(Mud seems to be having issues posting photos. I'll do that later.)
More engine rebuild drama…
I found a different shop to install the cam bearings properly and they did a great job. I thought I was home free to build the engine so I spent a couple weekends cleaning and organizing my shop for the task.
Yesterday I went to install the crank … the first machine shop (who screwed up the cam bearings twice) never took the main bearings out of the package and didn’t accommodate for the increased thrust clearance of #3 on the set of undersized bearings. Crank wouldn’t fit because the thrust surface of #3 was too wide. F#*%!!! I think when Toyota originally assembled these engines #3 main bearing was flat and the thrust washers were a set of separate half-moon pieces. Now you can only get bearings where #3 is saddle shaped, incorporating the flat bearing surface and the thrust washers into one piece. And if you get undersize bearings, they come with thicker/wider thrust surfaces.
After that failure, I pulled the #3 bearing out and plastigauged 1, 2, and 4. Not great.
Spec = .020-.044
1: .051
2: .049
4: .063
These are approximate numbers, just using the stuff printed on the plastigauge paper and approximating the value if it's between two. Probably fine, probably typical for an engine with some miles. But on a new motor I paid a machine shop thousands of dollars to "do it right"? Nah. Like I've said before, my math is that I'm not willing to bet all the money I have in this project on a "it'll probably be fine" kind of feeling. I didn't even check the rod bearing oil clearances, I was too heartbroken at that point in the day.
Tomorrow I'm going to pack everything up. Everything. Block, pistons, crank, cam, every single bearing, all of it. It's all going to this new machine shop I found. I'm going to have them inspect it all and give me a price estimate for what needs fixed. At minimum I think the crank journals will have to be ground down to the next undersize and will require a new set of bearings.
Oh, and the bad machine shop rebuilt a 61040 head for me about three years ago. It was originally destined for the Tomato truck, but when I acquired Matilda I thought I'll eventually rebuild a block and use this rebuilt head to make a whole new motor. It's been sitting on a shelf and now I'm wondering how messed up that might be. May as well have it inspected. I had that head rebuilt to stock - bottom got machined only for flatness taking off as little meat as possible. Manifold surface was made flat. Only about 4-5 valves were replaced, seats were only replaced as necessary. All the seats then got cut. Since the block was bored +1.00mm over and the cam is an RV grind, I'm wondering if I should just have the head redone with the larger Chevy valves and do a little light DIY port matching - get it to breath better and accommodate the "improvements" on the bottom end. Race tractor? I don't think it would hurt reliability. I wouldn't be trying to push the limits of a 2F ... more like as long as I'm spending the money anyway, may as well.
I don't know. Somebody give me some advice. I'm pulling my hair out about this.