Recently started working on a 1996 FZJ80 with a blown head gasket... amongst other minor issues. The cylinder head was totally warped with the apex of the damage happening between cylinders 4 and 5, with a peak of about 0.029" (29 thousandths). I'm getting the head machined down and spent some time trying to find a copper "saver shim" to put between the block and the head gasket to make up for the inevitable change in compression ratio that's going to occur when the volume of the combustion chamber is changed. To my disappointment I could not find the correct solution online so naturally I did what I enjoy doing, came up with a solution that seemed to meet the requirements of the problem.
I went ahead and took the new head gasket and drew up a 1:1 cad file of the gasket and had it water jet, below is a sample (aluminum from some scrap) from my local water jet company that seems to be a very good match to what I need. I should be picking up the copper shims tomorrow and putting the beast back together over the weekend... it needs a few flushes as the previous owner managed to rust out the rear heater lines by using a diluted coolant mix or just water. It seemed a sign that there would be sometype of excitement... well that and the water consistently dripping out of the tailpipe. Also a good time to bypass the rear heater lines while I'm at it.
Anyways, I was pretty stoked when I brought the sample cut home to have everything match up.
If anyone needs a shim to solve a similar problem I'm having three made, one at 29 thou, and two at 21. The last two mainly to have on hand, it adds no additional cutting cost to have them cut one vs three a 60000 psi blade of water and garnet doesn't care whether its one thousandth thick or 8 inches (sorta).
I'll post some photos of the finished copper shims when I pick them up.
Thanks,
Justin
I went ahead and took the new head gasket and drew up a 1:1 cad file of the gasket and had it water jet, below is a sample (aluminum from some scrap) from my local water jet company that seems to be a very good match to what I need. I should be picking up the copper shims tomorrow and putting the beast back together over the weekend... it needs a few flushes as the previous owner managed to rust out the rear heater lines by using a diluted coolant mix or just water. It seemed a sign that there would be sometype of excitement... well that and the water consistently dripping out of the tailpipe. Also a good time to bypass the rear heater lines while I'm at it.
Anyways, I was pretty stoked when I brought the sample cut home to have everything match up.
If anyone needs a shim to solve a similar problem I'm having three made, one at 29 thou, and two at 21. The last two mainly to have on hand, it adds no additional cutting cost to have them cut one vs three a 60000 psi blade of water and garnet doesn't care whether its one thousandth thick or 8 inches (sorta).
I'll post some photos of the finished copper shims when I pick them up.
Thanks,
Justin