after I looked over the block for gennaro, It was pretty obvious the primer didn't adhere to the aluminum. I think the mismatch in products may have caused that, or the fact that there was a 2-week wait between primer and paint.....even with a re-scuff it's just spraypaint, and I bet the silver re-wet the primer and caused it to lose adhesion. that coupled with temperatures too cold for proper cure....and bam, flaking paint. After he soda-blasted it all back down to metal, he brought it to my shop where I wire-wheeled the whole thing, scotch-brighted it, and sprayed it down with degreaser and acetone. Then finally a few light and even coats of paint and it looks great....so long as it doesn't get any chemicals on it, it should be fine.
We also took a few extra precautions in re-assembly. I had noticed two or three small nics in the gasket surface for the head and I wet-sanded them back flat with a block and 320 grit paper. We also sprayed both sides of the base and head gaskets with copper spray. All in all, the assembly ended up going fairly smoothly aside from figuring out the rear tensioner is best put in place before the jugs are all the way flush with the cases. With all the oil leaks Gennaro experienced on his last two 550's, he isn't taking any chances lol. I assume I'll be back over his shop when he wants to install the motor, last thing he needs is a scratch or gouge in all that fresh paint and powdercoat.
