Time to start assembling 1.5 TD / 1.9L Franken Diesel.

[Jetmugg]

Yesterday, I picked up the engine parts that I dropped off at the machine shop a while back.  Everything looks great.  The shop did an excellent job of balancing all the rods to the pistons, setting all the bearing clearances, polishing the crank, setting up the head, etc., etc. 

Here are some pics...


Reworked stock rods, new small end bushings, ARP bolts installed, resized big ends, and individually weight matched to the corresponding pistons.



Matching pistons, sized for each bore, and balanced in conjunction with the rods.



The stock, forged crank only needed to be cleaned up and have the journals polished.



For reference purposes, the bore sizes are noted on the piston box.



The assembled head



A view into 2 ports, showing the tapered guides, lightly ported bowls, and 7mm stems.



The guest of honor, with head studs, main studs, line honed main caps, and fresh intermediate shaft bearings.





,

[vanbcguy]

Very sexy IDI build! Looking great!

Sent from my HTC One X using Tapatalk 2

[rallydiesel]

The TT 7mm stem valve parts worked out ok? Did you increase the valve sizes?

[theman53]

Looks good but I bet they could have ported your head quite a bit more around the guides. Let us know if you dyno it. I would love to see what it makes for power.

[Jetmugg]

Yes, the TT valves worked out.  They had to do some mixing and matching of parts to get the right combination, though.

Sorry about posting on the wrong forum - I must have been too excited.

I'm sure there was plenty of room for more porting, but this was basically just a cleanup operation.  If/when I get a chance to dyno this engine, I will absolutely post the results.

Next on the $$$ list is a Garrett GT2056 turbo.  I need to check my funds, then make the buy.

Steve.

[RabbitJockey]

All hail.  Gt2056 good choice which exhaust housing have u chosen?  Beautiful parts

[RustyCaddy]

Such a nice motor build!

Kind of a shame what the speed record will do to it...i guess its live a short fast life and go out gloriously

 

[Jetmugg]

I'm hopeful that the engine will survive the LSR attemp in good condition.  I've already had visions of putting this engine in a small streamliner and going after the 1.5L diesel streamliner record.

Steve.

[theman53]

In all honesty I don't think it will be hurt a bit. If you test and run it say 10 times. That is only 30 miles. Yes it is all at wide open, but if you have it warmed to operation and cool it down after I bet you could do this several hundred times. The worst parts I bet will be the precups or some part of the head. The block as long as the head doesn't destroy it I bet will be fine.

[Jetmugg]

My thoughts exactly - the only parts that I'm really worried about are the pre-cups.  I have heard of people "peening" them in place, but don't know if that's a good idea or not.

Steve.

[theman53]

I peened all of mine, when #3 failed the others were loose. I am not trying to clutter your build, just trying to give good input. They didn't coat your pistons? That is something I would for sure do before sticking them in.

[RustyCaddy]

They didn't coat your pistons? That is something I would for sure do before sticking them in.

That is a really good point.

i wonder how the small diameter wrist pins on the 1.5l pistons will hold up...a local rebuilder once cautioned that 1.5l pistons might have problems in a TD because of this difference compared to a 1.6l?

But then again, Kevin had a 1.5l w/ a VNT-17 and it was the weak 1.5l block that failed, not the wrist pins...and he may have set a speed record or two in the process

 

[Jetmugg]

I did not have the pistons coated.  It's not something that I know a lot about, and decided to keep things a little more on the simple side.  I am prepared to learn and spend more if it will help, though.

What can you guys tell me about piston coatings?  (cost, who does them, dimensional changes, special precautions, etc)?

Regarding the wrist pins - I was shocked at how "beefy" these pins are.  They are very thick-walled.  That being said, the small end bushings were pretty well beat on the rods before being R&R'ed.  New bushings have been fitted.

Steve

[RabbitJockey]

They didn't coat your pistons? That is something I would for sure do before sticking them in.

That is a really good point.

i wonder how the small diameter wrist pins on the 1.5l pistons will hold up...a local rebuilder once cautioned that 1.5l pistons might have problems in a TD because of this difference compared to a 1.6l?

But then again, Kevin had a 1.5l w/ a VNT-17 and it was the weak 1.5l block that failed, not the wrist pins...and he may have set a speed record or two in the process

 

i don't think the wrist pins will ever be an issue, high hp gas engines use their stock small wrist pins with out issue.

i agree with theman53 tho ur engine shouldn't have any trouble lasting, as long as u keep all your temps in check u should be golden.

[Jetmugg]

I just sent an email inquiry to Swaintech regarding having a a coating applied to the piston tops only.  The piston to wall clearance is already set, so the diameter of the pistons can't be increased.

Steve.