[Lee]

" I replaced the front push in plugs with threaded plugs."

Did you perform the drilling & tapping before the block went to the machine shop, or after it came back?

[Mwieczorek]

Thanks for all the suggestions all!

I did look in the intake ports of the head that I removed. I don't see any oil in the intake ports. Looking at that Butler valley pan, the PCV provision had just 2 slits and they are barely bent up. I wonder if lack of PCV flow causing the crank case to build up pressure and push oil past the rings? I do have a breather on one of the valve covers and one would think that it would relieve any pressure. I didn't really check blow by before tearing into the engine, probably should have done that.

The cam bearings - the machine shop noted that one of my cam bearing holes was oversize and they bought a set of cam bearings and used just one for that single hole, the rest were standard bearings. The cam slid in just like any other build I've done, but I didn't mic the cam bearings and cam journals.

I DID mic the crank journals and rod and main bearings and they were all great, I have the numbers written down and can get them next time I'm out in the shop. I even used plastigauge to double check the bearing clearances and everything looked good.

For the low oil pressure... Am I just pumping all the oil up to the top end and starving the pickup? I did read up on the Morel hydraulic roller lifters and Butler's site said you don't need restricted flow pushrods with the Morels, so I didn't use them. Perhaps using restricted pushrods would help? I could spring for a set I guess.

I'll definitely dump the flat valley pan and order a Tomahawk to replace it.

I'll also take pictures of everything tomorrow when I can get back outside to the barn. Maybe you guys will see something that I'm not seeing...

I've assembled 2 other Pontiac V8s and several small block chevies and have never had this much trouble.

[Mwieczorek]

Originally Posted by Lee

" I replaced the front push in plugs with threaded plugs."

Did you perform the drilling & tapping before the block went to the machine shop, or after it came back?

I tapped the plug holes before I took it to the machine shop. The block came back surprisingly clean! and I did run a brush and mop down all the galleys before I put the plugs in just to be sure.