Austin Healey 3000 Alloy Block Project
Machining Process
All of the jigs and fixtures have been produced for holding
the block during the machining processes. The block is now partly machined
and progressing steadily. Shown above the Durallium bearing caps have been
trial fitted, and the rolled thread main bearing studs have been procured.
The image above shows the machined head gasket face, and note the threaded freeze plug holes
The partly finished block with DMD cylinder head and Weber manifold. The block is now ready for line boring of the main bearing and camshaft bearing bores.
The first run of blocks. From left two 3.8 litre, one
standard 3 litre and two 3.2 litre. Cylinder liners are now installed.
The view above with bearing caps fitted and ready for
line boring
Close up of the two 3.8 litre blocks
The billet crank, forged piston, conrods and extruded
aluminium main bearing caps
Close up view of the conrods with the standard and 3.2
litre version on the left, and the special offset conrod for the 3.8 litre
on right
After lots of delays trying to find suitable machinists the block is set up for line boring the crank and camshaft bearing housings.
The boring bar is carefully set in preparation for boring. The boring bar has multiple tools and will bore all the housings in one operation
The Block with billet crank trial fitted during the process of checking bearing clearances
Another view showing the block with crank and cam trial installation. All tolerances were maintained and the rest of the batch are now being machined
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