Engine Block Changes
BLOCK changes – The factory core engine blocks are reused in our operation provided they haven’t had a rod thrown through the side or wasted. Most core blocks meet this criteria fortunately and give us an ample supply to work with. The blocks are first stripped of all components and given a good hot bath to remove all oil and dirt deposits. Then the block is fitted with a pressure test device which seals off the water jackets in order to perform a leak test. 200 degree water is then circulated through the water jackets to heat the block and then pressurized to 30 psi to check for leaks. Should any cylinder have a leak, it is noted at this time and the process continues.
From there the factory liners are removed, counterbore is made and new liners installed. The cylinder is then sized with a rough and final hone to receive each piston. This allows for exact fitment of each piston to its own cylinder.
The last process our block goes through was borrowed from the oil field industry here in Oklahoma where downtime on equipment means millions of dollars lost in production. The process is called a “hot seal” which addresses the porosity found in the water jackets by introducing a solution at temperature that fills the fractures and coats the walls of the water jacket. Most machine shops would identify existing cracks in the cylinder walls and weld them but what about those micro fractures that hadn’t made it all the way through yet? You could install new top hat liners and still have coolant come through a future crack or pore. The flange liner in theory would stop the water from going up and into combustion as before but what about going down and into the oil pan? Other liner designs use an o-ring to help trap the water going down but what does that poly ring look like after several years of water, heat and pressure? It would be just another point of failure and how would you service it?
This solution has proven to meet this challenge head on in that all porosity and micro fractures are sealed off from the water jacket side. This single process is vital to future block health and integrity as it relates to porosity. Without it, the block can still experience future coolant travel in behind the liners and subsequent overheating.
The block is fitted with the hot seal equipment, heated once again to 200 degrees. The hot seal cocktail is then introduced and allowed to circulate for 2 hours. Every porosity channel or fracture is filled and the water jackets themselves are coated and sealed off. 24 hours later, the block has cured and a final pressure test is made confirming no leaks if there were before.