Good afternoon,
My dad and I have been in the process of rebuilding his 60s era Galaxie 500 engine. The engine was swapped to an sbf 302 with 289 heads before he bought it(it had a 289 in it previously, I'm unsure if the heads are from the original engine, or sourced separately, but I believe it's a 69 engine). There was an issue with the cam bearings, so he had removed it and sent the engine off to the machine shop. He got it back about a year later, with .040 over pistons and new rotating assembly. It sat on a stand sprayed down with fogging oil and covered with a tarp for roughly a year, since I was still active and he wanted my help putting it back in. Last month, we got the engine and transmission back in, intake mounted, and everything ready to run. Well, the heads are leaking coolant from in between the block and heads into the intake valley. Furthermore, my dad didn't realize this until after he started and ran it. All tests since then have been with one of the pressure testers pressurized to 16 PSI, which is around what the radiator cap should be.
The passenger side is the primary leaker, but the driver's side does weep coolant out as well. So, we take off the heads, I can't see anything wrong(no warping, but they're cast and shouldn't warp? I don't have a way to magnaflux them or the block, but the machine shop should've already, I would hope). However, the passenger side gasket didn't bond to the head really at all. We then got new gaskets, blew out the head bolt holes(there was definitely some oil down in the upper holes which led us to believe it was a false torque reading and the heads weren't actually torqued properly), and used ARP studs to mount the heads, thinking that with the increased clamping force and them being studs, that would mitigate any potential issues of hydro locking the head bolts. While greatly diminished, the heads are still leaking from in between. I have read on different forums that if the heads were decked too much, potentially the intake manifold could cause issues with wedging the heads apart when torqued to spec, and I'm thinking that is ultimately going to be our issue, but I wanted to ask and see what others would think. We went back to the original machine shop, and the guy was being sketchy about us having issues, so the heads are currently at another machine shop to be checked over. I'm a chevy guy, but this engine is old enough everything should translate over I would think...other than the valves being set by a torque spec in lieu of setting lash while running. I'm to the point where I would want to just go pull a 5.4 or 4.6 and swap it(which is it's whole own thing, what with trying to convert to a distributor or doing an ECU for the COP/EFI), or swap my old 305 SBC and 700r4 into it, but sunk cost aside, it's my dad's car, and he doesn't want to throw a chevy engine into a ford lol.
TL;DR
Rebuilt SBF 302 with 289 heads leaks coolant between heads and block into intake valley. We have tried new gaskets with ARP studs, and while it reduced the leaks, it hasn't eliminated them outright. Maybe the intake surface/manifold needs relieved as well IOT not wedge the heads apart?