2005 Volvo Penta 4.3gl Overhaul with pitted cylinders (Can it be done?)

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This video is about a 2005 Glastron 4.3 GL Volvo Penta. The background on this boat...one of my customer's got this in a trade and had another mechanic look at it. The mechanic started on it and saw water coming out of the side of the block. At this point the mechanic said, the block was cracked. It sat for 6 months in the elements with the intake manifold off, water still in the block. THIS BOAT MOTOR was DOOMED BY A BAD DIAGNOSIS. \
We take on the project and take a closer look to find that 2 freeze plugs had popped out. Likely the boat wasn't winterized properly when it was running. The expansion plugs saved it but the original diagnosis ended up making things worse. As we started the teardown things were looking pretty good. Once the pistons were out, we noticed some pretty hefty pitting in the cylinders. After the glaze break, the pitting reared its ugly little dimples. Haha
IMPORTANT INFORMATION: The customer knows about the pitting and has a reman block that is 3 months out to replace this motor with. He really wanted to try and see if this boat motor was salvageable. Knowing what he spent on the reman and that pitted cylinders are not the best thing to an overhaul, there were certain decisions that had to be made.
-Do we throw a lot of money at this block? NO.
-Do we see where we can save as much money as possible for the customer? YES
-Did we want to remove all the pitting? Absolutely.
-Were we able to in the time frame we were given? NO. We would have had to send the block off have it machine honed and that would have been another 3 weeks added. All shops are backed up. To remove all the pitting would mean, potential new pistons, rings and that was extra money the customer wasn't interested in spending.
-WHAT DID WE DO? We reused every component we could. This block had 250 hours on it and still had original crosshatching in the cylinders. We used a flex hone to minimize the pitting as much as possible without changing the current clearances to keep the same pistons and rings.
OVERALL we inspected and cleaned all parts that were reusable. We changed all the gaskets and rebuilt the heads. We also changed the impeller. Oil filter/Fuel Filter... Everything else is original to the block.
Moral of the story: Sometimes customers want to do things we don't recommend doing. We tell them what the best options are in the situation and they either take the advice or they don't. This customer is currently 40 percent of our business so we will work with him in anyway we can even if we don't agree.
LAKE TEST: Went well. We chose Lake Alvarado which is primarily known to be a fishing lake. It was small enough so that we wouldn't have to paddle that far if need be lol. We also went on a day where there wasn't a lot of traffic for the respect of the fishermen out there. All in all it was a great run. Had to tighten up some pulleys. The trouble alarm went off on us but it was corroded wiring. The customer is happy and can call us anytime should issues arise.
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