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Old 01-24-2018, 05:00 PM   #2061
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Ok, just spent the afternoon with a Micrometer on these Cummins internals!

I am not the greatest with a Micrometer, but I did multiples on each measurement until I got some consistency.
Each journal was measured at the front and rear of the journal, and again, at 90 deg to original measurement.

Here is my crankshaft numbers:

Main Bearings:
1995 Dodge Manual gives OEM Diameter as 3.2677" +- 0.0005". Minimum diameter Limit is given as 3.2662"

#1: 3.2672" to 3.2673"

#2: 3.2671" to 3.2673"

#3: 3.2674" to 3.2675"

#4: 3.2676" to 3.2677"

#5: 3.2675" to 3.2676"

#6: 3.2674" to 3.2676"

#7: 3.2675" to 3.2676"

Then on to Rod Journals:
1995 Manual States: Rod Journal STD as 2.7165" +- 0.0005" with a Minimum size Limit of 2.7150"

#1: 2.7164" to 2.7165"

#2: 2.7165" to 2.7166"

#3: 2.7166" to 2.7167"

#4: 2.7165" to 2.7166"

#5: 2.7165" to 2.7166"

#6: 2.7165" to 2.7166"

So, based upon the numbers above, I feel the crankshaft is well within spec and will probably just need a micropolish, and a new set of STD size Mains and Rod bearings.

Looking good!
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Old 01-26-2018, 12:38 PM   #2062
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Wrapped up the measurement phase with the pistons and bores.
Except #1 all were within spec. The bores came in at as factory sizes or 0.0005” oversize. The pistons also came in way within tolerances.
A clean up of the bores with a fine pad and acetone revealed the original hone marks still visible.

At this time I’m leaning toward replacing just #1 piston and having the bore sleeved back to std size, then having them all lightly honed and reusing the original slugs with new rings.
Will wait and see what the Machine shop says of course.
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Old 01-26-2018, 12:46 PM   #2063
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Excuse my rambling, but spotted one interesting thing on Cylinder and piston #2.
There is a scuff line on the bore at 90deg to normal wear spots. This where it intersects with bore #1 which suffered the meltdown. I have to assume that during the failure the cylinder got so hot it expanded enough to close up the piston/bore clearances on #2.
This caused the piston above the top ring to scuff the bore a little.

Pictures tell the story!
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Old 01-26-2018, 04:31 PM   #2064
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What a pity you can't remove the cylinder sleeve and just buy new piston rings, as we Isuzu owners can.
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Old 01-26-2018, 06:13 PM   #2065
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Yeah, it is what it is tho. Sleeving these motors is very commonplace.
Pretty much have my plan in place now, so I will build a stand for the motor, and tuck it away until i am ready to build it.

That aside, I started on the drivers side wrap again. This time built it with 3003 aluminum. I pretty much have the first piece of the outer lower formed already.
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Old 02-06-2018, 06:45 AM   #2066
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Did some work on the sheet metal. It’s laying down close on the buck, so I will need to trim it next to see where it needs more work.

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Engine stand is progressing.
I’m actually using parts from the rotisserie I built for the Alfa. I built it to be modular, and that is paying dividends. I hadn’t finished it, but what I am adding to it for the engine stand will mostly carry over.
I’m hoping I can get the engine, on it’s stand(minus head) under my workbench, which is 36”. That way I can tuck it away when I’m not working on it. Had to ditch the huge 10” casters and build out some small ones.
The basis of the Rotisserie is all 2 1/2”, and 2”, 1/4” wall trailer hitch, so beefy.

Engine mount plate is done but might get junked or modified still!
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A trip to the metal store got me most of what I need.... a piece of 48x6x3/4 plate was about 80lb and will be useful for the the Jack mount as well as the Hossfeld bender hydraulic conversion I’m doing.
Cutting it down to size was fun!
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Jack mount done.
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Mock up of engine stand with jack, and pivot tube for engine.
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As we are in the planning stage of a trip to Europe, to visit family and celebrate out 10th Anniversary, I dug out some old pics.

This was my Workamping rig.
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And I did my fair share of cold weather too!
This was Tuscany, living on an Olive Grove, winter of ‘98!
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Old 02-23-2018, 05:50 AM   #2067
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Cummins mounted!

Now, where was I?

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Old 02-23-2018, 07:17 AM   #2068
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Quote:
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Cummins mounted!

Now, where was I?

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How in the world did you get it on the mount?
Last I heard you mention was that you wanted to rearrange your garage
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Old 02-23-2018, 09:14 AM   #2069
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I lifted it with my engine hoist.
That thing is heavy. I have a 454 in my storage and so I can compare, and I bet this bare block is similar in weight to the complete big block.
Cummins quote this engine at 1100lb dry.

I did a quick test for myself.
Tried the block, mounted on one side, and it was fine. Not as stable as the two sided, which is gonna be important for torquing stuff down later.

My garage is tight. Just a simple 2 car garage... with the Red ‘74 Alfa on the ramp on one side, and the tools, and equipment on the other.

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Old 02-24-2018, 09:09 PM   #2070
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Scrapped all the old gaskets off nowvits stable and at working height.
Doused the block with degreaser, scrubbed, and it’s now clean enough for now.
Popped the #1 and #7 bearing caps in, then gently dropped the crank back in for safe keeping.
The crank weighs 130lb, I know I did it now!
Tucked away.

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Old 02-25-2018, 05:15 AM   #2071
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6 in a row makes em go!

Later take a side by side pic of a piston and rod assy vs a 454 Assy.
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Old 02-25-2018, 03:20 PM   #2072
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I do hope you put a nice coat of anti-corrosion oil all over that nice block and crankshaft before you put it away....
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Old 02-25-2018, 08:34 PM   #2073
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I dried it all with compressed air... then sprayed it down/wiped with wd40.

Block will be boiled out, bored, decked, and honed, and crank will be polished or ground.
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Old 02-26-2018, 04:07 AM   #2074
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I dried it all with compressed air... then sprayed it down/wiped with wd40.

Block will be boiled out, bored, decked, and honed, and crank will be polished or ground.
WD40 is good for the short term protection, but I recall hearing that it dries out in a short time and leaves a sticky film?
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Old 02-26-2018, 04:49 AM   #2075
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If Steve lived here in HUMID Kentucky then I'd be real concerned with rust. However living where he does in California humidity may not be much of an issue.
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Old 02-26-2018, 07:33 AM   #2076
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Hey, we had some rain.... couple of weeks back!
On Saturday, the overnight temp was 35!

Seriously tho, thanks for the reminders.
For reference, the rear end of my ‘74 Alfa has been in bare metal for over 18m in my garage and I’ve not noticed any blush on it yet.
I’m sure I do need to add some more protection to the crank and block. Will take a look at it again today. I think I have some spray grease somewhere.
What I didn’t post was while I was finishing up the block cleaning, I took a big chunk out of the back of a finger on a sharp machined edge. Was bleeding everywhere, so had to call it a day, and get attention from my Girl!
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Old 02-26-2018, 07:45 AM   #2077
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Careful Steve, hopefully it wasn't an important wrenching finger!

Jealous of your humidity, I had my windshield channel bare metal for about 2 days and it was orange!
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Old 02-26-2018, 09:39 AM   #2078
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Lol. No, it was the back side of my “Freeway Waving” middle finger.
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Old 02-26-2018, 04:39 PM   #2079
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Lol. No, it was the back side of my “Freeway Waving” middle finger.
The proverbial British backwards V salute? I always get a perplexed look when I whip mine out.
Cheers
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Old 02-26-2018, 09:14 PM   #2080
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Perplexed look?
Around here, if you whip it out in public, you get arrested! Well, unless you are “Not here officially”, in which case you are fine.

So, all this talk of protecting the bare metal, and flash rust had me freaked out...
I checked the motor and it looked fine...
I checked the rear quarter on the Alfa that has been in bare metal for maybe 2 years in my garage AND closest to the door....
Dang.... I’m freaked out now.
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I’m talking about the bloom on the feature line, not the holes on the tail panel flange. Lol.
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