Dressing out damage to port. Intermediate iron.
 

Just want to gather some opinion on how good an idea reusing this iron would be.
As you can see from the photo it's taken some damage around the port, would I be safe to carefully dress it out using a curved Dremel grinding stone? I'm thinking just enough to smooth it out and take any rough edges off it.

It seems a shame to waste the whole iron over a tiny nick, what's everyone's thoughts?

http://i.cubeupload.com/dens5Z.jpg

Iron is garbage unfortunately. That is right in the oil control ring path and any imperfections there will cause oil consumption and smoking.

Not what I wanted to hear, but thanks anyway. Guess I need to start looking out for another iron.

considering the effort and cost involved in pulling the engine and rebuilding it a second time, i recommended the same as IRP, if your time is valuable at all then spending a little on another iron for peace of mind should help comfort you with the additional cost.

You're correct and I'm on the lookout. They're pretty rare over here. I can get an FC3S ones and FD ones, but so far no S4 NA ones.
I do have a spare from one of the engines, but that's got some pitting from being sat with coolant in the cylinder for 15 years.

Luckily I'm a way off the rebuild so hopefully something will turn up.

FC3S and s4 N/A technically are the same car

his appears to be an S5 due to the lacking EGR port(that or the eurospec didn't have EGR), but an S4 center iron will also work with a block off plate and removing the studs that hold the EGR and using low profile mount screws. even turbo FC irons are virtually identical as well for another option.

so technically any 1986-1991 iron will interchange with a little bit of work.

Its an S4. Correct, no EGR on UK models.

All I can get is FC3S intermediates. All UK FC3S are the S5 type to my knowledge, the S4 was not offered in a turbo form.

Is the port opening different on the turbo models? And will the fact its an iron from a 4 port cause any problems?

it doesn't look to me like it's definitely in the oil ring track, the only way to be sure would be to coat that area with a dye (felt pens work great for this) and assemble a mock up engine with just the oil rings/spings installed on the rotors.

It's in the hardened area where the oil rings run but there's a tiny bit of leeway available.