Engine build

[907DAVE]

Its has began, got the girdle in tonight........





http://i619.photobucket.com/albums/tt274/907dave9/IMG_4416.jpg





And got some filler in one bank..........






http://i619.photobucket.com/albums/tt274/907dave9/IMG_4418.jpg





After the other bank if filled its off to the machine shop.:woot:

[88Racing]

Subscribed.

[cleatus12r]

Dang Dave, I thought you had some actual "build" pictures going on but the first picture kind of threw me for a loop....


My first thought was, "Hey, he forgot to put the crankshaft in it......"

[907DAVE]

:rofl::rofl:

Yeahh...it was weird torquing a head on that didn't have any valves in it.

I guess its not an actual build.......yet.:D

[907DAVE]

And the other bank is filled.......




http://i619.photobucket.com/albums/tt274/907dave9/IMG_4419.jpg






Sorry or the boring pic's, it will get better.........I promise. :rock-band:



lol... I have wanted to use that one for a while now.

[907DAVE]

Came home today and there were some goodies waiting for me........




http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4434.jpg






http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4432.jpg







http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4433.jpg

[907DAVE]

These are just damn sexy................





http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4436.jpg








http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4437.jpg










http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4430.jpg









And is off to the machine shop for awhile.:woot:

[88Racing]

Getting closer!

[cleatus12r]

I hate you Dave.

Is there an envy or jealous smilie?

[907DAVE]

Nothin to be jealous of here.........the old lady wanted the house to get finished this summer, looks like it aint gonna happen.:D


I will pay the price until then.:sigh:

[Driximus]

Pure envy from over here.

[88Racing]

Are you done yet?
J/K!
How's the machining coming along?

[907DAVE]

Well it has been at the machine shop for about a week now, and it sounded like they were going to try and squeeze it through for me. I will call them tomorrow and see if there has been any progress, but truth be told the anticipation has been killin me. I HATE not having my truck, but this is not something that should not be rushed, so its a good lesson in patience.:D

[epowers777]

very nice!! Were did you het your spare engine to rebuild?

[907DAVE]

FREEBEE

Funny because I had been planning on my motor breaking for a while now. As soon as I started modding my original, I got this one "just in case".
I did some diagnostic work for a guy and he offered this engine up to my service writer, for the work I did, so needless to say I ended up with the motor after offering up some free labor to my service writer.:doh:

[cleatus12r]

Ah yes, the all-dreaded "freebie".

We as technicians never do any of those, do we?
:rolleyes:

[907DAVE]

LOL......turns out the "free labor" was for me to help him R+R a 6.5 in a 98'.:cursin: He is not very mechanically inclined, or motivated either.

I think I got the short end of the stick, since then I have told myself that I would never do that again.

[epowers777]

I could us a free engine LOL if you know any toss it my way!!!

[Longshot270]

Nothin to be jealous of here.........the old lady wanted the house to get finished this summer, looks like it aint gonna happen.:D


I will pay the price until then.:sigh:

Technically the engine is part of your property. And if the laws say that she owns half then you can tell her you are doing her a favor by building her half. :hehe:
*I will not be held responsible for any damage you receive as a result of that statement. :smiley_roll1:

[907DAVE]

:rofl: Too funny.....I will have to remember that one.

Well we are not married.........yet......... but I think the common law stuff says half my stuff is her's anyways.........:censored1:

[Power Hungry]

Dave,

What're you using for filler? Also, whose girdle is that?

[907DAVE]

Block filler is the Moroso brand, and the girdle is a WOP duplicate.;)

[907DAVE]

Got a call from the machine shop.......they said my stuff will be ready for pickup tomorrow!:woot:

[Buddy Starr]

Looking forward to more pics....:drool2:

[907DAVE]

Well looks like there has been a minor setback with my motor, but it should be in my hands by the weekend.

But here are a few pic's of some parts I sprayed to day to hold you guys over for a while. Sorry picture quality sucks, had to take them on the celly.




http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/Multimediamessage-1.jpg




http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/Multimediamessage2.jpg





http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/Multimediamessage3.jpg





A little light sanding, and some buffing and they will be ready to go.

[Buddy Starr]

I'm a little curious... studs, rods, girdle, 300/200 injectors. What are your power goals? I'm guessing 5 something maybe 6 plus? Or does my math suck?:hmmm: What turbo or turbo's are you running? Very interesting. Man I need more money to burn on my truck!!!

[907DAVE]

No HP goals in mind, I am just planning for the worst.:D

If I had to guess it should be low to mid 600 range on fuel.

For turbos I am using a 88mm over a 66mm, both are Turbonetics T-Series.

Here is another pic...........


http://forum.gopowerhungry.com/members/907dave-albums-truck-pic-s-picture461-twin-whistlers.jpg

[Buddy Starr]

SWEET! You are my new hero! Are you doing anything different this go around? Also was curious are you doing a fire ring kit?

[907DAVE]

Just bigger injectors and stronger parts.

No fire rings, there isn't anyone around here with alot of experience with the machine work involved and I cannot afford the freight to have them sent out. I will be using Cometic head gaskets, I am not very concerned with popping one since before I was running stockers with studs with ZERO issues. The Cometic's were more appealing to me anyways because their ability to "reseal" if they were to ever start to leak and get me home.

[Buddy Starr]

Very cool. Looking forward to seeing your progress. Thanks for sharing the build and the information. This gives us rookies an education. Best of luck!!!

[88Racing]

Done yet?
J/K!!!!!!!
:)

[907DAVE]

Very cool. Looking forward to seeing your progress. Thanks for sharing the build and the information. This gives us rookies an education. Best of luck!!!

Ha.. If you learn anything from this its that these engines are one of the most expensive to build, and get the least amount of power.

Still cheaper than a new one though.:)

[907DAVE]

Don't take that the wrong way, no trying to discourage anyone. When it comes don't the the "bang for the buck" factor, it is not as good as other platforms. I still wouldn't trade my ole 7.3 for anything else, because when it comes down to reliability, simplicity, and durability (within reason:D) no other can even compare IMOH.

[wriott]

your doing dang near the same build im doing, except for injectors and turbos.... but everything else is dang near the same. i dont remember reading it but did you have the bottom end balanced??? if so to what RPM??? what damper you using???

[907DAVE]

They don't balance to "RPM", but they are balancing it to +- 1 gram.

The motor will be getting the Fluidampr Balancer. IMHO the Fluidampr is a superior design, a little heavy but no rubber to wear out compared to the ATI.

[907DAVE]

G-DAMN MACHINE SHOP................heads are gonna roll come Monday.:censored1:

[cleatus12r]

This is true of ANY service no matter how good or bad the people are. Any time you have to rely on someone else to get anything done, you're going to be disappointed.

Unfortunately, there are things that not everyone is capable of doing themselves so the problem is experienced by everyone at some point or another.

[907DAVE]

Very well put...

[907DAVE]

Got the call today from the machine shop.:woot:

Everything is done and ready to go, but when I go to pick it up the block had not been decked and the heads were not finished yet.............:sigh:


I think you guys need to change my screen name to SOLdave........grrr.

[88Racing]

I've been down that road many times myself with engine/machine shops.
So I know what you're going through!
At least they aren't swapping parts on you like they used to try and do when I'd rebuild a cheby motor! :)
That one shop use to try and swap my 4 bolt main blocks for 2 bolt ones.
Oh no you don't! I said.
I told them everything is stamped to match and if I didn't get the right parts I was going to bill'm for a HO crate motor.
I built A LOT of 383 strokers for kids back then.
That allowed me the extra cash to play with my Dodge blocks. Dang those 340's were expensive to work on and beef up.
Ok enough of my engine/machine shop experiences and back to Dave's fabulous build!
:2thumbs:

[907DAVE]

I keep saying to myself patience, patience, patience, patience, patience.
I just hate when things are out of my control and I have to rely on others, especially when they dont stick to their word.

On the upside I came home today and found a little white box in my mailbox, from a perfect stranger who when out his way to help me out. Thanks again Cody!

[907DAVE]

Ok, back on topic.:D

Got the block back today and got some paint sprayed tonight. It will be a short block tomorrow, and hopefully my heads should be finished up.


http://i619.photobucket.com/albums/tt274/907dave9/IMG_4445.jpg

[F-127]

On the upside I came home today and found a little white box in my mailbox, from a perfect stranger who when out his way to help me out. Thanks again Cody!


Glad to hear you will have some form of programming taken care of. Looking forward to seeing it completed. Looks sa-weeet! :drool2:

[907DAVE]

Finally, some actual build pic's.


http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4448.jpg




http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4451.jpg



http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4453.jpg



http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4460.jpg



http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4459.jpg

[907DAVE]

Just waiting for the paint to dry on the heads and I will have her all buttoned up.

[907DAVE]

http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4461.jpg

[ticopowell]

Wow! that's BEAUTIFUL!

[Power Hungry]

Gosh, that is sexy! :2thumbs: :woohoo:

[907DAVE]

A-_OqUmvyvI













Nuff said!

[choupique108]

Man you didnt mess around:evillol:

It looks dead sexy. Ive been trying to get me a list of parts together to do a build this summer.:cheesy smile:

[907DAVE]

Thanks everyone!

I figured since I am spending sooo much money on this thing it might as well look nice.

Well just got back from a test drive and this truck has NEVER ran so smooth. Even when it was bone stock it was nowhere near how it is now. Tuning seems ok, I have a slightly rolling idle so that would be first on my "to do" list.

The injectors are riiiiidicules, the daily program pulls like hell! Not sure how egt's are yet because my Autometer:censored1: gauge finally quit working.

Here is another video...........more to come.:D



OL93OrDay5s

[cleatus12r]

Well Dave, that was fast. I guess you weren't foolin' around when you said you wanted to drive it again.

Looks good, man.

[Longshot270]

Thats pretty cool watching that engine come together. Good job! :thumbs up yellow:

[907DAVE]

Thanks guys!:thumbs up yellow:

[fifity]

seeeeeick

[88Racing]

Looks good Dave!:2thumbs:
:gone-to-his-head:

[907DAVE]

Well I have over 300 miles on the new engine and after working out a few bugs all is well. I was concerned that oil and coolant temps would be high because of the block filler, but everything is VERY normal. I got the EGT gauge working again and cruising temps are where they were before the build, but when I hammer down it gets HOT.......quick. Going to have to get my water injection setup finished and hooked up before I run any race programs. The power is amazing, very, very smooth and strong as hell. And finally mileage seems comparable to what it was with the 238's in there, but have yet to hit the open road and get any highway mpg's.

All in all I am very satisfied with the results.:D

[hayjayhorses]

were did you get that turbo inlet pipe set up from? I like it.

[907DAVE]

It was custom built.:D

[88Racing]

Dave.
I took and copied YOUR posts of the build and started another thread.
Its consists of your posts only with no other members posts.
Hope you liked it.
If you don't I'll delete it.
With your permission could the new thread be added to the resource library?
Thanks

[907DAVE]

Errr........umm.............ok.:thumbs up yellow:

But could you remove all of my whiny complaining posts first?:D

[Driximus]

Very nice im Jealous!!!

[907DAVE]

Well 650 miles later, I blew a head gasket last night..............SOL

[cleatus12r]

I tell you what. You can ship the engine and all of the ancilliary stuff to me and I'll trade you for a stock PMR engine. I'll deal with your headaches.....

[907DAVE]

Should have kept my word when I first got the truck and.....................




















left it stock!

[hayjayhorses]

that blows

what kind of driving were you doing when the head gasket let go? were ya beating on it or pulling a load?

[907DAVE]

I did TWO runs at 60+ psi. Parked it, and on the drive to work the next morning it puked all the coolant out.:thumbsdwn:

[907DAVE]

Tonight's progress..........


http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4466.jpg



http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4467.jpg



http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4468.jpg

[907DAVE]

Heads should be off in the AM........

[fifity]

Damn....Nice lift..is that in your garage?
I'd love to be able to rip the cab off...Heck I'd love to have any type of lift...or a garage that my truck fit into... Bad ***!

[907DAVE]

Nahh..... I dont even have a garage.

My boss is cool with me living in the shop, I mean staying after hours to work on my stuff.

[fifity]

Hit the game/chat room real quick...

[epowers777]

Dont give up I am sure I have a solution for you blowing your head. I am a big mercedes diesel fan and have followed this guy who is putting out alot of ponies from a 5 banger.
Here is the link.
Mb 2.5d 20v superturbo projekt - Page 2 - MBWorld.org Forums (http://www.mbworld.org/forums/e-class-w124/270817-mb-2-5d-20v-superturbo-projekt-2.html)

I sure since he used this he has not blown a head gasket. Here is a picture of the bottle.
before he used the spray he went threw MANY head gaskets

[907DAVE]

Thanks for the advise!

In this case I don't think that would have helped much...............




http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4472.jpg




http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4470.jpg

[907DAVE]

Just for giggles I checked to see if any of the head bolts lost some torque, but they were all tight.

[cleatus12r]

Dag nabbit!

Well, knowing you (speedy), you'll have the thing back together yesterday.

[907DAVE]

LOL

Well time is running out, I need this damn thing working for the summer months, I gotta trailer to haul!

Actually what I really need is a spare truck so I can just switch em out when they break.:smiley_roll1:

[907DAVE]

So something has been bugging me...........why cylinder #1?

Rod popped out of #1 in my old engine, and blew a gasket on #1 on the new engine.

This is a completely different engine, crank, cam, block, heads, injectors, so what is the culprit?

Just a coincidence, tuning related, or engine design?


:hmmm:

[cleatus12r]

I'm hoping it's just a coincidence for you. I can't see any common denominators at this time.....like you said....everything's different.

We can always blame the CMP sensor. :sigh:

[epowers777]

I was reading about fuel bowl deletion. They stated that one of the cylinders gets starved of fuel with the fuel bowl. Also do you have a blow off valve?

[hayjayhorses]

I see one common denomonater....
















... the loose nut behind the wheel:hehe:

[907DAVE]

I do have a regulated return setup, along with a fuel bowl delete.
No, I do not have a blow off valve.


The only thing I can think of is crank flex. Not sure how much these crank's twist, but if there was any, #1 cylinder would have the most advanced timing. :shrug:

[907DAVE]

Look what showed up today.............



http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/0_1-1.jpg

[907DAVE]

If all goes as planned it should be back on the road by next weekend.:rolleyes:

[hayjayhorses]

sweet :thumbs up yellow:

do you need to fire ring the heads?

[907DAVE]

That is the plan!

[907DAVE]

Grooves are cut, now they are in for a final rinse and assembly.


http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/0_12.jpg

[907DAVE]

:censored1: :censored1: :censored1: :censored1: :censored1: :censored1:




I am so pissed off right now.......machine shop is killing me.




Might be back together in another 2 weeks.

[cleatus12r]

:sigh:

Man that sucks.

I don't know what to say except that you have my condolences.

What are they givin' ya the run-around on now?

[Power Hungry]

Why two weeks? What's the holdup?

[907DAVE]

Yes and no.

When the gasket popped 2 weeks ago I noticed that I floated exhaust valves enough to contact the piston. Well first thing I did was check installed spring height, which I should have done the first time. With the height they installed them at I only had 80 psi seat pressure:doh:. Sad because I brought them a baggie with tons of shims that I have collected over the years to use on my heads.

When I took the heads in I told them the situation and left feeling assured that they would be shimmed to proper height. I was told earlier this week that heads would be ready to pickup on Friday......great! I call them up in the afternoon to see I they were ready to go and they said .......no:cursin:.

Fine, I will just assemble the heads myself, no big deal really. I tell them I am on my way to pick them up and they said OK.

When I show up I asked......Where are the shims?

Them: Uhhhh, er, uhhhh what shims?

Me: WTF do you mean, what shims?

Them: I dont know what happened, but we don't have any.

Me: None!

Them: Nope

So I left.

I will be heading in Monday to retrieve all my parts, so I can finish the job.

On a positive note I found a supplier for the shims and they should be here Tuesday. So maybe it will only be another week.:)

[907DAVE]

Why two weeks?

That is what they said it would be.

[907DAVE]

Funny thing is I actually feel much better now.......usually calm and cool, but that hit me hard.

[Power Hungry]

By the way, don't you live in BFA, not BFE?

[907DAVE]

Good point.:)

[Power Hungry]

BFA = Brrrrr... Freezing Alaska!

[907DAVE]

BFA = Brrrrr... Freezing Alaska!

I guess it could mean that too.:rofl:

[907DAVE]

Alright, I got some new shims in yesterday and got the heads assembled.

Today I was able to put the heads on and toque them down, and if I get permission tomorrow I will do the the hot re-torque.


http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/0_1.jpg

[Power Hungry]

That's the sexiest thing I've seen all morning. (Of course, Corey is asleep ;))

Can't wait to see her breathing life again. :2thumbs:

[907DAVE]

Hot re-torque done, hoping to drive it home tonight.:D


http://i619.photobucket.com/albums/tt274/907dave9/NEW%20MOTOR/IMG_4474.jpg

[fifity]

Its hard for me to imagine, going from that state to driving in the same day...I work so sloooowww..

Can't wait to see it up and running!

[907DAVE]

Well got it all put back together and got about 20 miles on it. I got a lot of work to do with it, but after that's all done I will go out and do some testing.

Here is a quick video of a 1/2 throttle roll on in my Daily program, as you can see boost is backed down to 50 psi until I can get some testing stuff on it.:D


Q06ZH5oFXYE

[cleatus12r]

I have NEVER seen a pyrometer move that fast. PHEW. Looks like a boost gauge.

[907DAVE]

You should see it in a race program, it pegs almost instantly..........:rofl:

[F-127]

That video is NASTY! :thumbs up yellow:

[907DAVE]

Well truck died tonight.







Interesting find though...................a open in the IPR harness, with dual IPR's is enough to keep the HPO reservoir from building enough pressure to trip the oil pressure indicator. And with both IPR's wide open it will still build around 300 psi.:hmmm:

Gonna catch a ride home to pick up some new connectors and get it going tonight.........hopefully.

[cleatus12r]

Hope for the best. Good luck.

[907DAVE]

Success!:happy-dancing:


Two new IPR connectors and all is well again.

Guess they were starting to loose a little tension from being taken apart about a thousand times.

[907DAVE]

I took the truck for it's first voyage out of town today. The trip totaled around 140 miles with 100 of it being in the mountains. I was able to top off the tank right before we got into the mountains and again on the way back. I averaged 18.2 mpg in the hills, and keep in mind this was either climbing a hill or going down one. There was NO flat land at all for this part of the trip, and these are not your average hills. Truck preformed well, there is still more fuel that needs to pulled out and a few shifting adjustments that need to be made but all and all I was happy. I was concerned that the fuel mileage was going to suffer with such large nozzles, but turns out they get similar mileage as the stockers. I cant wait to get this thing out on the open road and see what kind of MPG's it can do. :D

[muns53]

That beast sounds SO sweet in the video. I was trying to figure out which guage was the boost guage - those are some nasty EGTs!! It's been fun following this thread and your mods - congrats on dialing it in!!

[907DAVE]

LOL

I am having a hard time remembering which gauge is for what now..............



http://i619.photobucket.com/albums/tt274/907dave9/IMG_4481.jpg

[F-127]

AH, what I would do to be sitting in that seat.:cheesy smile: