I need advice on the re-assembly of an Allis Chalmers G153 gasoline engine I'm putting back into an old FP40 A/C forklift. The G153 engine was the same as the 4-cylinder Buda engine; A/C bought the design.I had the head rebuilt by a machine shop. They did a very nice job. I'm ready to put on the (huge!) 1-piece intake/exhaust manifold, but I noticed that an earlier coolant leak had pretty much disintegrated the 7/16 NF threads on 3 of the studs. Nuts on those studs are now "press to fit". Further, several of the other studs on close inspection could stand replacement also. I've made some measurements, and have 3 different plans. I was wondering if I could ask you all for criticism and recommendations? Plan 1:
New studs are available at about $30/each. Ouch! Plan 2: As it happens, a 7/16"x5"x14 Grade 8 capscrew bolt, with a lockwasher and 1/8" thick washer, is just shy of bottoming out in the head when fully torqued. Replace all 10 studs for about $27. Plan 3:
Replace all 10 studs with 6" long Grade 8 NC capscrew bolts. Cut the caps off the bolts with a bandsaw, and cut 1" of 20 TPI threads on the end opposite the existing 14 TPI threads. Basically, make my own studs out of bolts. Still cheap, but a good bit more labor. I'm very much obliged for your help. Dave Doerschuk
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