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Engine Specific Info and Questions => IDI Engine => Topic started by: Mikeyworks on March 31, 2005, 03:39:26 am

Title: What a miserable end
Post by: Mikeyworks on March 31, 2005, 03:39:26 am

I got most of the accessories off my 1.6TD that threw a rod....here's the pics of the carnage.

(http://www.photodump.com/direct/mhitchings/P1010044.jpg)

and a closeup of the internals at this point.

(http://www.photodump.com/direct/mhitchings/P1010046.jpg)

I think a rod endcap bolt failed (do not re-use these) but the final diagnosis will happen when I get the oil pan off, etc.

Mikey

Title: What a miserable end
Post by: moTthediesel on March 31, 2005, 05:33:39 am

It that what they call "Positive Crankcase Ventilation"?

Sorry, that's a big bummer  :cry:

Thanks for the reminder though, I'll be sure to use new bolts when I freshen up my TD.

moT

Title: What a miserable end
Post by: dieselweasel on March 31, 2005, 09:37:59 am

Did the rod bearing spin/seize or did the rod just break?

Title: What a miserable end
Post by: Mikeyworks on March 31, 2005, 03:10:51 pm

Not exactly...I think I may find tonight when I go to pull the rest of the bottom end off!!!!

Mikey

Title: What a miserable end
Post by: Mark(The Miser)UK on March 31, 2005, 03:45:01 pm

:evil: If the hole is the only damage to the block; why cant the casing be patched and welded? :shock:

Title: What a miserable end
Post by: Mikeyworks on March 31, 2005, 03:48:58 pm

Can you weld cast iron??

What about the water jacket?

Mikey

Title: What a miserable end
Post by: Mark(The Miser)UK on March 31, 2005, 04:46:48 pm

Quote from: "Mikeyworks"

Can you weld cast iron??

What about the water jacket?

Mikey

Everything can be welded given the right bloke with the right torch :lol:
(Not me though I weld like I swim) :wink:

Does the water jacket reach down that far? :?:

Title: What a miserable end
Post by: Mikeyworks on March 31, 2005, 04:55:27 pm

Quote from: "Mark(The Miser)UK"

Everything can be welded given the right bloke with the right torch :lol:
(Not me though I weld like I swim) :wink:

Does the water jacket reach down that far? :?:

Just checked...no waterjacket that far down...I will check with some of my friendly local skilled welders and see what they say about welding the block back together.  I would do that if I could before I try to sell it (if I do sell it).

Mikey

Title: What a miserable end
Post by: Mark(The Miser)UK on March 31, 2005, 05:19:30 pm

Quote from: "Mikeyworks"

Quote from: "Mark(The Miser)UK"

Everything can be welded given the right bloke with the right torch :lol:
(Not me though I weld like I swim) :wink:

Does the water jacket reach down that far? :?:

Just checked...no waterjacket that far down...I will check with some of my friendly local skilled welders and see what they say about welding the block back together.  I would do that if I could before I try to sell it (if I do sell it).

Mikey

I know in the past people have looked at these incidents and after spewing up have just consigned the block to life as a boat anchor... Not me; something has to be truely trashed before I throw it out (and then it often takes the wife to bin it whilst I'm out) :roll:

 :twisted: Why it occurs to me that it might be patchable; is because there's only sump pressure there and as far as stress goes it looks like its right in the middle of 'nowhere' :twisted:
"Fingers crossed fer ya"

Title: What a miserable end
Post by: Mark(The Miser)UK on April 01, 2005, 02:10:25 am

:twisted: Maybe brazing is the way to go... :twisted:

Title: What a miserable end
Post by: Patrick on April 01, 2005, 03:22:25 am

Brazing doesn't work very well. I've got a one lung gas engine here that was "ventilated" in a similar fashion. Pieces were put back in and brazed. Stayed together, but leaks. You might try a good tig welder with silicon/bronze rod though. Don't have much faith in cast rod.

Title: What a miserable end
Post by: lord_verminaard on April 01, 2005, 05:01:04 am

Quote

Just checked...no waterjacket that far down...I will check with some of my friendly local skilled welders and see what they say about welding the block back together.  I would do that if I could before I try to sell it (if I do sell it).

Mikey

Dibs!  ;)

Brendan
84 Scirocco 8v
00 Camaro L36 M49

Title: What a miserable end
Post by: lord_verminaard on April 01, 2005, 05:09:24 am

OOh, had a brainstorm.  (watch out everyone)

A while back, there was a discussion about the maximum overbore of a 1.6 block - perhaps enough to fit 1.9 pistons.  If this block cannot be repaired, perhaps it would be a good donor to test by means of cutting it in half... etc. or just by boring it as far as it will go to see just how far it can actually go.  

Hey, that way if the block is trash, then we can at least use it for research.   :twisted:

Just a thought.

Brendan
84 Scirocco 8v
00 Camaro L36 M49

Title: What a miserable end
Post by: GoFaster on April 01, 2005, 08:42:51 am

What's the bore diameter on a 1.6? I think it's only a couple millimeters less than the 79.5mm bore on a 1.9 engine. The stroke was a bigger difference.

Title: What a miserable end
Post by: lord_verminaard on April 01, 2005, 04:30:26 pm

I think it's somewhere around 76.5 stock.  The highest (factory) overbore size is 77.5.  3mm sounds like a lot to me, it would be interesting to see how thin it would get.  (and if it could hold the pressure!)

Brendan
84 Scirocco 8v
00 Camaro L36 M49

Title: What a miserable end
Post by: Mark(The Miser)UK on April 01, 2005, 11:57:13 pm

Quote from: "lord_verminaard"

I think it's somewhere around 76.5 stock.  The highest (factory) overbore size is 77.5.  3mm sounds like a lot to me, it would be interesting to see how thin it would get.  (and if it could hold the pressure!)

 :twisted: Can you explain where your figure of 3mm comes from ?
A change in diameter of 1mm is 0.5mm radius; which is 0.5 mm of machined flesh. Areas between cylinders will thus see 2 x 0.5mm  which is 1mm decrease in wall thickness between cylinders... Or am I truly as stupid as I pretend to be? :twisted:

Title: What a miserable end
Post by: Mark(The Miser)UK on April 02, 2005, 12:02:36 am

Quote from: "Mark(The Miser)UK"

Quote from: "lord_verminaard"

I think it's somewhere around 76.5 stock.  The highest (factory) overbore size is 77.5.  3mm sounds like a lot to me, it would be interesting to see how thin it would get.  (and if it could hold the pressure!)

 :twisted: Can you explain where your figure of 3mm comes from ?
A change in diameter of 1mm is 0.5mm radius; which is 0.5 mm of machined flesh. Areas between cylinders will thus see 2 x 0.5mm  which is 1mm decrease in wall thickness between cylinders... Or am I truly as stupid as I pretend to be? :twisted:

 :shock: Yep I am...:shock:
1.9l diameter is 79.5?  hence 3mm between walls to bore out a 1.6...
At least I can admit it when I'm wrong :oops:

Title: What a miserable end
Post by: Mikeyworks on April 02, 2005, 04:16:24 am

pride is knowing when you're wrong.... :P

Title: What a miserable end
Post by: lord_verminaard on April 02, 2005, 05:18:55 am

Quote from: "Mark(The Miser)UK"

 :twisted: Can you explain where your figure of 3mm comes from ?

Ummm, yeah.  79.5 - 76.5 = 3

 :P

Just messin with ya.  *poke poke*

:)

Brendan
84 Scirocco 8v
00 Camaro L36 M49

Title: What a miserable end
Post by: veeman on April 05, 2005, 05:51:36 am

I believe you can weld cast iron blocks.  I was at the welding shop and I saw one of the guys welding up a two inch hole in a recent dorF V6 engine that had been involved in an accident....crazy to see the whole motor sitting on the table with everything attached and the guy just welding away at it.

According to him, it's a matter of preheating the area, using the right rod (arc) and doing it bit by bit (somewhat slowly).