Author Topic: 1.6td connecting rods, polish and peen or h-beam? Pictures! (Read 11220 times)

DVST8R · « **Reply #15 on:** March 12, 2008, 06:59:27 pm »

Well, I spoke with Dave this morning, and he had pulled the head after the alternator bracket broke and knocked out the water pump, the motor got kinda hot, so he pulled the head just to be safe.

The head was flat, and all rods and pistons were in good shape, and there were NO BENT RODS!! It looks like one of the valves has made contact with the piston, it was checked over was straight no damage to the piston or the valve, so it was put back in and the valve spring was checked over. Now if you have been following the franken motor thread you will know that the big limiting factor to this point was that the turbo was surging above 26psi so Dave custom machined an anti-surge compressor housing for it and now can run 35psi, however above 32psi it just flutters now as the external gate spring is to soft, so Dave is going to get a harder spring, and attempt to re-dyno it this weekend. Both with the stock injector's and then with some 1.9 dual springs with some merc nozzles. It still needs an equal length exhaust manifold, and a cam, but it is getting there. :wink:

Subsonic I am looking forward to the results of your build.

DVST8R · « **Reply #16 on:** March 12, 2008, 07:00:38 pm »

Oh... The point of my last post...

I think that stock rods appear to still be holding just fine. :wink:

subsonic · « **Reply #17 on:** March 12, 2008, 08:35:45 pm »

That is just fricking music to my ears Brett! I was really worried about the rods, thought about it all the damn time!
"I'll never be able to run full boost!" :cry:
I am glad to know I will have a little buffer with the polish and peen and balance.

How the hell did valve contact happen? Think it happened at max rpm? Float?
I wonder if that piston is a hair above the other ones on piston projection?

I sent those injectors to Dave! Those are the one I will be using in my build. I don't need them yet so run em hard :twisted: I will be interested in seeing if the Merc nozzle route was worth it. I hope they can put enough extra fuel out to get past his 200hp goal.

What's this here new fangled anti-surge compressor look like?

I don't think I am going to be able to put up numbers like Dave with my turbo selection. I think it will spool faster, but I will get spanked in the top end.
.48 A/R Turbine
.42 A/R Compressor
45 Trim
Here is the turbo map for it.

DVST8R · « **Reply #18 on:** March 13, 2008, 09:19:46 am »

I'm not sure what the compressor cover looks like, as I just spoke with him on the phone about it. I would "assume" that it is a gun drilled style, vs slots, as it is a lot easier to machine, but then again Dave isn't known for taking the easy way.

That turbo is about 5/8 the size of what Dave is running.

As far as the valves, I really don't know we talked about it a bit, but didn't come up with anything concrete. It has HD valve springs, and only one hit, and not hard enough to bend the valve... So???

subsonic · « **Reply #19 on:** March 15, 2008, 07:14:26 am »

I went and picked up my connecting rods this morning. They certainly look different. I will get some pictures up later today. After the polish, each rod came out 1 ounce lighter. Still need to swap out the old bolts for the ARP's and have the big ends resized. That should happen in the next week or so.

subsonic · « **Reply #20 on:** March 15, 2008, 08:14:30 am »

What do you think? I thought that the sides would have been done as well, but the guy at the shop said that would take a lot more time and the real benefit is on the sides. I still think the look pretty cool :twisted:

rabbid79 · « **Reply #21 on:** March 15, 2008, 08:59:29 am »

Those do look cool. How much (if any) was removed from the end cap? Do you know the total weight of each rod after the work?

subsonic · « **Reply #22 on:** March 15, 2008, 09:45:46 am »

I do not have the starting weight. I was told the they are all approx. 1 ounce lighter than in stock form. If I go digging in the attic and set up my reloading scale, I could get a current weight. The weight will change though when the stock bolts are replaced with the ARP bolts, the big end is resized, and the pin bushings replaced. There was no material removed from the big end that I can see. To me, it looks like if you spent some time on them, you could clean up the sides and the top to achieve a much smoother overall product, might lighten them up around another 1/4 ounce or so. On the small end, the 3 clamping surfaces have been removed. That is where the majority of the weight came off I believe. If anyone has a picture of a stock 1.6TD rod, I will post it next to one of these for comparison.

subsonic · « **Reply #23 on:** March 19, 2008, 12:05:26 pm »

Just dropped off the rods, new ARP con-rod bolts, and bearings to my friends shop. Old bolts are coming out, new ARP's are going in, and the big end is going to be resized if neccesary. New pin bushings should be delivered in a week or so and then they will be installed.

subsonic · « **Reply #24 on:** March 20, 2008, 12:51:08 pm »

New ARP rod bolts are in! Rod was .0001 out after installation. Resized it to perfection

subsonic · « **Reply #25 on:** March 31, 2008, 03:43:13 pm »

Wrist pin bushings are in. The wrong ones were sent the first time. Brand new Mahle one will be going in the next day or so.