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Fixing a crack in a 503 FM cylinder.


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Old 01-17-2010, 10:53:21 PM
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Default Fixing a crack in a 503 FM cylinder.

These big cylinders (346 and 503) have a bad habit of cracking on the inside in the combustion chamber. The cracks are about two inches down and are from stress right where the bottom end of the head stud is trying to pull out of the cylinder. The cracks let coolant into the chamber and compression out into the water jacket, this is not good. Often these are shaped like a U or a smiley face (but not if you own it). I have a way to fix these, I'm doing one tomorrow and will put up several pictures showing the procedure.
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Old 01-18-2010, 03:35:29 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

cant wait to see some pics
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Old 01-18-2010, 09:33:35 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

Didn't get too much done today, just the old sleeve bored out and started on the repair. My camera quit working just as I started on the chamber but I'll get pics of that tomorrow. Here is a picture of the crack though.

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Old 01-19-2010, 02:51:24 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

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Old 01-19-2010, 02:53:25 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

set the depth

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Old 01-19-2010, 02:56:31 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

if there was any doubt that was a crack, after cutting the chamber out for it's sleeve you can still see the crack and notice the porosities and a small developing crack to the left, it was failing too

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Old 01-19-2010, 03:00:09 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

the chamber sleeve

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Old 01-19-2010, 03:02:37 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

up in the press

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Old 01-19-2010, 03:06:09 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

the sleeve installed and the cylinder is ready to go back to the bar, I'll bore the entire length for a new sleeve and press it in from the bottom over lapping them. This doesn't "fix" the crack but it covers it so well it can not leak.



I'll get some pics of the long sleeve going in and refacing the head gasket surface when I get back after lunch.
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Old 01-19-2010, 03:58:39 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

these studs are 3/4 10 right ?
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Old 01-19-2010, 04:05:27 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

The threads are 7/8 9 tp"
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Old 01-19-2010, 04:15:29 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

Thanks for the picks.........I enjoy seeing a projects progression.


Tbar
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Old 01-19-2010, 07:19:25 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

Here's the cylinder with the chamber sleeve installed and bore for the liner.

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Old 01-19-2010, 07:23:28 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

pressing the liner in from the bottom

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Old 01-19-2010, 07:25:48 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

liner in and pinned (1/4" bolt is my trademark)

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Old 01-19-2010, 07:30:35 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

Reed Engine,
Is cracking a problem with any of the other ZC's !!!!!

Thanks ,Pete
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Old 01-19-2010, 07:52:24 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

Yes, 118 and 208's crack in the threads, pretty much ruins the block. It can be fixed but it's slow and expensive. The big engines also crack to the outside, this is bad news too, always hard and expensive but as there are no new cylinders what do you do? If you want it to run and be dependable you have to bite the bullet.
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Old 01-19-2010, 10:26:08 PM
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Default Re: Fixing a crack in a 503 FM cylinder.

Quote:
Originally Posted by Reed Engine View Post
The threads are 7/8 9 tp"
ok i thought they were 3/4
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Old 01-20-2010, 12:02:39 AM
Pete Mueller Pete Mueller is offline
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Default Re: Fixing a crack in a 503 FM cylinder.

Is this cracking due to over-torquing of the head bolts?
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Old 01-20-2010, 12:21:09 AM
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Default Re: Fixing a crack in a 503 FM cylinder.

Pete, possibly or maybe just due to 50 years of service. I'm sure F&M never intended for them to last as long as they have.

If you look at how they are made it is a weak point. They should have beefed up that area and put more head studs in all of their engines.
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