Haydns Rebuild

[Headsex]

Around 6 months ago, Haydns F6's engine failed.

Plenty of theory's and rumors flew around on why it failed, and usually the tuner is always to blame, which was me.

Too much power brought on too early, Detonation, Pinging, Running lean. Blah, I heard it all.

Too much power? nope, The car was not running much boost, with very conservative timing, as I had told Haydn he needed a more sufficient fuel system (surge tank, 044 for example) before I would push his power.

Bringing the power on hard? Nope. People usually assume I spike the boost to 22psi coming on boost to make it come on hard. But nope, that's not me. My boost is always Flat 15 - 17psi the whole RPM range, depending on modification and power level.

After Disassembling the engine, and taking the parts and photos to 3 independent engine shops came back with these conclusions.

1) There was no sign of detonation/pinging of the engine. The Pistons, ring landings, and bearings were like BRAND NEW (except for the missing number 2 piston).

2) There was no whiteness colouring in the exhaust / turbine wheel / turbine housing. Indicating it was not running lean.

So that ruled the "bad" tune out.

They all concluded to this.

3) Clearly what you can see is the head of the conrod bolt on the left had sheared off.

In doing that, the big end of the conrod opened up, pushing stress onto the other conrod bolt on the right, opening up the conrod big end up, eventually putting so much stress on the bolt it stretched so much it sheared off.

Further Impact markings seemed to indicate once the crank journal had broken free of the conrod, as it came around again, it hooked ontop of the big end, ripping it downwards, Indicating the big end let go before the beam did.

Why did the conrod bolt fail? Various assumptions were made. Such as, Excessive High Revs, Excessive down gearing/engine braking, faulty bolt, stress crack in the bolt, where some idea's that were floated, But one particular engine shop noticed that the head of the bolt that failed had left a imprint in the conrod. Much like you leaving a footstep in wet sand, Suggesting it was potentially over torqued initially.

Haydn has even mentioned on occasion his floor mat getting stuck holding the throttle down, and shifting the Auto to Neutral whilst the engines bouncing on the rev limitor could also have contributed to it.

Which one of the assumptions were correct? Who knows.. But it definitely rules out tuner error. The engine would have failed a hell of a lot earlier if it was the tune.

Anyways.. That was several months ago.

NOW for the fun stuff!

Its a Hovering engine!

Darren's a Dentist, So we can't show you his face

Found the oil leak!

Nude engine

Freshly refined Oil anyone?

Brand new FG F6 Short motor

The H beam on the right, vs the Factory F6 Rod and Piston.

Shiney Forged Pistons, and H Beam rods.

Freshly Painted Block, and Reco BF Head

Cams and lower inlet manifold installed

Everyones Familiar with these!.... But, I think it looks a little boring..... Soooo

After a bit of love, it was looking like this!

And then this....

And this!

Afew beers later, It was now homed like this...

And now on the streets looking like this!

Most of you may have "noticed" "Why does a F6 have a red rocker cover?!"

Well.. that's because haydns BLUE rocker cover and rocker cover garnish are getting painted. The colour has not been decided on.. So we both are open to suggestions.

Currently I am running the engine in, and making sure there's no abnormal noises or any oil/water leaks what so ever. So far so good. Dyno time is happening in the next week or so.

Further to this. It was originally planned that a replacement F6 FG Short be dropped in with some H beam conrods. Haydn later decided he wanted forged pistons whilst it was at this stage.. That explains why a FG Short was initially purchased.

Also.. Its amazing how pretty the engine looks with some paint on the block, sump and timing covers. These engines dress up very nicely.

danny.

Edited 11/12/09 07:03 AM by Dagabond

[RAP1D]

Nice work Danny, and very good of you to show the failed parts and go to the lenghts to find out why they failed.

Looks like another super quick Headsex'd car!

[Headsex]

A number of rumours needed clearing up. Clearly if Haydn didn't have trust in me, He would have taken his vehicle elsewhere to repair.

It is quite a very toey car to drive around. very very responsive. I can't wait to delivery it back to Haydn once its all completed. He will be quite impressed I must say :D

[fordboy1981]

Good work Dano, if only all the shops out there were as ethically well minded as yourself.

[Headsex]

Cheers dave..

Haydn just reminded me.. I also fitted billet oil pump gears. What a mission that was. Turns out, they were 5/100th of a mm thicker than the factory ones, and bind up when assembled in the housing.

Not going to mention WHO the oil pump gears came from, but when contacted, they wanted it sent back for them to examine. Time was a issue.

However, after speaking to another workshop who used to buy oil pump gears from this place, has had the same problem.

I went with his recommended method of fixing the problem, which was to wet sand them down to the correct thickness on a piece of glass. Once I did that, I put it in a lathe to make sure it was still true. But what a mission that was.

[smXR6]

Great work Danny , you truely are the master haha

good to see the all the rumours were cleared up , keep up the great builds

bet haydn cant wait to get behind the wheel

[R-SPEC]

It pulls VERY hard I must say. Sure is an F6 to envy now. Tyres will be no match for that beast

Danny that red coloured rocker has grown on me even more in the last few days...

[Headsex]

I have to agree.. Im quite amazed on how it suits.. Althought it would have to be 2 pac..

[R-SPEC]

Yeah, maybe a bit more fluro like the Bionic

[jacob_xr6turbo]

looks good mate

I cant wait to pursue a build like this in the future. hopefully not because of engine failure though!