yes Sam you are zoning in.

So the piston lost a piece of it through a seriously lean condition. no other damage noted. It was noted the engine was running extremely perfectly....the bearings are perfect...the rods, the head the valves the other three pistons golden brown on top the bores A1. Marc said its a real shame as the engine was running brilliantly. I noted no oil usage and no oil in the catch can....quite a bit of breathing out the catch can vent which Chris said "heavy breathing engines make power!" and that it did. it only breathed when cold....after a run it was pretty sweet.

So what caused the lean condition???...that is what concerns marc.....the injectors flow test perfectly.
He asked me to look at my wiring. I have noted a broken tab on the no.2 on the plug where the clip fits. The clip was in position when removed however it is possible that with vibration that the clip was allowed to loosen the plug enough to get a sporadic signal to the injector....and probably caused the running on 3 cylinders that we thought was a build up of fuel on the plug....I thought...we should check that....damn it....did I?...no.
on that run the lad drove from 12th to 4th and the car ran fine with all parameters looking great.

The data shows a wicked lean spike for 30 secs...probably or most likely that no2 cyl. Marc commented that it looked like it was not lean for that long but was seriously lean....if the injector failed or just stopped working altogether the engine probably would have been fine.

so marc is unhappy to allow our project to sit idle and has donated a block he will bore to new forged pistons and is getting a price for four new pistons. I want to ramp down the compression maybe 12:1....the rest of the engine is fine. It may not take too much to resurrect and both marc and chris want to see the car back on the track....so Im in it for one more.....minus the hydraulic lifters as long as the price is right. Id only go for this given the fact that the rest of the motor was running awesome and something I have done has caused it.

now the confession. I knew that plug tab was broken but I thought it was holding the plug onto the injector just fine......fecking idiot.

That all sounds like positive progress. 12/1 will work fine, that's what I'm running.

The only thing I'd say is to make sure you sort out the oil supply. You shouldn't need a shim in the pressure relief with a new pump. Make sure the head is good and if it's not use the one off the donor car. If you've got some spare cams see what Kelfords can do with them in terms of a profile for solids, you might be pleasantly surprised both in terms of power and reliability.

I guess you might also want to ask some questions around your ecu config. An injector dropping out needs to raise a red flag. I can't remember whether you can use that in engine protection but ideally it needs to be a stop condition.

Marc is onto it. He is looking into the engine for me. We will rebuild once more....definately want to get the hyd lifters out. He is donating some ID injectors to the cause as he does not like to risk the 28 year old ones. I have to check all the wiring right back to the ECU and replace that one plug on no 2 injector which I am sure was the cause.

Jeez I have been a bit unlucky with this motor... we are going to bring the compression ratio down under 12:1. If the bearings are running fine which they are ill leave the oiling system alone unless removing the hyd lifters increases it some more.

not given up guys...just taking a small break while I get my boat done....marc will rebuild the motor and we are reducing the compression ratio....sticking the spare d16 pistons into another block but set the ring gaps properly....probably 11.5:1.

we are at least 3 seconds too fast for our time band at our local track....so we are DE Grenading the motor to a sensible NA level.....probably still get 130 hp at the wheels....146 is just going to put us in the risk zone I reckon...because it lives at such high revs. Cant get just one forged piston done...bugger it....but if d16 engines can do 160 hp plus then surely they can live at 120-130 in the gti engine.

The dog box makes it a weapon anyway....the standard GTI boxes are not very good getting the best out of the motor but I honestly believe 120 HP will give us the time we need anyway...

Its now more about the racing rather than the all out power level and wankiness.

back soon.

Good luck with that!

Datman has had his car listed on TM for the last few months and I see included in the spares is a fresh standard bore long block with 11.5:1 Cultus pistons. A sensible offer for that might be a win for both of you.

what part of the piston was missing.
Wasnt the top outside edge was it...sign of incorrect or too small a ring gap?

GTP

Sam...Im not dropping money on another car...have my boat to do now. are you just talking the motor?

GTP....definately not too small a ring gap at all. that was addressed after the last engine. They were perfect and all other cylinders running perfectly.

it was a misfiring injector caused by a faulty plug that had a broken clip on it. It started on three cylinders at the last meeting....playing with the injector plugs....it ran on four....it wasn't apparent that playing with them at the time fixed the issue (even though it sounds like that) ...we thought it had loaded up on fuel. the car ran fine till it crapped out after that. The only thing found in the strip down was the broken clip on the injector plug of the blown cylinder. and the log showed a lean condition for about 20 secs before the failure. That lean condition was masked by three other cylinders running well....so for it to show up the blown cylinder had gone very lean....no head gasket issues...no air leaks...all checked.....injector flowed the same as the others...I can only assume that the plug had not completely disconnected from the injector and like an intermittent electrical connection was sometimes firing the plug and other times not....enough to keep the cylinder running but not enough to keep it from going lean. be better if it fell off all together.

anyway...we are depowering it...it would probably do the time we need on a stock motor with the bog box anyway and a decent set of slicks....so no longer interested in a grenade.

No, not the car just the long block. Cheaper than building one I'm guessing.

Still here just on winter hiatus. Car to be fixed reasonably soon.

still here just waiting for word on the donor block and pistons and what we can do...will try to have it going for the summer series again...less power though...less of a grenade.

meantime i have been doing this with my time....orange again..lol. but not the seat thats just a borrowed one to set up. should put this in the suzuki!....then it would go but probably not around corners....

im back. ripping the donor car apart...got the engine apart today....solid cams!...great...excellent crank and bearings have been running sweet....4 thou out of round...but stuff it...im going to get it honed...chuck some rings on the pistons and shove it back together with a redone head i got on another deal...ill run a stock engine compression (slightly higher due to surfaced head etc) with all my other stuff put on it...the three tech cams and the cultus manifold. im putting a smaller..(yes smaller) throttle body on it from 54mm to 44mm....2 mm over standard size. why?....well the 54mm one is just far too big....we get full power at 60% opening and its the reason i believe im getting the rev up on up shifts as its DBW. its worth a try.....car will go slower but how much....find out soon...

Anyone got any forged pistons?

I've got three!

I've got three.

Mmmm.....common theme here guys