly. Cam bearings and core plugs -- brass plugs only -- will be installed. All clearances will be checked and adjusted if needed. And finally the complete engine will be re-assembled."
1. Edges of holes cut to a symmetrical sloping rim.
2. The process puts a magnetic field into metal parts to reveal flaws in patterns of ferrous dust accumulation.
3. A "bottom tap" cuts a thread without taper on the inside surface of a hole, creating a female surface which functions like a nut.