The '2 ton bugswatter' - back for a gentle stroke

[JP]

truely amazing build!

wish my block came back that clean after acid dipping. The guy who gave mine back did so with it looking like it had just been dug up!

you'll have to start charging for those quick blats in the local dip in the road with this monster!

I got mine blasted using walnut shell

As for trips down the dip took my mates rs4 down there part throttle whilst running in and hit 140. Felt sick to my stomach and started building my new engine

[prj]

Okay, I had the (wrong) impression you were using the smaller hotside... need to read more I guess.
Are you planning to upgrade the engine management as well?
You are combing very close to the hardware limits of this old Motronic, which starts to have lots of issues (knock monitoring, injector resolution) after 600hp crank, even with the bigger MAF...
The load calculation according to the spec sheets only goes down to 1.2ms for example. In practice it's a bit less...

[JP]

Crank has been fitted with a 60-2 wheel with the intend to fit a syvecs unit in the long run, which can come with an adapter loom for plug and play and has configurable inputs. It's what we are running on our 1.8t and I'm very impressed with the hardware and software for the price. We originally came across it because of our choice in mapper and went with the ECU he was best with.

[prj]

Very cool, can not wait to see the final result of one of the most serious builds on this forum.

[JP]

Finally got a chance to take the pics of the camera, so in no specific order


The money shot (literally )




Rifle drilled rods, I've stuck with 21mm wrist pins to keep reciprocating mass to a minimum as the Pauters are heavier than your generic h-beams so rifle drilled the rods like OEM ones instead of going to a 22/23mm wrist pin to provide a constant oil pressure to the small end to reduce wear at high rpm/boost application.




625 ARP's instead of the conventional 2000's these are tq'd up to 60ft/lb instead of 50ft/lb most likely overkill but the parts cost and machining time is getting to the stage that it is a small extra.




Broached big ends to aid oil flow at high rpm so I can run tighter big end to crank side clearances with the added benefit of extra oil spray to the bottom of the pistons.




Calico coated KS sputter big ends, decided to run sputters in both the rods and the caps and send them of to Calico to put their dry film lubricant on them.




calico Coated Mains and thrust




Custom 1.2mm total seals top ring, normally wouldn't run a total seal top ring on a street car on these engines as the already thin 1mm ring is made even thinner and tend to flutter under high load giving them a shortened lifespan. However after some discussions with total seal via JE they custom made me a set of 1.2mm top rings for improved street use.




Diamond Like Carbon coated wrist pins, carbon plasma coated wrist pins create a diamond like hard surface on the wrist pins reducing wear and more importantly make them like slippery eels to reduce friction.




End over end rod balancing, sort of speaks for itself bit more exciting to look at than a piston on a scale




Checking the ring gaps, squaring tool ensures ring sits perfectly square in the bore before taking a measurement.




Adjusting the rings accordingly, good old ring grinder with diamond coated disc for a nice clean cut.




Block finally zinc prepped and painted. Just before it was loaded in the car to take half way across the South East for Line Honing.




Just working on finishing the crank of and getting it all balanced in time for the return of the block. Hopefully having the bottom end finished in the next fortnight ready for the last couple of particulars on the intake ports of the head. Just need to do a dry build first and double check compression incase any alterations on the combustion chamber cc are required.

[bazburn]

Crikey JP, you work on a different level...had to google most of it...

Excellent read tho.....

[mcandmar]

Engine porn, loving it

Never heard of getting bearing shells and wrist pins coated, fascinating stuff, keep it coming...

[Bram]

Wow, that engine will be optimized to the max. Like your work mister

[AndyP]

Whats the coating on the pistons? They look very shiney!

[raymor]

Some fantastic attention to detail... a professional build and real interesting thread

[JP]

@ Andy, the coating on the pistons is a thermal barrier coating. It keeps the heat in the combustion chamber reducing expansion in the piston. At first I had my doubts on its longevity due to Tue extremities it is subjected to. But we've had it in a couple of engines now and the only one that showed any signs of org coming of was one were a spark plug had let go leaving some exposed ally but even in those locations it hasn't peeled away so I've taken the gamble for my one.

What would be really cool is if we can somehow apply a thermal barrier coating on the intake ports of the head and combustion chamber in order to ensure the coolest possible air charge and the maximum energy spent on the combustion cycle but I don't know if there is anyone that could do that. Possibly a search for Google this week

[JP]

^^^^ camcoat in the UK do the techline powerkote coatings. I'll have a word with them but looking at the literature I think its not suited for FI use.

[Billman]

Sticky please

[biggerbigben]

Good indepth thread.. I would expect nothing less from you JP! Good luck with the re-re-rebuild :-)

PS - Have you got Karls engine back up and running yet?

Ben

[JP]

Good indepth thread.. I would expect nothing less from you JP! Good luck with the re-re-rebuild :-)

PS - Have you got Karls engine back up and running yet?

Ben

Hey, thank you very much long time no speak. karls went back together last night, just waiting on the waterpumps to arrive so I can go and dial the cams in tonight. Then it's a waiting game for the new clutch plates and she'll be ready to rock n roll and get mapped with the new 1600cc injectors