What is generally involved in rebuilding a block?

350kmileford

Well-known member
I'll be rebuilding a 200 ci block soon... My plans are to get a big cam, stock (cast) pistons, probably gapless rings, and possibly forced induction within the next 5 years. So durability is key.

I know that people normally bore the cylinders, replace pistons, rings, gaskets, and bearings. . . but besides this, what all is involved? Any other boring required? I am not too familiar with crank seals, can someone elaborate on those (links to best replacements?)
Ignore headwork, I know how to do that, plus I'll be purchasing the aluminum head soon enough.

Also, does anyone know what the approximate weight of a connecting rod out of a stock 200ci is?

Thanks folks
 
im rebuilding my 200. im replacing all the bearings and al the seals, rod and main bolts, piston rings, and maybe getting a new cam (depends on how much money i have and if my old one is reusable). my block doesnt need bored, im just going to hone my cylinders, hot tank it, and deck the block. it all depends on what your block needs and what you want to do. if your gonna use forced induction and want to use a stock cast piston, you might try to find some with the 13cc dish used in 66-67 200s in california. crank seals arent that big of a deal.
 
Well I am all about durability.. I forgot to mention that I will be replacing all the fasteners with stronger arp's. Are there any 'better' crank seals available? or are they all about as good as stock?

p.s. I just bought the book heh.
 
You should consider going to forged pistons if your going to do every thing you talking about they'll last much longer.
 
Yes I had considered it, but many people said not to go with them. They would cost around 800 bucks for a set, wouldn't they?
 
Hypereutectic pistons are a good balance between cost and durability.

You should look also at physically descaling the block before handing it to the rebuilders - remove all plugs yourself, and dig out as much scale as you can get with long screwdrivers. Now have the block hot tanked, and roughly bored.

Go with the minimum overbore, and have it torque plate honed. Finding a shop to do this part, is not so easy.

Get the crank reground or linished, and have your flywheel refaced. Also check your balancer (damper) and either rebuild or re-use. Rods may be closed and honed. The pistons, rods, crank, flywheel and damper are now subjected to first static, then dynamic balancing. Pistons are fitted onto the rods. Remember that with the hone-to-fit, each specific piston "belongs" to a certain bore.

Mock up the block and crank, with pistons/rods for #1 and #6 fitted (no rings). The metal between your bearing backs and the block, is to be bone dry - no oil whatsoever. Check your deck height, then tear down again and deck the block. You can use this mock-up, as a good time to test bearing clearances with Plastigage.

Now clean and deburr that block for most of a day. Don't forget all the bolt holes need chasing (preferably with chasing taps, not thread cutting taps) and to clean the oil galleries. I wash the bores last, as when you're rinsing them out, rust spots develop in seconds - wipe dry with paper towel and immediately oil the bores with a hand-wiping of motor oil. Fit the plugs for oil gallery and coolant, at either end of the block before mounting on the assembly stand. I suggest a light smear of Permatex #3 on each type, when installing.

Remove the old pilot bushing before the crank is refitted. Bearing shells are pressed in dry to block and caps as noted above; be aware that sometimes there are tiny shavings of metal from this process, that you need to dab up.

Apply a modest amount of either break-in oil or assembly lube to each main journal, sit the crank in place and finger-tighten your main cap bolts. Offset the rear main bearing oil seal halves by 1/32 and put the tiniest dab of gasket sealant on the mating faces of each seal half. Put a light smear of motor oil on each main cap bolt thread, and torque all to gently snug before final torque is applied to any. After torquing, check rotation is totally free.

Give the pistons/rods a quick "hose" with solvent to rinse away any honing grit or other contaminants on the outside. Make sure the gudgeon pins are well-oiled with either heavy oil or break-in lube.

Fit the piston rings, taking care to get the gaps sized, gap positions correct and rings the right way up (don't laugh too hard - it's a common mistake). As you did for the main bearings, make sure the shells are pressed against perfectly clean and dry metal, and crankpins lubed. Install piston assemblies one at a time, making sure the rod or rod bolts don't mar the bore or crankpins as the assembly slides down into place.

When all are torqued up to spec (oil on the threads, as for main caps), rotate the crankshaft a couple of dozen times in the normal direction. This will help bed in the crankshaft oil seal.

Pretty much everything else is as the many available manuals cover it, but the few variations above will get a more accurate (efficient) or reliable motor...
 
:) You might want to have the alignment of the crank saddles checked.
If they are off,you might want to consider having the block align bored
so that everything is nice and straight and turns freely.
Leo
 
What is descaling?

What exactly is involved in regrinding or 'linishing' the crank?

I assume that static balancing of the parts simply means to make sure that each one ways the same . . How would I get them dynamically balanced?

As far as deburring the block, you're talking about cleaning up sharp edges and fluid paths (filleting edges)?
 
Decaling - I mean removal (chemically and manually) of all the rust and oxides that build up in coolant passages. It's important, because this will aid most efficient cooling of the motor. Many rebuilders are slack, and unless you remove the press-fit plugs they won't take 'em all out...

You're pretty close with interpreting deburring. As manufactured, and as-machined, most blocks have some edges that are nearly razor-sharp. It's unnecessary and dangerous; spend some time with extra-fine files and/or emery cloth to soften these harsh edges - you only need put a bevel 1/64" wide to make a huge difference.

Getting back to the balance - as you surmise, a static balance equates each item in a set, to the lowest mass of any item in that set. Rods are weight matched at both ends, not just overall. Dynamic balancing is a machine shop procedure, and uses a setup that (with an electric motor) spins the complete crank, flywheel and damper up to about 3500 RPM between a couple of centering pins.

The weight of pistons and rods is simulated by little "bobweights" full of shot, that are clamped to the crankpins where your big ends normally go. Imbalances in the whole deal show up under a strobe light, and the operator's skill lies in removing strategic small amounts of metal from the crank, damper or flywheel over-heavy areas which caused these imbalances.

Crank work - linishing is a very fine polishing, that removes light scoring while not appreciably changing the crank measurements. Regrinding is when the round parts (journals) of the crank are ground by use of a spcialised fixture, to perfectly round and smooth, but typically either ten or twenty thou smaller than you started.
 
a little off topic, but while i have my 200 apart can i stroke it? does anybody sell a kit? i looked at classicinlines.com real quick but i couldnt find anything.
 
No stroker kits available; you could "steal" a tiny amount by offset grinding the crankpins but cost involved in getting it there (different rods from another brand, different pistons) would exceed any benefits.
 
Right, the available stroke gained add up to about 6 ci if I remember correctly.

The camshaft is already relieved to clear the rods, so there is little available room. That's why there are no stroker cranks. They had to move the cam 2" to get the 250's stroke increase.
 
If one were to grind down the crank journals, how would they compensate for the difference in metal? Thicker bearings?
 
That's how it's done. You remove ten thou, and the bearing metal is ten thou thicker to compensate. It's why bearings are sold as "undersize" to request.
 
Okay, you have taught me something.

So, say an engine had been rebuilt within the past few thousand miles. Would it be acceptable to replace only the pistons and rings, without altering anything else?
 
You should barely need to touch anything. Make sure the rings have bedded and that's about it. I'd also pop a few metal plugs and look for junk/accretions in the cooling passages and oil gallery.
 
I will be doing a full inspection, among with a few other changes (ARP fasteners) I am asking, if I wanted to change the pistons/rings, could I change them w/out re-honing,etc?
 
No problems on the rings, but pistons could be a slippery one. You'd really want to measure the pistons and bores with a micrometer.
 
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