New Engine, Lots of Smoke

[FlyTDI Guy]

Update: Cylinders #3 and #4 both had holes in the same spot because of the porting. The machine shop also found a broken outer spring in cylinder #1 (which I had not taken apart). Maybe the holes were a blessing in disguise. I hope to be back on the road in a couple of weeks.

Back on the road again. Immediate cold start with essentially no smoke. No wretched stink anymore. Thanks to everyone for the help.
Next step is to get these insane engine/trans mounts removed and get some proper software loaded.

Been lurking w/interest. Could you elaborate on exactly what you ended up with? Is the head repaired, new, re-ported but less-so??? Details please...

 

[arne487]

The head was repaired. One tiny TIG weld on each of the four intake ports (the other two were also thin).

Steve took care of everything for me including shipping and gaskets, etc.

 

[shadowmaker]

I have always used polyurethane windshield glue to stiffen original engine mounts. Sounds cheap and guess what, it really is.

Just clean old bushings really good and use some rubber adhesion additive. You can go wild with the glue depending how much torgue it needs to hold. Let the glue dry atleast two days. It will have some annoying vibrations for a day or two, but after that none.

Have tried aftermarket bushings too, but every time have gone back to windshield glue. Have worked fine for 600-800Nm, well maybe 800Nm could do with some additional gas shocks.

 

[Thetdiboi]

Hi, what main bearings did you use for the bhw crank in the alh block? Alh main bearings or bhw main bearings? I heard they are not the same and they re different items on idpsrts.

 

[arne487]

I bought the bottom end from someone who built it but never installed it, but "BHW crank in the ALH block for the larger bearings" is what he said.

 

[Thetdiboi]

So it requires some kind of machining?

 

[arne487]

I'm pretty sure the main bearings are bigger on the BHW shaft and ALH bearings thus won't work on a BHW shaft.

 

[Thetdiboi]

So i would have to machine the bhw crank to fit the smaller journal width of the alh block and bearing?

 

[arne487]

I have no idea. Maybe the main bearings are the same size and only the rod bearings are bigger? You'd probably find a more qualified answer starting a new thread in the power enhancements area. I didn't build the block myself, so I'm just guessing.

 

[BustedBolts]

Bhw and alh have the same size main journals, the rod journals are different tho.

 

[TDIMeister]

Hi, Arne, did you get the engine and tuning completely sorted out? How about any dyno testing? Very interested to see how the camshaft affects the powerband.

 

[arne487]

I never did get a dyno test with that cam in there. Repairing the holes in the head fixed the smoke, but several years later one of the valve guides started leaking oil badly (turned out the whole guide was wobbling in the bore). My wife had just had twins, so I sent it down to Anuthee in Golden. He suggested just swapping the whole head out since it's been nothing but trouble. I wasn't about to argue with an expert, so now it's a Colt Stage 3 cam in a brand new ported head. It's been my daily driver since 2008 and still runs great, despite any issues over the years.

 

[TDIMeister]

Ok. Do you know whatever happened with the cam?

Congrats on your twins, btw. I have 2 young kids myself.

 

[arne487]

I sold it to another member: https://forums.tdiclub.com/index.php?members/mozambiquer.435698/