Expensive maybe, but that's a hell of an ashtray!

Hope its not too terminal and its sorted quickly

Not too Terminal?

Nah looks a quick fix

:lol:

Its about as terminal as its ever going to get.

Hope its not too terminal and its sorted quickly

Not too Terminal?

Nah looks a quick fix

:lol:

Its about as terminal as its ever going to get.

STFU the pair of you, obvs can see that its a bit FUBAR'd, meant in the sense of the head being able to be saved

He's already sourced a 1341 engine with a big valve head man! Haha.

Ima shush now,or I'll get moderated

if it was the bolt that went you could tell from how it sheared, take a photo of the top of it!

if it was the bolt that went you could tell from how it sheared, take a photo of the top of it!

See the previous page mate, I need to break off the other rod bolts to reach a conclusion, just because the bolt has sheared, doesn't mean it went first. I have my suspicions as to why it wasn't the rod bolt, and why it is the rod.

Rod WHYYOUNOSTAYINBLOCK

because boost.

this made me nearly cry lol

glad your getting things sorted and getting it back on the road =D

had my man look at the photos and he said he can see what looks to be the start of a fatigue failure on the bolt, if you want a conclusive answer then he would want to put it on our S.E.M (scanning electron microscope) to confirm it.

looking at the other photos he said he would need to see the other angles of looking at it.

The guy is amazing at his job- been doing it over 40years. we test loads of our parts to destruction and look at failure modes and all sorts.

if you want an answer, give me a shout and i can find it out for you with some very nice images of the failure under the S.E.M

Edited 12 July, 201214 yr by KiZ

Would be interesting to see what he thinks, the problem as with most big failures, is ends of components get peened over after failure, and the aftermath of twisting/distortion paints a different picture, our metrology lab at work can give some fantastic images of failed grain structures, but the root cause isn’t always clear.

My reason behind the rod bolt not letting go first is simple, I don’t rev the engine much harder than stock (200rpm higher rev limit) and the forged piston/pin is lighter than its cast counterpart (from memory) so the stress on the rod bolt is actually fairly similar to stock.

My cylinder pressures however are ~ 55% higher! So I think it’s fair to say the rod is much further away from its FOS than the bolt.

It’s not a massively wild assumption to make, that the rod bent/snapped and fouled the block, snapping bolts and putting the block face(s) through. Also I’d expect much more piston/valve damage if the rod bolts had gone first.

I could be wrong and the rest of them could be loose- indicating they’ve stretched and are in fact beyond their limits.

Were they stock bolts anyway yeah?

Lots of people tend to upgrade to the ARP stuff not even going as mad on the engine like you have, IMO the rods and bolts have withstood a lot of shit, regardless of factors of safety etc, its going to be stronger now anyway, I dont at all see this failure as a negative, apart from the bank balance :p

Did you try that rad place?

yes- we see a lot of twisted aftermath! its the experience of knowing which is key isnt it, which is what my man would bring to the party as i wont be any help hahahaha.

he did say with high tensile bolts it only takes a small part to make the hole thing go bang in 1 go, which is why he wants to see it in more detail- he can tell if it was a forced break or the start of the events.

I've seen some awesome failures on aircraft wheels which have been put down to things (and then proved) which i wouldnt have even thought about.

So, time for an update. I have the Club Polo trackday booked at Blyton in a few weeks time, and BVF was falling on my birthday weekend, and I'd just shat my engine fairly comprehensively.

Sat 14th I picked this up from Surrey:

Saved some time as it came with a 1341cc bottom end (but no BVH).

Already had stuff booked that weekend and Monday, so that basically gave me Tuesday- Friday lunchtime to strip en engine out the black G, rebuild with forged rods and a BVH, get all the rebuild parts, repair my leaking ally rad, put it in the car, and drive to BVF. Simples eh? Quickly filled my holiday sheet in on the Friday, and told work I'd see them in a week...

Here in, lies the tale, of the engine I have aptly named, 'the bastard'.

So we start on Tuesday, engine out, gearbox split, and head off... to find its a stock head, bugger. Quick call to previous owner and PeteG40 sees me with some cash back, and me due to pick a new head up from Pete (thanks Lewis/Pete).

Spend the rest of the day splitting parts off my failed 1341cc motor. That evening I drive up to collect the head from Pete and have a brew.

Wednesday- parts arrive from Germany, and rods/bolts are already here, so split the new 1341cc further and take rods from pistons, install new rods. Start to put new rods back in bottom end, torquing them up happily (ARP torques not VW), and SNAP.

Fuck. Game over.

So a call to the supplier and some head scratching later, I realise I've been an utter rainman and torqued them up to the incorrect bolt spec. 15lbft too much. With my background this is an epic failure. Call back to supplier, £80 later, lesson learnt, don't be a smart arse and read instructions properly.

Removed the other bolts, which had started to neck, they're now on my shelf of broken shit.

I didn't take many pics over the next day or so...

Thursday comes, and rod bolts arrive by courier about half 2. Hmm, leaving Friday lunch looks highly doubtful! Anyway, put everything back together and find on Thursday night, 'the bastard' strikes again, this engine can't like the thought of 1.5bar up it's arse or something... fighting every step of the way, 2 cam bearing studs pull. Arse, they're M7 and need helicoiling, not a problem I've got a kit as this is a common problem, kit is at my old unit 120miles away. The Bastard strikes again.

So I get everything back together anyway, and figure I can sort it Friday, this is 7hrs of work:

I finished about 10.30pm Thursday night, engine still not fired/checked.

5am Friday morning, drive to Chelford, collect Helicoil kit, tell myself I'm mad, and drive home. Helicoil both studs, torque/angle them and they're good, sweet! Fill with fluids, and then fire it up. Running on 3 cylinders, arse, it's half 12 now, should be leaving in an hour for BVF.

Whip the plugs out, carbon deposit stopping cyl 1 firing, sound. Back to the full 4 now. Time it up and chuck the tent in the back, have a shower and wonder what I've not torqued up...

Andy gets home from work, we load the car up and leave about half 2 to meet Pete and Sam and convoy onto BVF. Car starts smoking.... hmmm, I did wonder where all the oil from my bottom end went, most of it seems to have been soaked into my manifold/downpipe wrap, que smoking for the next 50miles whilst other road users look generally worried.

Arrive at BVF, beaming. It's my birthday weekend, and my car and mates are there, sweet!

I was utterly shattered all weekend, but well worth it. Currently got a boost leak, but no other problems!

See you at Blyton in a few weeks, I need to put some more miles on it before then, will hopefully be back on full boost by then too (still quicker than a 'Rado G60 at 0.9bar)

Yoof

Hahaha epic, see things can be done quickly! Takes some people a year to bolt an AFH in haha

YEAH BOYYYYYY gwarn yooofyyyyy!!!

Wow, good work. You trully are mad, as you so thought.

Whats your back ground then Yoof? Only you mention you should have known better when torquing up those bolts. And also, where can you get ARP stuff from for a polo?

Engine development engineer, formerly a test engineer for Bentley and I now work for the Indians :-)

Me too :( hahahah.

You down at Gaydon at the min?

Awesome determination pete, bet your chuffed!

Looks great too, how much power was the G60 putting out then?

Me too :( hahahah.

You down at Gaydon at the min?

Not for any length of time this week, why?

Max- No idea, just met him on the M42!

Ah right, i thought you meant you new the guy. I would have thought it would have been worlds quicker than a G60.

Was just wondering mate!

Glad youre back on the road

You gonna up the boost now its stronger?

Edited 24 July, 201214 yr by harris.racing

I guess you'll be right on the edge of detonation with that boost pressure won't you pete?

No point winding up the boost so far you have to decrease spark advance or majorly increase inlet temps to ward off det.

epic!!

come do mine if you want? ull have it done in approx 5 mins

Good stuff! :-D

Excellent Busy man, all whilst still posting bits out off of the Black breaker :p

Hope to see it soon :-)