While I know I'm probalby overdoing things, I'm tryin to build this engine to take as much abuse as possible. To that end, I'm going through and removing as much of the casting flash as possible so that I can reduce stress risers. I had no qualms removing anything from the block, but then I began looking at the crank and noticed that there was quite a bit of flash (cast crank engine).

Well, I thought about it, and the flash was fairly evenly distributed, and even then, the weight of the flash removed compared to the weight of the crank should cause negligble balance problems. Now I find myself looking at the connecting rods and caps. there are some definite mold marks, but I'm very hesitant to do to much to them because I don't want to have them rebalanced. On top of that, much of the flash is on the top end of the rod, which would require removing the pistons to really get to well. Am I stressing (pun intended) too much over little things or would it really be worth my time to have the pistons removed and then have the rods rebalanced when I'm done? Pics to follow soon in the gallery.

Edit: Forgot to mention, I'm not looking for terribly high revs.

If you leave them alone, you will almost certainly be fine. I did not touch that stuff on my 68 motor, or rods on my 64 motor (both forged crank, though?) and they have taken lots of abuse for many years.

Lou

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Home of Slant6-powered fun machines since 1988

Casting flash and other "positives" (unintended extra metal on the castings) generally do not have any effect on strength. Sharp INSIDE corners, nicks, cold shuts, gas pockets, and the like are a lot more troubling.
Before you do much, remember that grinding and polishing can induce stresses themselves. Unless you are doing it to remove a clear stress riser, I'd leave the flash alone.

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"When you find a big kettle of crazy, it's best not to stir it." - Pointy-haired Boss

1964 Valiant V200, 225/Pushbutton 904
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