2insane’s Random 6.2/6.5 Diesel Projects

[2INSANE]

Upper and lower plenums and exhaust manifolds agitated (Wire Brushed) enough for the Jet Machine. Will need a new set of clothes after doing that…

Also tapped 1/8 npt ports for the pyro and boost gauge. Got plugs on them for now until the motor is installed and gauges ordered.

 

[Big Ray]

No, its 3rd in line lol...

 

[2INSANE]

All 8 cylinders honed with a 320 grit flex hone. I got cylinder #2 at a tight .021 ring gap but the groove is still there just not as bad. Customer wants to proceed without putting a sleeve in. The goal is not to take the groves out, but to smooth them out to raise compression in cylinder #2. If I can get 320+psi on number 2, I would be happy. 380+ would be ideal but with that deep grove, it will not be possible. We believe the carbon build up will fill in the groves and raise compression numbers as time goes by.

I cleaned the deck, tapped the head bolt holes 3 times and power washed the motor. Twice.

The hone material is Aluminum Oxide. Full respiration is a must!

 

[2INSANE]

Cam, crank, girdle, timing chain, freeze plugs and block heater is installed. So far I got 2 pistons in with all the rings gapped to spec. Will do the other 6 pistons tomorrow.

 

[Big Ray]

Making it look easy...

 

[2INSANE]

Making it look easy...

Thanks! It is a lot of fun!

All 8 pistons are in, new rings gapped and lubricated. Got the oil pump in as well and test fitted the new oil pan. Only worked a few hours today on the motor. The rest of the assembly should be easy breezy. There will be some wait time because I am going to take the heads to the machine shop to get cleaned and inspected.

 

[ZooMad75]

So is the main bearing girdle just a thick chunk of angle iron with sections cut out for clearance to the crank counterweights? Not knocking it, just curious as that's how it looks from the angle of the pic. Pretty simple and elegant way to tie the parts together.

 

[2INSANE]

So is the main bearing girdle just a thick chunk of angle iron with sections cut out for clearance to the crank counterweights? Not knocking it, just curious as that's how it looks from the angle of the pic. Pretty simple and elegant way to tie the parts together.

Yes, exactly! This Girdle is a DSG brand sold by Kennedy Diesel. It is not a full coverage girdle but does provide a lot of protection against the micro vibrations and movement of the webs. They can be made easily at home. The bolt holes on the Girdle are precision cut so that they fit the kit provided 6 ARP studs super tight.

When making a girdle, it is crucial to make sure those holes align perfectly with zero play/movement. If there is any play, the girdle could cause more harm then good.

 

[2INSANE]

Spent 30 minutes after work and installed the new oil pan/2 piece oil pan gasket tonight. I used Optimum Black RTV on both sides of the gasket, which is also very oil resistant and has a temp range of 500 degrees. I’ve had great success with it so far on other builds.

Also took the heads to a local machine shop to have them disassembled, cleaned and inspected. 2-3 weeks out.

 

[joshuak]

Spent 30 minutes after work and installed the new oil pan/2 piece oil pan gasket tonight. I used Optimum Black RTV on both sides of the gasket, which is also very oil resistant and has a temp range of 500 degrees. I’ve had great success with it so far on other builds.

... snip...

Always pleasantly surprised how much one can accomplish doing a little bit everyday.

Nice work, thanks for posting up.

 

[2INSANE]

Got the lifters installed, checked lifter interference with lifter guide plates, timing cover all cleaned up, all bolts refurbished, timing cover installed, water pump plate and pump installed. I used Optimim black for the oil side of the timing cover and blue RTV for the coolant side. Every bolt got Permatex 80632.

 

[Truckman4life]

I like The Right Stuff in the little caulk tubes for all my silicone needs. Learned about it way back doing 7.3L oil pans that require A LOT of silicone.

 

[2INSANE]

The heads finally got finished at the machine shop. Head #2 is 7 thousands of an inch below spec and had to have the valves lapped. The .10 thicker head gaskets I ordered should be good to compensate the difference.

We decided to use new TTY head bolts instead of Arp head studs because the customer does not plan on going above 15 psi boost and they seal a lot better with less of a chance of coolant leaking threw the threads.

Last nights progress…

Install heads, clean and install pushrods, rockers, valve covers, injector line brackets, injectors, rubber injector return lines, injection pump, harmonic balancer, crank pulley, water pump pulley, water pump bypass nipple, crank position sensor block off cap, glow plugs.

Today I’ll finish putting the long block together and getting it set up for a test run next weekend. I want a whole week for the RTV and gaskets to dry/seal.

If she runs good next weekend, I will install the rest of the parts making it a complete drop in turbo 6.5. and start the swap.

 

[campfire]

The heads finally got finished at the machine shop. Head #2 is 7 thousands of an inch below spec and had to have the valves lapped. The .10 thicker head gaskets I ordered should be good to compensate the difference.

We decided to use new TTY head bolts instead of Arp head studs because the customer does not plan on going above 15 psi boost and they seal a lot better with less of a chance of coolant leaking threw the threads.

Last nights progress…

Install heads, clean and install pushrods, rockers, valve covers, injector line brackets, injectors, rubber injector return lines, injection pump, harmonic balancer, crank pulley, water pump pulley, water pump bypass nipple, crank position sensor block off cap, glow plugs.

Today I’ll finish putting the long block together and getting it set up for a test run next weekend. I want a whole week for the RTV and gaskets to dry/seal.

If she runs good next weekend, I will install the rest of the parts making it a complete drop in turbo 6.5. and start the swap.

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Why do you need an entire week for the gaskets to seal?

 

[2INSANE]

Why do you need an entire week for the gaskets to seal?

It is a standard process I like to do. Sometimes a month of cure time is better IMO. I’ve had leaks before within 3 days of cure time.

 

[Truckman4life]

I love the black Right Stuff silicone in the small caulk tubes. Cures pretty fast.

 

[campfire]

Any update on the metallurgy testing?

 

[2INSANE]

Any update on the metallurgy testing?

Not yet. Still have 2 more samples to collect. I did buy a auctioned junk Optimizer on Govplanet.com down in Utah. I plan on getting a sample from it soon!

 

[campfire]

Not yet. Still have 2 more samples to collect. I did buy a auctioned junk Optimizer on Govplanet.com down in Utah. I plan on getting a sample from it soon!

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Must be a pretty serious water pump to need four belts.

Also, is that a speed sensor occupying the vacuum pump port?

 

[2INSANE]

Must be a pretty serious water pump to need four belts.

Also, is that a speed sensor occupying the vacuum pump port?

It is an incomplete tach sending unit. I think I have a complete one if you are in the market for one?