HI PSI

I think, that it is best that I stand aside here, as Daryn is best qualified to answer these questions. I believe that his reply will be some time this afternoon.

Yes, it exhibits the same symptoms when under load.

It has factory engine mounts.

I think that my inbox was full. I have now made room. :D

Sorry, I missed your post. Great input!! Thanks....

Great lateral thinking.... Just what we need.

I don't know which mounts he is using, I will enquire tomorrow and post the results. It's dry sumped. from memory it is a Peterson.

I will pass this on. Believe me when I say that he will try almost anything....... He indicated that it seems to be coming from around the front of the rocker cover.... It is strange that it moves up the rev range when extra tension is placed on the timing chain though....

Yes it is.

No problem. Nice to know about the Nason chains though.... I'm sure that others will now be wary also

New chain, guides, tensioner and lash absorber have been replaced since... Only quality units have been used.

I'm not certain. However, I think that this is the case. I will ask him tomorrow. :D

Manual.

At this point in time, the owner will not disclose any information regarding the shop involved.

Only happens over a 300-400 rpm range, starting at 3,000rpm, then disappears. If he places extra tension on the chain, it moves further up the rev range.

Forgot to mention, that they have also removed the gates belt, to ensure that it was not an ancillary making the noise.

Hi all, a good friend has a rather peculiar sound coming form his freshly built engine. The sounds seems to occur at around 3,000 to 3,300 rpm. He is at his wits end with trying to diagnose and fix the noise. Given this, the owner has gone to extraordinary measures to try and identify the issue, all with no avail. As he has exhausted every idea possible, he requested that I create this thread in the hope that other may assist in its identification and rectification. History: The car has been built with quality components, with no expense has been spared. The engine was rebuilt (at great cost) around 7 months ago by a reputable engine builder who is based in South East Queensland. The engine ran for three days, before the intake valves smashed into the pistons and cracked the head casting. A new cylinder head was built (By the same Engine builder) and has just been fitted to the bottom end. Ever since the car has been making this "Rattling sound". The said engine builder was consulted and his advice constituted of: "It's fine, just run it. But, there is no warranty if it "blows up". As you could well understand (And you will after you view the video posted below), and given the time and money taken to complete the build, the owner is not happy with this advice and lack of support. He has now taken matters into his own hands and has surrounded himself with very experienced and knowledgeable people. That given, the source has not yet been found. He described it as being related to, or affecting the timing chain, as if extra tension os placed on the chain, the sound commences at a higher rev range. To date, they have: Replaced timing chain, guides, tensioner Replaced cams, vernier gearsRemoved Jesel rockers and replaced with factory unitsRemoved solid lifters and replaced with hydraulic lifters.Removed cams and checked for straightness and tolerances. timing chainRemoved VCT actuators and fabricated a billet relpacements which fed additional oil onto the timing chain. etcThere are no evidence or telltale markings of any kind to suggest rubbing or anything untoward. Any advice or assistance would be greatly appreciated. The owner would greatly appreciate it, if the thread could maintain focus on the problem. At this point in time, he would like to keep all emotion out of it, as he just wants to find and fix the issue. https://youtu.be/kYpgbLsMIQU MOV_4338_1.mpg

Final install of the intake today. I rerouted a few hoses and installed the new main hose for the header tank. The catch can has also been connected to the intake. It looks a lot neater now. I need to source a few hose separators and a clamp cover for the header hose. Besides that, it's all good. As promised, here is a pic of the intake and shield in place. Unfortunately, I didn't have a clean soft cloth the clean all of the hand mark off the intake pipe, so be gentle.

Thank you for your kind words JVK. Unfortunately, I am not a rich man, but, I'm trying the best that I can, to ensure a quality finish throughout the project. Got a call today and the rocker cover chroming will be completed this week. :D So, not long now.

Haven't updated in some time, as I lost interest in posting. I mostly have the build completed and have been held up with the chroming of the rocker cover. Apparently it will be completed and shipped tomorrow. I've heard that before, so fingers crossed that it's true. Once it get's back, the hosing for the catch can will be completed and hopefully, first start up. In the meantime, I have been chipping away at the some of the cosmetic items. I had made a new air box for the car and started shaping the side wall to fit around the piping. I quickly realised that there wouldn't be much left and it quickly turned into two separate pieces. The chassis rail was drilled end riv-nuts installed. I the went to fit the lid and quickly realised that it wouldn't sit flush, as the filter sat too high. Not happy!!! I spent hours trying to find a work around. I looked at slotting and cutting around the filter,but they all looked like poo... So I came up with this.. Still in the prep stage of polishing...... As previously mentioned, we changed where the location rocker cover breathers. The standard locations have been blocked off. Due to this we have also modified the Nizpro garnish. Given the new location of the dump pipe, heat damage to hosing, and lines are a major concern. To address this, I have made a heat shield to cover the dump and fitted it up today. Please note that this is still in a raw finish and it will be cleaned , and new, nicer fasteners sought.

I spoke to Darryn a few weeks ago. A new head has been built and the engine was back together. I'll call him tomorrow to see how it's progressing.

I too, have obtained quotes from Ford for a replacement leather with suede trim and I was as shocked as you were with the quote. Even my local Fords parts man cannot understand how they can justify the pricing on a lot of the parts. There were few new (In box) sets of genuine 50th anniversary leather covers on Ebay about 8 months ago and I managed to purchase a set. Apparently, Ford sold 10 sets of these as the parts were no longer required do the line becoming obsolete. Similarly, I have purchased a few sets of N.O.S BF GT bezels and bumper inserts from a guy who purchased (Was offered to him) the remaining parts from FPV. I wish that I was lucky enough to know the right people, to get these types of deals.....

I know a bloke up here who has had a similar problem with a BF turbo ute. He replaced pretty much everything but the rear wiring harness for the tail lights, and still had the problem.......Even after an engine change the cylinder drop persisted. To cut a long story short, the cylinder drop was a result.of faulty software. Even when changing the ECU, the Ford flash that was reinstalled (By Ford) still contained the fault. Therefore the problem persisted. They eventually overcame the problem by flashng the ECU using a different VIN (Therefore a different file) and it has been running fine ever since...... This may or may not be the case with your vehicle, but strange things do happy. I cannot and do not understand how this happened to his BF ute, but it is something to keep in mind... Be aware that if you do go down this road, to set your Xcal back to standard, before changing the VIN. old mate has a nice Xcal 3 as a paper weight..... Good luck with finding your fault....

Pic of fittings on the rocker cover.

I had previously contemplated venting the rocker cover breathers to atmosphere, but I changed my mind. I have gone to great lengths to ensure that the car is a roadworthy and legal as possible. So, no point in changing values when the build is so close to completion. We fitted two -12 breathers into the rocker cover and modified the Moroso catch can, so that we can vent it back into the intake through -16 line. The factor breathers have had threads tapped into them and will be plugged. I had intended to vent the engine from the drivers side of the rocker cover, but lack of room for the catch can, forced me to change sides. We welded the fittings in between a gap in the cam lobes, to reduce oil throwing towers the vents and mounts a splash shield over each vent. I started to dummy up the lines, but ran out of time. So, now I have to research and decide who will chrome the cover and send it while I'm away at work. So as to avoid further delays. Any recommendations would be greatly appreciated... http://i210.photobucket.com/albums/bb52/sirhsv/Mobile%20Uploads/20150728_222644_zpsqkfiyanv.jpg[img/]