Updates (Long)
Posted: 19 Apr 2009 9:03
Hi everyone.
Just thought I'd give you guys a run down on how we're progressing wih the car.
We've had the box stripped for a bi-annual refresh and found a couple of things wrong, nothing major the worst being a trashed front planetary where a circlip has come out and managed to find it's way to the back and destroy the bearing surfaces of the planetary and carrier. So we've upgraded to a five pinion steel. While we were in there we refreshed everything and also upgraded to billet servo's, wow those springs are tight, they should release the bands a lot quicker than the old oem ones. The plates clutches and bands were in real good condition so I think I'll extend the rebuild to every 3 years now. Though we inspect the pan after the first race and every year.
The motor was a bit more interesting . Since it was built we've been chasing a haze/smoke problem from the LH header bank. At first we thought it was a head gasket, since it was gone through to the waterway and head studs, we replaced it. It went again, We traced this to a low spot on the head and got them skimmed. Problem solved? No. It still smoked/hazed on the LHS but apart from that it seemed to run OK. Anyway we had to change the rear seal this year after a bad flex plate failure (More on that later) so the motor was completely stripped.
Well well we found this
This lined up perfectly with where the head gaskets had been going which is where the low spot on the head was. You can see here that we use Hemi/wedge head gaskets. Something to do with the KB block design been based on a Hemi since wedge head gaskets hang into the water way a bit too much for my liking. Imagine the gasket traveling strieght to the top on the LHS of the photo and look at the witness marks for the water way. There is also evidence of the head "lifting" look at the gasket between cylinders and the distortion on # 3 cylinder fire ring. This was the worst gasket BTW the last one out doesn't look bad at all.
# 1 piston, the top ring has lost a lot of coating and the piston has nipped the 2nd ring. So there's why it smoked and the cause, would be detonation. The contaminated intake charge has got between the ring lands. Oil, water and fuel doesn't make for good combustion . I fear this is what it's been like since it was first run! and it has run 9.71 @ 140 (on 7 1/2 cyls )
Trouble is we should have spotted this years ago since the 528 had issues with head sealing too
We've also been having issues with converter bolts working loose so we had the crank checked for balance. It was out, slightly, OK for street, sub 6000 rpm use but not good for a 7500rpm motor. EDA ( http://www.engine-data.co.uk/ ) balanced it for us and got it perfect, well done guys Bob weight was around 2400 grams (can't remember exactly) slightly lighter than a stock 440, so its heavy but not bad for a 4.5 stroke, steel rod rotating assembly . I'm tempted by alloy rods but have always worried about fatigue and that you have to replace them every so many passes. Also it's advisable to get a valve body with an extra neutral after 3rd to stop the loads being reversed on the rods when you coast after a run.
Anyway the motor was cleaned, re-ringed, new bearings, piston repaired, quick bottle hone, new valve springs, cam timing checked etc etc
We also replaced the flex plate (again) and upgraded to better bolts. I should have done this the after the first flex plate went since the land under the head bolts were all galled and damaged, they would have had difficulty holding on the the plate and the slight misbalance wouldn't have helped here either.
So the motor and box are all done.
Now whilst it may look like a million bucks , contrary to rumour this motor cost us $10800 ( Yep Dollars, I have the reciepts and thats rounding up ), since we re-used a lot of parts from the 528. The reason I explain is someone asked and had heard that I had £35,000 in the motor alone I wish
All we need now is the car back from the bodyshop which returned home after a 11hr trip (Traffic was diabolical ) from Chipping Norton on Friday night.
Paint is HOK Kandy burple, the night time pics do not do it justice. 4 coats of burple over 2 fine silver followed by 3 of clear. It's kind of like a cough sweet purple that changes to an electric blue when the light hits it right. I'll take some more pics when it's back together.
Were racing in 2 weeks time and I want to get it MOT'd (though thats not on the highest priority ) so I best be in the garage rather than tapping on keys
Thanks for reading.
Tig
Just thought I'd give you guys a run down on how we're progressing wih the car.
We've had the box stripped for a bi-annual refresh and found a couple of things wrong, nothing major the worst being a trashed front planetary where a circlip has come out and managed to find it's way to the back and destroy the bearing surfaces of the planetary and carrier. So we've upgraded to a five pinion steel. While we were in there we refreshed everything and also upgraded to billet servo's, wow those springs are tight, they should release the bands a lot quicker than the old oem ones. The plates clutches and bands were in real good condition so I think I'll extend the rebuild to every 3 years now. Though we inspect the pan after the first race and every year.
The motor was a bit more interesting . Since it was built we've been chasing a haze/smoke problem from the LH header bank. At first we thought it was a head gasket, since it was gone through to the waterway and head studs, we replaced it. It went again, We traced this to a low spot on the head and got them skimmed. Problem solved? No. It still smoked/hazed on the LHS but apart from that it seemed to run OK. Anyway we had to change the rear seal this year after a bad flex plate failure (More on that later) so the motor was completely stripped.
Well well we found this
This lined up perfectly with where the head gaskets had been going which is where the low spot on the head was. You can see here that we use Hemi/wedge head gaskets. Something to do with the KB block design been based on a Hemi since wedge head gaskets hang into the water way a bit too much for my liking. Imagine the gasket traveling strieght to the top on the LHS of the photo and look at the witness marks for the water way. There is also evidence of the head "lifting" look at the gasket between cylinders and the distortion on # 3 cylinder fire ring. This was the worst gasket BTW the last one out doesn't look bad at all.
# 1 piston, the top ring has lost a lot of coating and the piston has nipped the 2nd ring. So there's why it smoked and the cause, would be detonation. The contaminated intake charge has got between the ring lands. Oil, water and fuel doesn't make for good combustion . I fear this is what it's been like since it was first run! and it has run 9.71 @ 140 (on 7 1/2 cyls )
Trouble is we should have spotted this years ago since the 528 had issues with head sealing too
We've also been having issues with converter bolts working loose so we had the crank checked for balance. It was out, slightly, OK for street, sub 6000 rpm use but not good for a 7500rpm motor. EDA ( http://www.engine-data.co.uk/ ) balanced it for us and got it perfect, well done guys Bob weight was around 2400 grams (can't remember exactly) slightly lighter than a stock 440, so its heavy but not bad for a 4.5 stroke, steel rod rotating assembly . I'm tempted by alloy rods but have always worried about fatigue and that you have to replace them every so many passes. Also it's advisable to get a valve body with an extra neutral after 3rd to stop the loads being reversed on the rods when you coast after a run.
Anyway the motor was cleaned, re-ringed, new bearings, piston repaired, quick bottle hone, new valve springs, cam timing checked etc etc
We also replaced the flex plate (again) and upgraded to better bolts. I should have done this the after the first flex plate went since the land under the head bolts were all galled and damaged, they would have had difficulty holding on the the plate and the slight misbalance wouldn't have helped here either.
So the motor and box are all done.
Now whilst it may look like a million bucks , contrary to rumour this motor cost us $10800 ( Yep Dollars, I have the reciepts and thats rounding up ), since we re-used a lot of parts from the 528. The reason I explain is someone asked and had heard that I had £35,000 in the motor alone I wish
All we need now is the car back from the bodyshop which returned home after a 11hr trip (Traffic was diabolical ) from Chipping Norton on Friday night.
Paint is HOK Kandy burple, the night time pics do not do it justice. 4 coats of burple over 2 fine silver followed by 3 of clear. It's kind of like a cough sweet purple that changes to an electric blue when the light hits it right. I'll take some more pics when it's back together.
Were racing in 2 weeks time and I want to get it MOT'd (though thats not on the highest priority ) so I best be in the garage rather than tapping on keys
Thanks for reading.
Tig