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Subject I did that recently also, some tips..
     
Posted by Turbodog (CT) on December 05, 2005 at 7:08 AM
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In Reply To 2nd on removing the flashing. posted by grevels on December 05, 2005 at 06:14 AM
     
Message It’s really hard to get to the middle area of the block. Home Depot sells an extension for drills that allowed full reach. If you punch out the rear freeze plug its much easier to work at it from both ends. I started out using an air powered grinder but switched to electric because it takes a while to do. Be careful not to damage the sealing edges of the freeze plug holes, I got the edge of one and the machine shop scolded me and said any worse and it would have needed repair. I ended up taking out all the freeze plugs throughout the block to more thoroughly blow out all the chips and stuff with compressed air before it was machined and boiled. I had the best luck grinding the flash out with the 1" round stone bit (course) and used flap wheels to clean it up nice. When I was done, a new 1" round stone would pass through the center of the block. The flap wheel was also great for smoothing the water pump hole, I even got into the outer groove circling the water pump area with a dremel and cleaned it up nice and smooth.

Parts on bench/on order to be installed:
87.5mm Weisco pistons
Solid motor & tranny mounts
1pc driveshaft
Brand new tranny
ported heads w/larger intake valves
Will be deleting HICAS & removing all related hoses
Relocate battery to rear to make room for PCV oil accum/tank.

Last dyno:
478 whp
435 lbs-tq
On 94 octane @ 17psi

Best 1/4 mi:
12.59 & 120mph on old steet tires

Daily driver, 05 Titan KingCab Tow package, 2.5" lift kit.
Looking for used trailer to tow Z to the tracks and back.

     
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