I temporarly lost the valve seals so didn't go any farther assembling the head, but there's not much left - just install the valves, springs, seals, retainers, keepers and lifters. Sounds like a lot, but goes quick. Fortunately, I found the valve seals, but not until later so I will have to put it together next weekend.
On to the bottom end assembly...Rods and pistons assemble together easily - just lube the wristpin and slide it in the piston and rod. Install the circlip and you're done. Sorry, no pictures of this process.
Once everything is thoroughly cleaned, and then cleaned again, you can begin assembly. I used ATF as an assembly lubricant - it has very good detergent qualities. Due to oily hands, I didn't take any pictures of the piston/rod assembly either, but more on that later.
I decided not to purchase new oil squirters as recommended by someone very early in this thread. Insted I decided to tweek the ALH ones to work. Below is a picture of the mis-match between the ALH oil squirter and the PD150 ARL piston oil gallery
A little adjustment with another very specialized tool...
Here it is aligned - it's a little difficult to see, but the squirter should be moved mostly to the side and just a little toward the center of the bore. You want it to hit the hole when the piston is at the top of the stroke as well as the bottom. Stroke the piston all the way to the top of the bore and eye it to see if you're still on target.
Be careful - they bend easy
I found a good use for the ARP Cosworth Head Studs
I spoke to my friend who took the block and head to get surfaced. He took his camera and took a couple pictures (of which I only have one right now). The block was fixtured up and a pass was made that just touched the top of the block on the edges and high spots on both ends of the block. A second pass was taken ~0.0035" deep and this was the result...
Notice the rings remaining between cylinder 1 and 2 and the depression all the way around cylinder 1? This was not present on any of the other cylinders. It's like the deck by this cylinder was depressed. First thought was that the block was not fixtured level, but the deck cleaned up beyond this part on both the very first and this pass.
A 3rd pass of ~0.0020" cleaned everything up for a total removal of 0.005"-0.006"
[EDIT] Piston Protrusion measurements are inaccurate/not repeatable - see post 243 - however these measurements support what was found in post 243[/EDIT]
The resultant piston protrusion is shown below - measured more/less where the number is written with a depth micrometer "vertically" as shown in the picture on the left and right sides.