Ok ive this internet thing sussed now... more pics
got the engine block and head back from the shop. He honed the bores for me, pressure tested the cylinder head, gave it a light skim, took out all the valves, put in new valve seals, recut the valve seats, lapped em all back in.
garage needs a tidy:
now to rebuild the fucker:
seriously, this is like porn to me:
Pistons in. nice new rings. Circlips are cunts, arent they? PING
Cylinder block on. That wasnt easy.
head on. finally got to use my shiny new torque wrench
cams and followers in. slathered in oil. good word, slather.
just had to put the rocker cover on, and it was ready to go back in the bike! over a couple of evenings we got the motor back in, rad and exhaust back on, fluids topped up etc.
while the engine was out, i sent the oil cooler and rad off to a radiator place where they cleaned out all the fins properly and pressure tested them. Whatever they soak the rads in to clean them must strip off the coating too, cos they came back to me freshly painted too.
While i had access to parts such as the steel fan housing, oil cooler mounting bracket, rad guards etc i got all the rust off with a wire brush and gave them a proper painting with red primer and black hammerite. they wont rust again in a hurry!
so this is how she looked for the first test ride:
is that oil leaking on that nice clean forecourt? FUCK!!
turned out thet the oil was from the various banjo bolts in the plumbing around the oil cooler, despite using new copper washers. had to coat each washer with silicone and reassemble it all. it did the trick.
what was another problem was that the engine seemed to be overheating like a bastard. even though the gauge wasnt budging at all. Turned out i needed a new fan switch, new sending unit for the temp gauge, and when i opened the thermostat housing to check it, it wasnt there! some twat of a previous owner had obviously taken it out when it wasnt opening.
and that, kiddies, is where i leave the story for now, cos im off to bed