At the engine shop

Friday April 13th 2007

We found the world's smallest van to drop off the MEL 462 engine at the engine shop.

 

After the shop owner had finished disassembling the engine he told me it was a very tired old engine indeed. They main bearings were so far gone he was surprised the engine held oil pressure at all... One piston had scuff marks it hot gotten so hot at one time. Other things found to be needed/problematic are:

• The cylinder heads will be rebuilt too and will receive hardened valve seats (LPG conversion).
• At some point one piston had been replaced. This new one was heavier than the original ones. Can you believe such stupidity?
• The camshaft needs to be replaced. Several cams were too far gone.
• The crankshaft will be reground & balanced. These marks suggest someone put a pipe wrench on it in order to turn the engine. This dumb-ass damaged the woodruff key the power steering pump attaches to.  
• The oil slinger plate was missing....

After the first cleaning blue paint can be seen (1961-1965 MEL 430 were black, 1966-1968 462 were Ford Blue). The cylinders will be bored .030 over. The block will also be decked and line honed.

As it turns out I have a Frankenstein engine: a '66 462 engine block + '63 430 intake + '66 462 heads. This is stupid because the runners in the '66 heads are smaller than the runners in the '63 intake manifold... resulting in an obstruction of the flow of the air-fuel mixture. I guess I need to find a replacement '66 intake.

So basically everything needs to be replaced except the block, heads, crankshaft, rods & valley pan. Yikes...! 

Here's my shopping list so far:
- Pistons (set) .030
- Piston rings (set) .030
- Main bearings (set) .010
- Rod bearings (set) .010
- Camshaft bearings (set)
- Camshaft
- Hydraulic lifters (set)
- Timing chain & gears (set)
- Valve push rods (set)
- High volume oil pump
- Oil pump intermediate shaft
- Gasket set
- Neoprene rear main seal
- Front main oil seal
- Freeze plug set
- Fuel pump push rod
- Crankshaft woodruff key
- Crankshaft oil slinger
- Connecting rod nuts (set)

Things to be rebuilt or replaced:
- Intake manifold
- Oil pan
- Rebuilt water pump
- Rebuilt distributor
- Water pump bypass nipple
- Water junction block
- Recored radiator
- Rebuilt radiator expansion tank
- Radiator hoses (set)
- Rebuilt power steering pump
- PS pump insulators
- PS hose reservoir to pump
- PS reservoir filter
- Harmonic balancer
- Flywheel Flex Plate
- Starter motor

The mechanic made these two water diverters out of old pieces of steel tubing. They fit into the block behind the water pump and divert the flow of coolant to the cylinder heads. 

Up to 1964 the MEL 430 was equiped with two bronze block thermostats (next to the water diverters). If yours are still there: remove and do not replace.
 

Saturday May 19th 2007
I found a replacement 462 intake & a very nice oil pan not more than 4 miles from home. What are the odds? You can find next to nothing for the 430/462 engines in The Netherlands - trust me - and there they were... just gathering dust. Anyway, the oil pan is very nice - no dents, no rust, no previous welding repairs.

 

Saturday May 26th 2007

When dropping off the replacement intake and oil pan I found my MEL 462 block sitting in the (align) bore machine. The mechanic said it went well (the block hadn't shifted/warped/distorted much) and he found no new nasty surprises such as cracks. 

 

  

Tuesday June 12th 2007 The final parts needed arrived today: a new camshaft to OEM design by Falcon Global (on eBay) and a set of .030 pistons from Egge. The pistons are very close to OEM design. This is a step design (not to be confused with a pop-up design. 100% correct replacement pistons are available but expensive. You can special order them from WISECO. 

Saturday July 14th 2007
Things are coming along nicely: the valve covers, oil pan and intake manifold have been powder coated. The cylinders have been bored & honed .030 The block has been align bored & honed .010, it has been decked, and has been painted. The crankshaft has been ground .010 I did have to order a set of connecting rod nuts because the previous mechanic had rounded these off... 

 And assembly has begun!!!

 

  

Saturday August 11th 2007

Engine assembly is well on it's way. The crankshaft, camshaft, pistons & oil pump are in. Timing gears and chain are fitted. The crankshaft has been balanced. The pistons & rods have also been balanced to within 1 gramme.

  

Saturday August 18th 2007
Almost there...   

 

Tuesday August 28th 2007 

The engine rebuild has finally been completed. Now it's only a case of re-installing it, breaking it in and going for a drive. In reality that's quite a lot of work but well worth it.