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On the engine in my avatar I sanded the flat spots first so it would be easier to shave them with a razor blade after I painted them. I started shaving after an hour of drying. (Not fully dry.) All I can think of for you to do is reblast and start over. It took all day but I'm happy with the...
Dwayne: Don't you think 150 on the seat sounds high? I mean, I think of a hydraulic roller taking a lot more spring and the Trick Flow .600" lift hyd roller only asks for 154 on the seat. I would have thought his cam would ask for more like a stock Street Hemi spring? Am I crazy?
Hughes knows more about cams than me but WOW, 150 on the seat. That's more than a Race Hemi. It sounds like 440 Source had them closer than your machine shop. I've removed those valve seals with Channellocks and I didn't think I hurt them but now I have a Goodson tool for that.
As Doug said most of these cranks today that they call Hemi cranks are really wedge cranks. You have to have really light components to get under 2500 grams. (I think that's what an Eagle crank starts out with.) And some are lighter than that. Nothings easy about building a Hemi today.
I don't remember which chain I used last time but it's usually a nightmare. Superformance make a .062" gasket that would help for starters. And people always ask why it takes so long to build an engine nowadays.
WOW, it looks like you have a long way to go. The idea is you keep grinding on the button until it fits. Hope you can do it without hitting the cam bolts. Don't go too far. You can't put it back on. 5-10 thou is fine but remember that's after the cover is torqued down. Did I ever tell you cam...
I've never seen a Hemi cam spec cold. You must assume that is hot. With aluminum heads you can set it .007" tighter cold and that will get you close. I haven't put anything together with iron heads in so long I don't know, maybe .004" tighter.