[Formulabruce]

Steve, ever use a "nibbler"? If not ask the teacher to try one on some scrap sheet metal. Cuts steel like butter and goes fast, and is a bit more "homeowner" type tool... I do love the plasma cutters though as well..

[Formulabruce]

Originally Posted by Rocky Rotella

Looks like it'll provide the functionality you're after. Just wait until someone opens that engine years down the road and sees it. We'll then hear, "My '72 Formula has a prototype oil pan on it!"

Now this IS funny! must be the pan of the "other" '72 Super duty ! hehe

[njsteve]

Hey, it's a handbuilt, prototype, anti-centrifugal force, oil deflection shield with reverse drainback capabilities. It is the only one made (until I make another or Norwood makes a more appropriate version.)

[njsteve]

Originally Posted by Formulabruce

Steve, ever use a "nibbler"? If not ask the teacher to try one on some scrap sheet metal. Cuts steel like butter and goes fast, and is a bit more "homeowner" type tool... I do love the plasma cutters though as well..

Actually, the bodyshop course starts again in January and I will be removing the homemade "boxed" trunk drop-offs that were hand built in the late 1980s when the NOS quarters were installed. I'll be installing the new repro units. So stay tuned.

[njsteve]

I got the pistons and rods back today. The crank should be done with balancing tomorrow so we can start the assembly process this weekend.

The machinist said that the rods and pistons were all within a gram of each other and didn't really require any modifications to get them all matched.

[Formulabruce]

Originally Posted by njsteve

The machinist said that the rods and pistons were all within a gram of each other and didn't really require any modifications to get them all matched.

Now that is nearly unheard of! I can see the rods being close, but , that is just WOW to me. I did my own, then watched the assembly balanced., spinning.. Im in shock , your engine should be able to pass the "Coffee" test for sure!

[njsteve]

What's the Coffee Test?

Is that where you no longer need coffee to keep you awake at night, after realizing how much you have just spent on engine parts?

[Formulabruce]

LOL Cup o coffee on the air cleaner at idle.. old school test for a smooth running engine!
sounds like money well spent, no balancing, thats just crazy luck!

[njsteve]

I have the balancing sheet with the weights. The rods were within 1 gram of each other out of the box: 4 were 758 and 4 were 759, which coincided well with the pistons, 4 of which were 779 and 4 were 778. So he just matched them to all together to come out to the same weight when he mounted the pistons to the rods.

According to the machinist, the new rod and piston combo was 100 grams less than the domed, forged pistons and cast rods that I pulled out of the engine. They had to drill out some material from the crank to lighten it up to match the new pistons and rods.

Everything is home now and we should be assembling this weekend!

[superdutybob]

Steve:

You're into the fun stuff now. I love building engines.

[Formulabruce]

Originally Posted by njsteve

I have the balancing sheet with the weights. The rods were within 1 gram of each other out of the box: 4 were 758 and 4 were 759, which coincided well with the pistons, 4 of which were 779 and 4 were 778. So he just matched them to all together to come out to the same weight when he mounted the pistons to the rods.

According to the machinist, the new rod and piston combo was 100 grams less than the domed, forged pistons and cast rods that I pulled out of the engine. They had to drill out some material from the crank to lighten it up to match the new pistons and rods.

Everything is home now and we should be assembling this weekend!

I had to have my crank drilled too, yeah Bob is right, now the fun stuff!

[njsteve]

We got the new BOP rear main lip seal in and installed the freshly polished and balanced crank. Now it has to sit overnight per the instructions to let the seal set. The boy did pretty well torquing down the 100 ftlbs on the mains (120 on the rear cap). He's gotten stronger since last year's engine build. :-)

[Formulabruce]

you get a hole drilled for the dist oiling?

[njsteve]

No. Just the regular plug in the oil galley.

[njsteve]

Went out Christmas tree shopping this morning with the family and then we spent the rest of the day assembling the short block.

We made it a family affair: I installed two pistons, the wife installed two and the daughter and son each installed two.

Much arguing over teaching the wife how and why you use a torque wrench. She couldn't seem to understand how/why the thing clicks when the correct amount of turning force is applied and how to set it. Luckily the daughter has an A average in Physics and was able to understand and explain "torque" to her. A most entertaining day.

The daughter keeps asking me to teach her how to drive a manual transmission, so I figure she can help assemble the clutch and install the transmission when the time comes, in order to learn how the clutch works before she melts this one during training.

After we got all eight pistons and rods in and Plastigaged each one (.002 oil clearance on all rods and mains), we then cleaned and retorqued it all again. I installed the timing cover, windage tray, oil pump and shaft, and oil pan after checking to make sure the dip stick cleared everything.

[Formulabruce]

Looks great! Since you installed the timing cover, dont forget the O ring on the front of the intake when its time comes Your family short block time is better than many shops! hehe. If you have a mechanical Bull locally you can get your neck ready for the "bucking" your daughter will give ya! Mine smoked the clutch in my Altima

[njsteve]

When it comes to the test drive vehicle, it it either the Formula or the 1993 Dodge Viper race car that is up on jackstands in the garage. It serves as a great workbench. Since I have conveniently neglected to teach my daughter how to use a floorjack, it seems to be safe for the moment.

[The Boss]

A healthy level of respect for the cars will make them more afraid of them (& breaking them) then thoughts of stealing them for joy rides. Mine learned on my 79 Formula and then got thrown right behind the wheel of the 72 HO. He won't go near the keys unless I'm with him, but he likes to show his friends the cars and tell them which ones he's driven. From what I understand his reputation is becoming legendary at the high school.

She'll be fine but remember to take a picture for us!

[njsteve]

I installed the heads this morning and then the kids put the valvetrain parts on. My son's favorite part was glopping on all the moly paste and red goo antiwear ointment to the cam, lifters, rocker arms, push rods, valve stems, and clothing. If it involves making a mess, he's happy to assist. My daughter on the other hand had just finished her nails and was quite content using the clean breaker bar to turn the engine over while I adjusted each rocker arm.

Normally a Pontiac is a set to 20 ft.lbs. with a non adjustable valvetrain but the shouldered rocker studs were previously replaced with a set of 7/16 x 20 Big Block Chevy studs with no shoulders. That allows for a more precise, individual adjustment.

[njsteve]

While it was 60 degrees out today I rushed and got the rest of the engine completed so I could get some paint on it. I did spend a good half hour or so priming the oil pump and pumping oil through the engine while constantly turning the engine over by hand to get the lifters filled and oil up to the rockers. The daughter assisted in running the drill...until it started smoking and she ran inside claiming she had homework she had to get done.

Here is something some of you Round Port guys might be interested in. Since no one makes the unique 1972-only intake gasket that has the small square heat riser port for the 7F6 cylinder heads, I had to improvise a little.

I ended up using the Felpro 90123 (RAIV, 1971 455HO,1973/4 SD455) large port intake gasket for the intake runner sections and then sectioned in the heat riser portion from the Felpro 90205 1972 455 D-port head intake gasket. This way everything ends up matching what it is supposed to mate with. And since the cast iron heat riser is a separate piece from the aluminum dual plane intake, there are no leakage problems to deal with.

And yes, that small, open, horizontal rectangle above the square heat risser port is supposed to be open to the atmosphere. It is sealed off from the inside of the engine and I believe it was created to allow ambient air in to prevent hot oil from "coking" onto the cylinder head's internal heat riser passages.