Thanks! I'm pretty sure that the shutter thermostat is there. I'll have to check tomorrow to be sure. I'll see if I can make sense of the manual on the adjustments and such. We're going to leave the thermostat on the cylinder head out. We won't be using the heater, so according to the manual it's not needed.

We worked hard today and got the engine back in the car. Took way longer than I thought it would. But we got it! Next up is finishing up all the items that need to be reconnected. Tomorrow we hope to get the engine running. If all goes well we will try a quick drive down the street.

This picture is in the middle of trying to line up the engine with the transmission. Such fun!
<img src="https://olyjha.bn.files.1drv.com/y4mYx ... t=660&cropmode=none" width="495" height="660" />

-Kevin

Well, we got the engine fully reassembled, everything hooked up, break-in oil added (pressurized through all the lines), radiator temporarily hooked up and water added. Gas tank drained, fresh fuel added, old gas pumped out of fuel line.
<img src="https://rryrha.bn.files.1drv.com/y4mhB ... t=768&cropmode=none" width="1024" height="768" />

The engine started up immediately and was incredibly quiet. Unfortunately we noticed it was beginning to run rough, and #2 cylinder was not firing. Pulled the spark plug and found the cylinder full of water. Ugh...that was definitely not what we wanted to see.

Fast forward a few days, and the head and block have been pulled. We see a pinhole in the wall of #2, with obvious signs of water leakage, as well as a possible pinhole on one of the valve areas. Also, the bolts holding the block to the crankcase had loosened up, likely due to the too-thick gasket we used. This was to make up for a slight over-machining of the block itself making it ever so slightly too short. Unfortunately this all means that this block is probably toast. It's probably not worth trying to fix it.

We're now hunting for another block, but also considering other options. We are looking into new-cast as a base to start with. But we need factory dimensions before that's even a possibility. For example we would need factory bore size, original block height, etc. With that information we can begin the process of drawing up CAD designs for a replacement block. With the scarcity of Super 8 blocks for 37-39's I imagine that a new-cast option would help other guys as well.

BTW, did '37-'39 Super 8's use the same basic block, but with different machining? The serial number on the '39 block we have has a 37 on it, making us think it was cast in '37 and used in '39.

-Kevin

My SINCERE condolences on your dilemma. No doubt you are very very depressed after ALL that work. Heartbreaking.

Now, as to casting replacement blocks, I would GUESS this is NOT even close to cost feasible, whether for one, or the few more guys that are near at hand. Sure, every once in a while I get a block, and it takes a bit to find a buyer, but it eventually goes. Problem with used blocks, you just learned...there's just no way to make guarantees. I even had one block boiled and magnafluxed for a guy before sending to England, and later there Still was one minor crack that was discovered under a valve seat area.

My crystal ball prediction is you will find someone to do some repairs on your block and you will sleeve the cylinder, and put it back together for the ego and strength of conviction of doing it after all you have put forth. But I think it will be on a stand in the garage as a showpiece to that effort and you will put a different engine in the car, add A/C and be more comfortable and reliable for that. (edit, oh, wait, I do see the compressor on the other side...hiding in plain sight) That said, there may be another 39 block out there, particularly from the guy you got the waterpump from (I tried to buy the car it came from, but too far away)....

And by the way, I've followed this progress but don't think I've commented, does your car have history from Mineral Wells?

Flack - thanks. And yes, it was a real blow to morale for all of us. After we found the water we all kind of went into a funk for a bit. We had spent dozens upon dozens of hours getting this thing back to this point only to have it fail immediately.

And I do understand that used blocks are exactly that...used. And they are very old, so there is certainly no guarantee. With the previous corrosion on this block before it was cleaned up (boiled and magnafluxed as well) and the overbore we had to do on the cylinders, it just left the walls too thin. Sleeves would work for the cylinders, and we could probably find and weld the small leak in #6 valve area, but the shortness of the block can't be fixed (as far as I know). It would be much easier to just replace/fix the block, as the lower portion of the engine is a complete fresh rebuild and is in stellar condition.

As far as the car history goes, it came from somewhere in Texas, but the town name escapes me. The car has two A/C systems in it from the previous owner. One for the front and one for the rear. To be honest, I'd prefer that it not have A/C because it has made everything far more complicated. And being up in eastern WA state, it's a drier heat and we can certainly live without A/C for the most part.

BTW, the 39' water pump worked excellently during the short time we had the car running. Putting a hand on the upper radiator hose you could feel the water rushing through at an incredible pace.

-Kevin

The saga is not over on this car. Shortly after our crushing defeat, I located a complete '39 Super 8 engine in New Mexico. It was part of a package that came with a restored '39 Super 8 that the guy had bought. It came disassembled and packaged in crates. It had been this way from the early 60's. The original owner had used a donor car in his effort to restore the other, and the donor engine was never used.

Long story short my dad made the long drive down and back and brought back the engine. He also brought back any other parts the guy had left including a complete S8 rear axle, drums for all corners, etc.

The upper block is in much better shape than the last one we had. It's currently getting machined and ready for rebuild.

We're not dead yet!

-Kevin

Good for you and your Dad, Kevin.
Thanks for the update, I was wondering where (and how) your '38 project was coming along.

Marks to both of you for staying with it.

Please keep the forum posted.

Jim