I just recently saw the sonic test results on a late racing block still in Ford cosmolene and Ford Parts crate. None of the thicknesses were less then .280" and they were all uniform.
Considering that the D2AE-CA blocks are no thicker then .180" new, how much off does the casting need to be to be rejected?
I was surprised to see that the test results were attached to the block. If your process description is accurate (and why wouldn't it be?), the sonic testing must have been done here before machining but I'm thinking, why wouldn't that all have been done in Australia and the failed blocks, salvaged by using them in production vehicles and just replaced with more castings for racing?
With casting thicknesses like the racing block has, it's got to be overkill to begin with. The bulkheads are huge and there is more metal added everywhere with things like solid oil pan rails.
It was impressive to look at but the guy wanted $3,500 firm. What's the point of that with the new aftermarket blocks available now?