Engine builders - a little advice please

[tubman]

Many of you have seen my thread about the '51 Mercury engine I've had for 20 years. I put it on my test stand and it had excellent compression (95 to 110 lbs, this after sitting 20 years and at 900 ft elevation, no less). I was real happy until I turned it over with no plugs, and couldn't even get the oil pressure gauge to even wiggle. Over the last couple of days, I transferred the engine from the test stand to a regular engine stand, removed the pan, flipped it upside down and removed the #1 rod cap. What I found was a good looking journal, and a bearing shell with some embedded material. I used to "Plasti-Gage" to check the clearance, and got .0025, but the "Plasti-Gage" was irregular. (I did not take any pictures of this; sorry)

I was lucky enough to find a set of standard bearings at a killer price about 2 years ago, which I bought. I got one of the new inserts and used used the "Plasti-Gage" to check it out. This time I got .002, and the "Plasti-Gage" was nice and uniform, Here are some pictures of the second check; for some reason, the journals look a lot better in person than in the pictures.

At this time my plan is to replace all 8 rod bearings with new ones (assuming they are all in the same shape as #1). I will then remove and check the oil pump. At this time, I believe I have a stuck relief valve.

My questions are : If the rest of the rod journals and bearings look like #1, can I just replace them, or should I "Plasti-Gage" each one. I ask this because it seems to me that I should try to minimize the times the caps come on and off and the price of "Plast-Gage" these days. Also, given the condition of the rod bearings, should I pull off main caps and check them, or just leave them alone? Again, I hate to disturb anything that's been together this long.

There are a couple of other things to consider. Earlier today, I got a call from the machine shop saying the block and crank I am going to use for my 258" Hot Rod engine are good, and they are going to commence building it. Trying to build one flathead on a fixed income is tough enough, let alone going all out on two. Thus, I'd like to minimize the cost of this one. Also, I am 73 years old, and doubt I'll put even 10,000 miles on it before I go. This engine is slated to go into my '51 club coupe, which is usually used in a leisurely manner. However, I don't want to do anything to jeopardize a "std.-std." Merc crankshaft.

This is them first flathead I've done in about 50 years. Back then I didn't have any problems with them, but maybe I was just lucky. Since I can't take a couple of hours off and get another engine at the junkyard for $35 any more, I'm trying to be real careful with this one. Any advice, criticism, or comments will be appreciated.