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Old 03-12-2014, 11:32 AM   #1
Ferox
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Bringing a Split Port back to life.

Im Starting a rebuild thread. I Purchased this car over a year ago and have been pretty busy with some life changes since. I have finally gotten to the point where I can concentrate on getting this car on the road and since there aren't many Build threads on here I figured id Post up pictures of mine.

I bought the car for next to nothing knowing something catastrophic had happened. It dropped a valve seat on number 4. At first view after pulling the head the damage didn't seam too severe. After spinning the crank and noticing that piston wasn't moving, I realized there was a lot more damage hiding under there.

At some point the piston broke in half at the wrist pin, bent the road and beat a hole through the cylinder wall. I had originally looked at all my alternatives including swapping in a Zetec. After a deal fell through on a smashed donor car with a Zetec and a 5 speed manual, this car was put on the back burner for a while. Luckily one of my dads life long friends owns his own machine shop and lets me work on a lot of my own parts provided i help him from time to time and of course pay him for what I can't do on my own. We decided to Re Sleeve the block, fix the head and replace all the Valve's and Valve Seats just to be sure. So off we went and here are the results of all the work so far.

First up are some pictures of How it looked when I pulled it apart.


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Last edited by Ferox; 03-12-2014 at 11:56 AM. Reason: Added details
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Old 03-12-2014, 11:42 AM   #2
Ferox
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Skip forward a while after the Machine work is all done and here you have some pictures of all the parts and the beginning of assembly. I'll post a parts list later but one thing that differs in those pictures is the bearings. I exchanged the cheap chinese Engine Pro's for Clevite M77's. It only made sense, especially considering I spent the extra money on Hastings rings and Hypereutectic pistons.
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Old 03-12-2014, 03:33 PM   #3
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Subscribed.

Looking forward to watching the rebuild.
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Old 03-12-2014, 05:03 PM   #4
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Moved to "Ford Focus Builds & General Showroom". Good luck with your rebuild!
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Old 03-12-2014, 06:42 PM   #5
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Old 03-12-2014, 09:14 PM   #6
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Today I finished assembling most of the long block. I still have a few parts to order before can install the engine and finish everything up.

Here are some more pics of the assembly process.
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Old 03-12-2014, 09:36 PM   #7
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More pictures..
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Old 03-13-2014, 02:11 AM   #8
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Movin' along.

Tx for the Pics!
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Old 03-13-2014, 09:25 AM   #9
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Looking forward to seeing how everything goes. Subscribed.
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Old 03-14-2014, 06:01 PM   #10
Ferox
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Everything has been going along pretty well so far. I wont be back to work on it again until Tuesday or Wednesday.

I still have some parts to order and some work to do before i'll put the engine in. The control arms and tie rod ends are getting replaced with new. I need to drop the pan off the transmission and replace the filter. The drivers side Cv needs to be repacked and have a new boot installed.

I expect the engine to run great. I checked the clearance on all the bearings and checked ring gap. Everything is well within spec, even the new sleeve.

The head is a little bit beat up but I don't expect it to have any effect on reliability. The important thing is we replaced "All" the valve seats and not just the one that failed as well as the valves.
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