Yes, there was alot of inconsistency on the surfaces.
I used a harbor freight knife sharpening stone, if you do this, inspect every single one on the shelf for one that is absolutely flat, 95 percent are not straight and would be worse than ineffective.
I keep the stone flat by feel, I did professional paint and auto body for 10 y, before changing careers, same principle as hand blocking bondo or paint to a flat surface.
let the block do the work, medium side, not fine, never tilt or turn on edge, keep moving, care to not work any area overly, and use feel to find the high spots, and don't take any more material than necessary. Probably shouldn't do this unless you've cut plenty of paint or body filler and feel comfortable with how to block.
So progress of the day, and a question..
I got the motor all put back together, everythings goin pretty smooth. Though it's a pretty big job and it's taking a lot of time.
I spent half a day, thoroughly cleaning out the cylinders and block and heads, took my time and care lowering the heads into place.
Ultimately ended up torquing the head bolts to 95 lbs. and put closer to 100 on the bottom and rearmost bolts, where they tend to seep. I went until I felt the pressure was building on the bolt and there seemed no more compression of the gasket, and it might be dangerous to push any further. 95-100 seems strong enough, it's definitely not gonna fall off there.
Got the Valley pan, rockers, intake, valve covers on, but the oil dipstick turned into a nightmare, and took half the day, and still isn't really done right.
I lightly gripped the tube with vice grips to 'press fit' it back in. Finally, after starter removal and a life or death struggle. I got it on. But the dipstick won't make it down, getting hung up on where I had to squeeze it (just a little, but) ..
Question, will the o-ring (rtv) dipstick tube, from the 7.3 fit my truck? Not much info that I could find searching the forum, but there was mention of an adapter..
Will the 7.3 tube fit the earlier press fit block, 85? If so, will I need a matching adapter? If so, will my existing dipstick slide through the 7.3 tube or will I need the matching dipstick.
It's a pita, but not the end of the world, I got it in so at least it wont leak until I can find a replacement, and I'll just slide wire down to eyeball oil level for the time being.
Got another full days work ahead and it should be finished..
Tasks yet,
Wiring, vacuum, cables
pump and lines
exhaust
starter
accessories
Misc
Greasing
Rebuild alternator
Almost there, I just want this to be done.