Coastal Casting Services

Block Reconditioning Procedures

Zero Hour - Partial Repair - Special Instruction
Zero Hour Reconditioning has two categories:

1. Full Rebuild
2. Custom Machine Work

Full Rebuild consists of the following processes:

1. Clean and Magnaflux - The block is fully stripped of all items such as down pins, plugs, studs, plates etc., then is hot acid dipped, steam cleaned and the water jackets sandblasted if necessary. Then the block is visually inspected and wet magnafluxed 100% top to bottom, inside and out to identify any damaged areas or cracks.

2. Preheat - Weld - Postheat - Stress Relieve - If cracks are located, then the damaged areas will be gouged out to for a “V” or the local area will be removed and a replacement patch will be fitted in place. The block will be preheated in a controlled heated oven to 875 degrees Fahrenheit. During the welding process the block has been removed from the oven and covered with insulation and kept hot. After welding is complete, the block is postheated, stress relieved and cooled. The process requires a minimum of 24 hours and larger castings, even longer.

3. Finish Grind - Re-inspect - After cooling, the welds are finish ground (in non-machined areas) and are magnafluxed.

4. Drill and Tap - All bolt and stud holes have the appropriate size drill run in to clean them out, then all are tapped to chase the threads clean.

5. Visual Inspection - The block is visually inspecting, focusing on 17 different aspects of the block. This inspection is performed from both sides of the block, top and bottom. The routing of the block through the facility is determined at this stage, based upon the different repairs the block requires.

6. Align Bore Evaluation - The condition of the cam bores and the main bores, cap fit, alignment and centerline check are evaluation. All areas are correctable, including complete relocation of the centerline. If necessary, we can flame spray all mains to bring the centerline to standard tolerances. We use the METCO spray weld process which, in most cases, is manufacturer approved. This spray weld process is also applicable in the relocation of deck heights.

7. Thread Repairs - Water Hole Repairs - Stud hole and bolt hole repairs are performed on Radial Drill Presses, not by hand drill. High stress areas such as head stud holes or main stud holes are repaired by oversize o.d. threaded steel inserts with standard i.d. threads. On low stress areas such as inspection covers, we will use helicoils unless otherwise requested. Eroded water passages can be solved with the installation of special brass inserts in all passages. The brass will never erode again. We have tooling to accommodate all makes for this repair.

8. Vertical Machine Work - Decks, counter bores and lower liner seal areas are addressed here. Cast iron or steel inserts are interference fitted with .001 press per inch of the diameter, then re-machined true in the original location. The decks are milled an absolute minimum to achieve acceptable clean up. All areas are machined within factory guidelines. We do NOT use portable equipment.

9. Test Water Jackets - We test all water jackets. We will install the liners and gravity test with kerosene or, in some applications where necessary, we have apparatus to pressure test the blocks with hot water circulating at 60 p.s.i. in the water jacket and at 200 degrees Fahrenheit.

10. Final Detail - After test, the blocks are deburred, gasket surfaces shines, wire brushed as required and hot steam cleaned.

11. Final Inspection - A thorough final inspection takes place prior to considering the job complete. The same inspector as in step #5 will perform the same inspection, top and bottom - 17 steps - and dimensional readings taken to verify accuracy throughout. A report is made and kept on file permanently. Each job has been assigned an ID number upon receipt; this number is stenciled into each part and traceability is no problem.

12. Paint - Crate - Shrink Wrap - We paint and preserve each block with OEM colors (unless otherwise requested). We apply Cosmoline to the crankcase areas and other machined surfaces to insure that rust can set in while the block may be in storage. The items are then shrink wrapped, crated and shipped on our truck at no charge or collect on common carrier.

Custom Machine Work usually consists of all details necessary in order to render the block "zero" hours but it is less expensive than Full Rebuild because casting repairs are not necessary. All of the same procedures are followed as outlined in Full Rebuilt with the exception of the welding process.
Partial Repairs can be described as focusing only on the majorly damaged area. For example: The block gets the same evaluation as in Full Rebuild. There are no cracks and may have a spun main bearing, but the decks, counter bores, lower liner seals show mild wear but are still serviceable. We will focus on the repairs necessary in order to repair the align bore of the block. After the align bore is repaired, then the block will undergo steps #9 through #12 as outlined in Full Rebuild.

Special Instructions apply only when the customer has dictated what needs to be repaired. The customer will be fully responsible for the condition and the integrity of the block in all other areas that we will not be focusing on. However, if we happen to notice something else, we will bring it to the attention of the customer at once. We are not responsible for any charges that are involved if we should, for example, be completed with the align bore job that we were instructed to perform and then find a crack elsewhere in the block. Most likely, if the block would need welding, then the align bore would require more attention afterwards, which would be of considerable more expense to the customer.

We are glad to perform any of the details as outlined above. We communicate thoroughly with the customer regarding both Partial Repairs and Special Instructions. We want to achieve customer satisfaction and, in the event of Partial Repairs or Special Instructions, many questions may be necessary to make sure you can visualize what we understand you to want. Zero Hour is the easiest for us because there is no window for misinterpretation, but we understand that not all jobs call for the attention that is required to render Zero Hours.

We can supply you with the best rebuilt blocks or the best custom work available. We are able to do this by quality control. quality control and more quality control. Nice in the step-by-step procedures the different steps that we take to check and double check.
It is our goal to supply components that are ready to install. Brand "X" components usually require much attention from the mechanic to "make it work". Not ours - just wash off the preservative, insure that oil galleys are clean, install all plugs in the proper places and build your engine. Our components can be assembled as if they were new. Your mechanics will recognize the ease of assembly and appreciate this aspect of our work. You will recognize longevity that properly reconditioned blocks have to offer.