I tried forcing solvent through boyh ways and let it flow reverse of the flow of oil for 24 hours and still no go.

Take it from me please get a new cooler Don't skip this step!!! I promise you will regret it eventually.

Call ams or any other reputable evo shop and ask to confirm what I am saying.

 

I've got the head disassembled for casting flash removal, mild porting and a thorough cleaning.

The shortblock is ready:

 

Some porting pics:

 

more

 

two more

 

I ground the casting flash smooth in the area of the head covered by the valve cover, but found the machining flash to be worse. There seems to have been no post machining deburring performed at all.

 

These burrs easily broke off and 15 to 20 minutes of work resulted in the pile of chips shown. That's a 10" screwdriver for comparison.

 

Duly noted and on order.

I've spent so much time cleaning bearing trash from everywhere that I decided that would be the wisest choice.

 

Port matching exhaust:

 

Turbine and O2 housing cleanup:

 

Bottom end shot:

 

Very nice thread. It'll be rewarding when your car fires up and turns out a lot better than when you bought it. Out of curiosity, was the deal good enough to cover the build so far?

 

nice

 

Thanks! Parts wise I'm OK; if any of my labor were factored in I don't know.

 

Ready to go back in: