Engine assembly help

[Marko]

Hi guys,

currently fitting a new welsh plug kit to a 308, can anyone advise which way the domed disc fits into the cam end of the block - dome in or out.

Cheers Mark

[60Special]

Should be dome out, so that when you tap the centre it will spread the welch plug and lock it in place.

[fastjbav6]

Dome is fitted facing the water jacket (dome in).
Use a socket that fits inside the cup of the core plug to fit to the engine block. Caution-make sure the socket is not a snug fit in the cup of the core plug, otherwise it will get stuck in the core plug after fitting.

regards Seb

[Marko]

Cheers Seb, got the core plugs sorted, specifically talking about the slightly larger domed disc that fits into the end of the block at the end of the cam shaft.

Thanks 60, I figured the dome would have to face out to clear the cam end once tapped in, BUT I destroyed the first one I tried to install so wanted to confirm I was doing the right thing - I will try again.

Thanks guys,

Mark

[60Special]

Hi Marko,
Sebs tips are good for the cup type plugs in the water jacket.
Use a flat faced mandrel, slightly smaller than the plug, when installing the dished type so that you don't dent the plug or go 'over centre'
Cheers,
Trevor.

[Marko]

Thanks guys, appreciate your help - I will grab another one and give it a crack, that is once I get the stuffed one out.

Cheers Mark.

[Doc Bob]

Gudday Marko...must be exciting to be finally putting everything back together

The cam plug is a different kettle of fish to a normal water jacket plug.

You are right, they are fitted with the dome facing outwards towards the gearbox side of the engine.
You MUST use a joint sealer with it as well.

#1: Thoroughly clean the plug and the cam hole before fitting.
#2: Talk to your local auto shop for a joint sealer (fuel/oil/heat resistant.) Loctite products are well respected and work well.
#3: Apply sealant to plug and block as per instructions.
#4: Centre plug in hole, dome facing out, use a short flat faced drift give it a good shap crack in the very centre of the dome.
#5: Plug should sit flush with outer side of block, may take a couple of good hits, ensure sealant has even coverage around perimeter of plug.

This can sometimes take a few attempts to get it right, avoid touching or damaging any outer edge of the plug.
Most importantly....if you are not 100% happy with the fit or any doubts about the sealant.....pull it out, get a new plug and do it again.
Better to do it right the first time.......nothing worse than getting it all back together and have oil pissing all over the place

All the best..............Bob.

[Marko]

Cheers Bob,
Yep spot on, big weekend for me, very exciting

Engine almost back together and van went into panel beaters Saturday morning.

After our discussions regarding inlet manifolds I went ahead and had mine (genuine GMH) repaired (corners etc) bead blasted, thermostat housing built up and machined and machined both the inlet/exhaust faces(you know what I mean)etc - and guess what

because I had the block and heads decked and the machining of the manifold there is now about a 1.5mm gap between the manifold and the heads (that's with the cork gasket either end) - I remember you said to be careful!! -

SO -

I gave in and brought a Performer manifold - good fit. I guess if I had a machine shop closer (and a heap more knowledge and experience) I could muck around with the GMH one and get it to fit but - for me, easier to go with the performer.

If anyone is chasing a very good condition original GMH inlet manifold and can make it fit their engine its up for grabs - all the work cost me just over $300, make an offer it could be your lucky day.

Also the date for the Mid West show and shine has been called, September 29th, I will upload a pamphlet when I see one.

Thanks again Bob and the other guys for your help.

Mark

[Doc Bob]

You can still use the manifold Marko......ditch the cork Gasket and use a sealant bead between the manifold and block.
That cork shit never stays in place, drys, shrinks, cracks and leaks
Have not used the cork ends for over 10 years now and never looked back.
If you still have space issues on the inlet faces, use good FELPRO gasket sets.
These are thicker than normal and have almost zero crush................


............or just run the PERFORMER manifold

All the best, may see you in September..........Bob.