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Motor clean & strip
After cleaning the motor is stripped down into its component parts and inspected for any damage or signs of impending failures, this includes:
Cylinder bores, pistons & rings
Connecting rods
Valve stems, face, seat & springs
Crank & camshaft journals
Transmission components
Oil pump
Measurements
The components that are to be re-used are measured to ensure that they are within an acceptable tolerance. This information is recorded on the build sheet that will be specific to this engine and supplied to the customer.
Bearing selection
Dependent on the the use for which the engine is intended, and the information previously recorded, the required bearing thicknesses are calculated to provide the necessary oil clearances at the crankshaft main bearings and big ends.
Assembly Preparation
All the component parts to be re-used are cleaned and re-assembled. Valves are lapped into their respective seats.
New gaskets, oil seals, assembly lubricants and the other new parts required are gathered together.
Trial Assembly
The engine is trial assembled so that clearances can be checked, this includes:
Piston Deck Height
Oil clearances
Ring end gaps
Valve to piston clearance at the required valve timing
Valve tappet clearances
Final Build
After all fit and clearances are acceptable the engine is finally assembled with new gaskets. Cam timing is checked/set and the valve clearances re-checked. The lubrication system is primed to ensure that oil is present at all the bearings under initial start-up.