Another method of checking the bore that has not been mentioned is to get someone to turn a couple of go/no-go plugs. Basically you just turn a piece of steel to the high and low limits and see if they fit--one should the other should not. Now to do this they have to be RIGHT. You have to use a GOOD and accurately calibrated mic and get a good surface finish. Also add a nice radius lead in on the gage. I am very hesitant about using telescoping gages for this. We rarely use them at work because they are not very accurate--at least for my line of work (especially the Chinese ones). The second problem is they require a lot of experience to get a very close measurement. Being off .0003" is probably not a good idea here--this isn't a piston bore. If you have a machinist friend that could measure the block with a set of tri-mikes or an inside mic that would be great. Those also help show up taper.
My question is if the bore is slightly oversize, are there any type of sealants/locking compounds that can be used as opposed to machining? I know Loctite makes stuff other than thread locking. I'm not suggesting trying to take up .005" but .0005" maybe.
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