Black-Hawk

iTrader: (4)

Nic, The moose's lwb shogun just had exactly the same head/gasket fault, so he binned it and treated himself to a stunning swb warrior in silver to replace it

simb 2

iTrader: (3)

Glad your getting it sorted, been down this road before and always difficult when your shelling out money on "maintenance", always best to spend a little more and get some gain out of it.

There will always be future mods and you don't want to look back and think, wish I did it that way now! You can then drive the car with peace of mind knowing the engine will take it

Simb

Rally fan 555

iTrader: (7)

Glad you found out what was happenning, even if it was THE hard way - great shopping there Ty, hope to see it back soon

The Stitcher

iTrader: (12)

nice list you have there ty should be quite a motor when its all finished hope to see it back on the road soon and getting that great camera back out with lots of new pics of the new and better than ever spec c

The Sheep Worrier

iTrader: (2)

Glad you've found the route of the problem there ty, bet it was a bot of relief(if at all possible) so see it damaged and there was nothing else. Cracking shopping list, growing all the time with you!
hope she's sorted out soon enough for you so you can do a bit of crusising in this nice sunshine weve been blessed with of late, shades on, ABBA on full whack, and elbow hangin out the window!!!
Good luck with the proj and keep us apdated!
Rob

bluerigster

iTrader: (9)

I doubt very much the warped head was the cause of the head gasket failure, it's more likely the warped head was a symptom of the gasket failure due to the engine over heating once the gasket had failed.

The initial cause sounds like one of the heads lifted due to a stretched head bolt. As this would only occur during the turbo starting to boost and cause a hesitation and whlist off boost and at idle etc the car wouldn't show any signs of a head gasket failure, until eventually the engine over heated and warped the head.

The stretched head bolt was most likely caused by a boost spike as the bolt or bolts were subjected to a force greater than their tensile strength. Then once the bolts had passed their elasticity range they lacked the strength to secure the cylinder whilst the engine came on boost.

Good luck with the new Ty

KJD Mk1

iTrader: (3)

Quite a shopping list

Any details on the reverse scoop

The Sheep Worrier

iTrader: (2)

[quote=bluerigster;9935725]I doubt very much the warped head was the cause of the head gasket failure, it's more likely the warped head was a symptom of the gasket failure due to the engine over heating once the gasket had failed.

The initial cause sounds like one of the heads lifted due to a stretched head bolt. As this would only occur during the turbo starting to boost and cause a hesitation and whlist off boost and at idle etc the car wouldn't show any signs of a head gasket failure, until eventually the engine over heated and warped the head.

The stretched head bolt was most likely caused by a boost spike as the bolt or bolts were subjected to a force greater than their tensile strength. Then once the bolts had passed their elasticity range they lacked the strength to secure the cylinder whilst the engine came on boost.


That's exactly what i thought it was!!! have got very limited knowledge me, but what your saying deffo makes sense even for a numb nut liker me!!

Rally fan 555

iTrader: (7)

I did tell him it was that some time ago

The Trooper 1815

iTrader: (31)

So in other words it was "fubar'd"

DYL 4N

Can I be really picky and correct you, if the bolt had reached its UTS as you suggested then it would be out of its elastic limit completely. You don't want your head bolts to be elastic as all that is why stretch bolts are used to take them out of there elastic zone. Thus why you should never reuse head bolts.


Buy I do agree its a head bolt failure rather than a head. Just thought id explained myself

Cannon Fodder

iTrader: (100)

I was just going to get the heads skimmed and 'bang on' just what was required but then I thought about uprating the rest of the engine, and your right I'd be kicking myself down the line if I hadn't of done it now.

Well it will take longer but I'm not in a rush to get it back, not yet anyway.

Cheers Lee, I hope it will be capable of handling up to 600bhp but it will never be run to that level but the option is always there but 450-500bhp is my goal.

Cannon Fodder

iTrader: (100)

The shopping list is now complete I hope, ABBA if I ever catch an ABBA disc in my car I'll use it as a frisbee.

So then chicken or egg?

I'll see if I can find a link to the scoop for you.

Cannon Fodder

iTrader: (100)

I know, I remember the two of you telling me...

Exactly.

STI Glenn

Looks good Ty ,kept that quite though

All the best with it ,better keep this one a while

bluerigster

iTrader: (9)

I wasn't suggesting otherwise, I think you're confusing elasticity with partially plastic! I mentioned the bolt had past it's elasticity yeild stress point (tensile strength) and stretched so was starting operate in it's partially plastic range. I never suggested the bolt had reached it's ultimate tensile strength if you read my original post.

I accept your apology in advance Dylan. ;-D

Cannon Fodder

iTrader: (100)

Kev, here's the link for the CF reverse bonnet scoop.

http://cgi.ebay.co.uk/2004-05-WRX-ST...item335de54d60

redwards

iTrader: (6)

As they say, onwards and upwards. Should be a nice block when it's all done.

Cannon Fodder

iTrader: (100)

I'd been thinking about it since the car had it's initial problem and if your going to do it then you may as well do it properly.

I won't be looking to change for a long while yet Glenn, I'm not doing all this for someone else's benefit.

It certainly won't be lacking in terms of potential for future power upgrades.

KJD Mk1

iTrader: (3)

Thanks Ty

ozzreid1964

iTrader: (32)

well m8 it will be a wicked motor when done will be nice to see you back on the road ty (and not in a van)looking forward to seeing the front bumper and bonnet scoop as well

Cannon Fodder

iTrader: (100)

Cheers Ozz, I've dropped the crankcase over to Advanced Auto's today for a deck skim and for the cylinders to be honed/re-bored in order to accept the forged pistons.

If anything I have gone and over specified the components (to allow for any future power upgrades) and the engine should be able to handle 500bhp easily with the option to go up to around 600bhp if I want to later on.

STI Glenn

600 mmm can i have a ride

"Taylor"

iTrader: (2)

Crazy hound!

DYL 4N

Look out Jarvis.

Cannon Fodder

iTrader: (100)

Not for a while yet Glenn but once it's all sorted you can happily have a go.

Well may as well go the extra bit further...

I don't know what you mean.

STI Glenn

Nice one Ty ,when car back on road

Cannon Fodder

iTrader: (100)

Well I've picked the block up today from Advanced Automotive after they did me a big favour and managed to get the machining done.

The block was warped and needed to be skimmed by just under 0.3mm at the deck surface, the bores have been honed and re-bored to accomodate the 92.5mm Mahle forged pistons.

The final spec list for the engine is

Cometic Head Gaskets
ARP Head Stud Conversion
Mahle Power Pack Plus 2618 Forged Pistons
Manley Sport Forged Rods With ARP Bolts
ACL Race Big End, Main And Thrust Bearings
RCM Water Pump
Uprated Thermostat
Advanced Automotive Inlet Manifold Spacers
Carl Davey Header Tank Spacers
Mocal/Setrab Competition Oil Cooler
Hyperflow Coolant Resevoir
Perrin Oil Catch Can
AP Racing/STi Group N Competition Clutch
Harvey Smith Turbo Blanket
APS FMIC & CAIK
Kakumei CF Reverse Bonnet Scoop
Full Samco Engine Hose Set

And I hope nothing else except...















































An upgraded twin scroll coming soonish.

R1CH D

iTrader: (8)

Nice one ty, not long now then. Then boring old running in.

Cannon Fodder

iTrader: (100)

I know it's going to be torture running it in, I had thought about taking back and for to work but I think I'll take some trips up and around Mid Wales plus a long drive to North Wales to rack up the miles.