The cap is 5.14 inches and inside the block is 5.12 inches.

Did you ever ask your machinist about this to see how he installed your caps. That would have been my first phone call

there is no way you have .020 interference and the caps were installed

No I have not called the machinist yet. I will be calling him monday. I figured I would ask on here first just in case it was just something I was doing wrong.

As far as the measurements, I can only tell you what digital caliper shows. I did have a heck of a time getting them out.

On your first post you stated you had a set of 440 source billet main caps, are they steel or aluminum main caps? Either way before you go to your machinest call 440 Source anbd ask them how much interference fit they want on the main caps you have I wouldn't say anything about having problems with the parts yet to 440 Source I would tell them that the instructions got lost and you want the straight scoop on the proper fit from them before going to your machine shop

I'm sorry, I should have mentioned they were steel. I will definitely give them a call Monday.

My guess is maybe you left a zero out on your readings of the cap and block. 5.012 and 5.014 and not 5.12 and 5.14 which is .020 difference and not .002. If it is .002 interference fit. I know my Source billet caps fit like any have for me after I had my studs installed and had the mains lined bored as I had no problems at all like you are having. Ron

383Man,

I am using a digital caliper and the readout says 5.12 inches and 5.14 inches. I don't think I am doing anything wrong.

I meant no offense by it. But wow thats .020 difference then thats not right. Ron

That number CAN'T be possible if the caps have been on block and it line honed. You can look at his pics and see it's not .020

Yes I agree, but I wouldn't use dial calipers for that, too many chances for error and I think that's what you are seeing.

383man, No offense taken.

Although I have built several engines, this will be the first one that I have put this much effort into. I just want to be sure I am doing it right.

It might be wrong, but I was using the tool I have readily available to me.

I don't think your measuring wrong. I would expect a .002-.005 error with a cheap crappy set of calipers. heck even the calipers I've used that were from harbor freight were within .002. the block dimension seems to measure ok at 5.12(0) probably missing that last significant digit but you're in the ball park. if the caps actually measure 5.14(0) you need another set of caps. that's a ton of squeeze to put on the block and the caps. and if your machine shop crammed them in there, find another shop to correct their work.

Have you tried all the caps or is it just one? Are they going in the right order/spot? I once had a block machined for an irrigation pump and the machinists 1-5 numbering is not the same order I would of used. At least we agreed on 3 though

I'd love to see how you got a measurement with calipers down inside the block

my point exactly.

Yes I have tried all of the caps. Yes I am putting them back in the right spot, not only are the numbered but I also took pictures of it when it came back from the machine shop.

To get the measurement down inside the block, I used all thread and some long nuts. All thread about an inch shorter than I needed. Backed the nuts off the all thread until it was tight (not crazy tight) going in and out of the block. Locked the nuts with secondary nuts. Took it out and measured it. I know it might be off a little, but certainly not .020 of an inch

That won't work

I use my telescoping gauges alot for a measurement like that and then just mike the telescoping gauge. Ron

An honestly that not good enough for what he is doing. I use inside Mics and they are always calibrated with my outside Mics that are calibrated with my standards