The piston looked like this close up, not a particularly pretty sight.

At this stage we had a slight diversion. A new cylinder head gasket was purchased but this was a handmade copy of the original which was not too accurately produced. Gaskets like these are produced from a template and any inaccuracy in the template is reflected in the gasket.

It was therefore decided to produce an accurate template CNC machined from aluminium plate which could then be handed over tto the gasket maker. Just producing the drawing took considerable time even though we could guess that all dimensions would be fractional inches perhaps with a placement resolution of 1/32".

Here is the template machined from 6mm aluminium plate.

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