POTD- PROJECT OF THE DAY: What Did You Make In Your Shop Today?

GoceKU said:
Yesterday i got a call from my brother, the diesel octavia is at a mechanic to get a new EGR but he seems to blow up the engine. In the last year my brother sunk lots of money in this car full paintjob, new lights, new brakes, suspension, and about 2 years ago i change the engine with a very low mileage one also it got a new turbocharger closely after that. So i went there with my little niva, the guy changed the egr valve and changed the vacum line from the vacuum pump to the booster then decided to take it for a test drive. Drove it up a hill and by his description the engine run away (diesel runaway). He managed to get it shut down in gear but from the marks and the tire, he was doing a one wheel burnout for 1/4 mile and on the other side there was a black stripe from the exhaust. I took the pipe from the intercooler off and about a liter of black engine oil come out. Check the engine oil there was non, so he added old oil and we fire it up it was smoking and knocking the knok changed sound with pressing the clutch, i took it for a test drive it was definitely hurt. Left there, talk to my brother and went back and tow it home because when it cool down it would even start. From paste existence sounds like a bent connecting rod, i immediately got to work took the oil pan off there i could see at least one conrods was sideways. But before buying parts i decided to get the conrods out so i can mesure them. I work all night but wasn't able to lift the head with the turbo by myself so i waited till today to get help with lifting it. Oh man what i've seen one piston is 5-6mm under the deck two centre pistons are melted, melted down to the piston rings. All 4 connecting rods are bent one is very bent. Crank looks Ok but the cylinder bores are scored, one gruve catches my finger nail deeply. This engine has a completely melt down, at this point i know it will need a complete new engine again, no way i'll trust any part of that engine. Now come time to who is going to pay for a new engine and turbocharger. The mechanic straight out said if you want any money you need to sue me, having dealt with people i made few phone calls and found out few people are already suing him but he has nothing in his name so no one can collect. This car may have to seat for a while i already have the abundant 12 valve to work on and about 12 more that constantly break down.
View attachment 443631View attachment 443632View attachment 443633View attachment 443634View attachment 443635View attachment 443636
Click to expand...
Seems consistent with when a diesel engine starts consuming crankcase oil by some failure mode. Somehow, it will begin to suck oil from the crankcase. Although you've already sai the tech has said (sue me", it seems a bit suspecious that he was working on the egr system and then the engine went into diesel runaway. An egr system doesn't typically pick up oil other than vapor, but it's hard to discount the mechanics actions (ie: working on egr) just before that type of destruction.....
 
On a long road trip this week. I think I managed to make more work for myself. One of those couldn't pass it up sort of deals on an arbor press, and a couple of Edwards vacuum pumps. Pumps work.

Press needs work. It was converted over to some other tool long ago, and needs to be converted back to a press. The rack was shortened, and now I've got to find or make a replacement. It appears to be a 8DP 20 degree angle rack (I think???). The width and depth of the bar are 1-1/4 square. I think the pitch depth is 1.125", but not sure. Based on what I'm finding blank rack isn't real cheap. May just have to set up the CNC mill to make one.

McMaster has one that would work if I could shave 1/8" off each dimension. That might be the way to go. Less time to machine than machining the teeth from scratch.



MoreWork.jpg
 
dkemppai said:
On a long road trip this week. I think I managed to make more work for myself. One of those couldn't pass it up sort of deals on an arbor press, and a couple of Edwards vacuum pumps. Pumps work.

Press needs work. It was converted over to some other tool long ago, and needs to be converted back to a press. The rack was shortened, and now I've got to find or make a replacement. It appears to be a 8DP 20 degree angle rack (I think???). The width and depth of the bar are 1-1/4 square. I think the pitch depth is 1.125", but not sure. Based on what I'm finding blank rack isn't real cheap. May just have to set up the CNC mill to make one.

McMaster has one that would work if I could shave 1/8" off each dimension. That might be the way to go. Less time to machine than machining the teeth from scratch.



View attachment 443704
Click to expand...
Nice finds!
 
Saturdays job, counterfeit $2 coins
coins.jpg
Actually for my daughters market stall, She uses a bubblegum dispenser with trinkets and a couple of $25 earrings as a lucky dip.
The tokens cost $5. First time Sunday and very successful.
 
great white said:
Seems consistent with when a diesel engine starts consuming crankcase oil by some failure mode. Somehow, it will begin to suck oil from the crankcase. Although you've already sai the tech has said (sue me", it seems a bit suspecious that he was working on the egr system and then the engine went into diesel runaway. An egr system doesn't typically pick up oil other than vapor, but it's hard to discount the mechanics actions (ie: working on egr) just before that type of destruction.....
Click to expand...
Having time to talk to couple more people, the mechanic misdiagnosed it. The complaint was an oil leak, the turbo charger has blown a seal and started to push engine oil in the intake. The mechanic instead of tracing the oil he seen oil leaking from the EGR valve and sold my brother an egr valve. When he took it on a test drive he probably pushed it, the turbo feed engine oil in the intake and caused a runaway, this is the best theory i can come up with, i did take a ECU dump the engine seen 8700 rpm and the temp at 210 degrees celsius, not sure how it measure that. I'm suprase the conrods stay inside.
 
GoceKU said:
Having time to talk to couple more people, the mechanic misdiagnosed it. The complaint was an oil leak, the turbo charger has blown a seal and started to push engine oil in the intake. The mechanic instead of tracing the oil he seen oil leaking from the EGR valve and sold my brother an egr valve. When he took it on a test drive he probably pushed it, the turbo feed engine oil in the intake and caused a runaway, this is the best theory i can come up with, i did take a ECU dump the engine seen 8700 rpm and the temp at 210 degrees celsius, not sure how it measure that. I'm suprase the conrods stay inside.
Click to expand...
Ah yes, bypassing turbo will cause a runaway.....
 
Did some brass casting today.
All old plumbing bits but no chromed parts, I did get it too hot but the mold filled.
filled.jpg
cooled and removed, the underneath with the bottom feeding runners etc
cast2.jpg
The parts I want, they look a bit gnarly.
cast1.jpg
cut all the risers and runners off and it looks solid, the feed sprue shrunk hollow.
runners-cut.jpg
The middle one of the top 3 was turned down to finish the brass head for my lead and brass hammer.
finished-hammer.jpg
However there was a shrink cavity in the middle but I drilled it out and tapped M12x1.25 for a threaded shaft to hold the brass section on.
I dont yet know if the other two disks have any shrink cavities.
 
You must log in or register to reply here.
Back
Top