Shame to see this Adam. Hope you get to the bottom of it and look forward to seeing it progress

 Thanks Charlie, caused a bit of a headache but all part of playing about with cars at the end of the day.

 

So on Sunday I cracked on with pulling the engine out of the car. Twas a cold day with it just above freezing so most important item of the day to start me off was a good brew.....

 

 

The engine was soon enough out of the car and sat on the floor awaiting to be stripped

 

 

I removed the gearbox, the manifolds and the ancillaries from the engine.

 

 

 

A nice empty engine bay....

 

 

I then took the engine to work today and proceeded with the head removal and was greeted with the following on No.2 cylinder

 

 

 

 

I plan on finishing stripping down the entire bottom end tomorrow and then make plans on how I wish to go about sorting out the damage and rebuild the engine.

That was out quick. Least you knew what it was going to be, no hidden suprises.

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Wonder what's caused it let go though? Did the car throw any EML light? Interestingly same cylinder as a thread i was reading about coskev car.....coincidence probably? As his melted and yours has just cracked

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That was out quick. Least you knew what it was going to be, no hidden suprises.

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Don't mess about when I get stuck in

Wonder what's caused it let go though? Did the car throw any EML light? Interestingly same cylinder as a thread i was reading about coskev car.....coincidence probably? As his melted and yours has just cracked

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We believe high cylinder pressures have caused it due to running standard injectors for long durations.

No EML flagged up or any lights on the dash.

Funnily enough Alex's has also let go on No.2, unsure if it's a coincidence or not.

I've ordered my BHW pistons today, along with a new gasket set, headbolts and complrte new set of shells and thrust for the engine. Going to get the block cleaned up and make a start on boring it out ready to accept the larger 81mm piston.

Will be also ordering a set of rods over the weekend

Did you find BHW pistons in your work catalogue eventually then? I've found a set for 430 made by nural. I'm also going to get prices for coating the pistons tomorrow if you're interested need to start making a list of costs!

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Did you find BHW pistons in your work catalogue eventually then? I've found a set for 430 made by nural. I'm also going to get prices for coating the pistons tomorrow if you're interested need to start making a list of costs!

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From what I've found out the BHW is a North American engine so that's why it wasn't listed in my book as it's a european catalogue, but after speaking with somebody from TPS, they confirmed that they share the same piston as the BGW so that's what I have ordered. The pistons I will be using are Nüral ones also.

No harm in letting us know what the price is for coating, which form of coating are you looking into?

Diamondyze.co.uk. I did talk to the lads at camcoat about it in warrington when they ceramic coated my inlet, they don't have the facilities to do it there but the owner also has a diamondyze facility in the UK so they will send anything off for you to be done, I'll get back on prices I think it's fairly cheap

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Sorry to hear about the cracked piston man, hope you get it all fixed up soon! This thread has been a really decent read

Well looked in the diamondyze and it's about 150 for 4 pistons another %5 off for 8 so would be cheaper if a couple of people were doing it, I'll find the link later and post the info

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Slight update, haven't really done a great deal lately as I'm awaiting my parts which I will recieve tomorrow.

I have now removed the pistons from the rods, this was the piston that failed.

There is no marks upon the wrist pin that would point towards a siezed piston which has caused it to crack so looks purely down to the cylinder pressures have caused the failure.

I fully stripped the block down and have put it into our wash off tank at work to clean it up.

Considering the car has clocked over 100k now and nearly 15k on the GTB setup the shells and crankshaft was in mint condition, however I have given the crank a polish up in preperation for the new shells arriving for the fresh build.

My H-Beam conrods also turned up the other day so here is a cheeky pic of them also

Plan is to measure up the piston tomorrow and make a start on boring the block out to accept it. As part of the rebuild I will be finally fitting my clutch and flywheel setup that I made the other year once I have made a couple of alterations to it.

Edited 24 February, 201610 yr by Southy

Also forgot to mention, the H-beam rods weigh in at 572g, compared to 676g standard item so a nice weight saving.

Also forgot to mention, the H-beam rods weigh in at 572g, compared to 676g standard item so a nice weight saving.

Have you weighed them individually Adam to see differences between each one?

Have you weighed them individually Adam to see differences between each one?

I have indeed. They are all spot on with each other which is a bonus

More progress today on the engine. Removed the block from the tank this morning and started cleaning all the machined surfaces up.

The we moved over to the boring bar, sat the block on the stands and secured it down.

Then went about setting the cutting tool for the job, taking the block from 79.5mm to 81mm is 59thou, I decided to take 2 cuts, one at 40thou and the last cut at 19thou.

At the point of no return.....

The finished article

Here are some pics also of the new pistons

Won't be able to get anything done on it tomorrow so will be Monday now before I hone the block up and skim it. I'm tempted to paint the block itself Kawasaki green to continue my colour scheme throughout.

I'm seriously sending you my spare block to do! :D

Definitely looks like the walls between the cylinders is getting quite thin, hopefully doesn't become the next weak spot?

Brilliant work anyway, will be keeping track on this

Definitely looks like the walls between the cylinders is getting quite thin, hopefully doesn't become the next weak spot?

Brilliant work anyway, will be keeping track on this

Not really a great deal been taken out of the block, only .75mm radially has been removed. The 1.9 block is the exact same as the 2.0 one, it's just a larger bore. There is still a good 8-9mm of meat between the bores. Cylinder walls are getting thin when there is about 3mm remaining as I have had in the past on another engine haha.

Should be ordering some more parts this weekend and cleaning a load more stuff up. Highly tempted to paint my block Kawaski green also jnstead of the usual black.

Good look with the build mate, keep the pictures coming too, always nice to see pictures of the practical stuff happening rather than pictures of a polished car at every angle possible! Lol

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Excellent progress mate. Keep it coming.

Really good mate. Having to block green will look naff when its dirty though, then it'll be hard to get in and clean. Would look cool though.

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Really good mate. Having to block green will look naff when its dirty though, then it'll be hard to get in and clean. Would look cool though.

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I had thought about this, but my idea was to use my Carbon Collective Platinum wheels to seal the block to help with ease of cleaning it. Seems to cope fairly well on brakes so can't see it being an issue on a block

Suppose, but its a bit warmer surely? More oil etc on it too.

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I'm all for a bit more colour to brighten the bay up, but I agree that you should stick to black for the block, especially for a daily. That's what I'm doing with mine anyway.