Come on tro, if you go, I'll go. And I want to go!

 

Actually I bet while it was sitting in WA all those years it's anti freeze was below par. Cold WA night prolly froze the water in it's cooling jacket. Ice expanded in it. Cracked the block. Freeze plugs a tad too high. While this makes perfect sense it amazes me the pressurized system didn't leak. Built Ford Tough casting must have sealed itself back up.

 

It truly is amazing and when I told the machinist he had a hard time believing it. Maybe it's another bulletproof trait of the 300. After all, that engine has been known to break off piston skirts without you knowing until you pull it apart.

 

I want to head over too.

 

That really sux, sorry about the block.

 

The 300I6 is a strange one for sure. In my shop in 20 years I had
three bad cast blocks. All on the #1 cylinder. It was cast like to thick
and the water pump impeller would hit it. The first one I saw was a new
truck still under warranty. I called Ford and asked what the hell. They
sent me a new block for that one. But the next two Ford had a spacer
plate to go under the water pump to clear # 1. That worked very well.
Anyone ever run into this besides me? Lets hear it guys.

 

I suspect that Jeff is right again, with the low water/antifreeze in the block, and a cold Wa. night, cracking the block like that. I am sitting in San Diego, with a retired machinist, of some renown, and he has never heard of a block cracking, and it not leaking, when the crack was through to the water jacket.. How unique.. Another sign of just how tough that engine is..

Baja

 

My new engine should be ready fairly soon. Anyway, I got my stainless engine bolt kit from Classic Inlines and my new valve cover mailed in from Clifford. It's way taller so it can clear roller rockers. Not happy about the casting flash. For 300 some odd dollars I was expecting a little better detailing but that can be dealt with.

 

Well, we know you won't be able to leave that alone! You'll be grinding and polishing that thing for a couple days at least! At least it's something to do while you wait for your engine........

 

Excellent choice for a valve cover. I always liked the finned aluminum look. As cast or polished will look good.

 

I'd send pictures and complain about the Clifford cover. That's poor quality. They might send you a better one or at the very least give you a discount.

 

2x.....at least 2 days
I can't wait to see the final product.

 

I wouldn't be able to just leave that "as is" either.

 

Quick trick to clean that up if they arent going to make good on it is to throw it in a blast cabinet with FINE silica beads and blast it. It takes a while to get an even sheen to it... Then squirt it with some high temp clear coat. You can buy it at your local auto parts store. Multiple thin light coats and be patient in the whole process. I do this all the time with intake manifolds.

On a lighter note... Good thread. I just spent the last hour reading it.

 

Holy casting flash! That's rough. Oy. I foresee quality time with deburring bits and Roloc discs.

Alternatively, get 'er powdercoated, sand the fins, and then powdered with clear gloss.