Slippery said:frenchyd said:Asphalt_Gundam said:Pretty much any Foundry won't touch it unless it's their designed mold, etc. Then you have the fact that unless you're getting A LOT of them, they don't want the job. I couldn't even find a foundry that would use a proven mold I already had and do a small production run for valve covers.....
The Cheapest (and fastest) DIY way would be: Buy a 5 axis CNC, Faro Arm, MasterCam, Tooling and a huge chunk of aluminum. Might be able to do it for under 150K
The local foundry I know of does a lot of art stuff, one off, Bells, Etc.
An engine Block you'd probably have to do open deck then weld the deck in place. Once everything had stabilized mill everything square. An ordinary mill will be fine unless you charge yourself for your time. . Later use top hat sleeves to seal it.
Once the block is squared up use the old main caps to locate the bolt holes for the crank and existing heads to ensure head bolt alignment. Really the only thing requiring measurement will be the location of the head locating dowels. You can measure one location and then using a transfer pin, mark the other.
Crank boring would be done after the block is decked. There are companies that specialize in line boring. Likely you've got 10-23 hours of work. But they'll give you a quote. Bring your old block with youSo the cam, oil galley etc would all line up. Boring up to the oil galley from the mains will require a guide held in place but could be done on a simple drill press. Maybe you should do a blind hole first so you don't have fragments coming loose. You could even drill up through the camshaft hole fit some Allen head tapered pipe taps in and drill back into the galley. Really depends on how the Chrysler factory did it in the first place.
Now the factory does all that in a couple of passes with gang drills. But doing them one at a time once the head is securely located isn't challenging at all.
Plenty of labor. Most in the set up. But all doable for a determined amateur.You have a way to make stuff sound easy ... yet you are here asking how hard it would be.
Others have found listings for that engine. So it doesn't make any sense to do a new block.
The machine work to straighten out a block is stuff I've been doing for a very long time. Heck anyone who wants durability in a race motor goes through all these steps. I've had machine shops do it for me and done some myself. It's really a case of time and care.
