Cracked a Piston #1 cylinder.

The beginning to a long day and many to come . Tear down at home . Engine tear down next on the list for today. Here are some pics of the procedure so far . More to come today.

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Notice the broken motor mount bolt from jumping the truck at Glamis . :D

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Heads coming off today. More pictures to come of motor.

Paying the dues for a good Floggin of the truck ......

This wont stop here , just going to go bigger on the HP and components to hold onto it.


John

John, good luck with the build, hope you get the truck on the road soon.

Thanks Chad.

Motor coming apart as we speak.


John

atta boy !!!!!

Wow, thats a lot of work bud! Good luck!! It takes a hell of a man to drive a big truck like that and ramp it on the dunes!:cool:

looks like some project, good luck!!!

How many miles did you put on it before the issue?

Best of luck with the build.

Good luck with the build......what improvments do you plan on doing to it while its apart?

Awesome pics John. While you got it apart...see if the turbo is the same on our trucks as compared to the 3/4 and 1 tons.

Let me know if you need any help.

Heads Almost off . Pics tonight .

John

How many miles did you put on it before the issue?

Best of luck with the build.

60k on truck , 15k on this motor. Pushes a head gasket at 45k.

Cracked Piston is the guess . Right foot is the problem . :D

Excessive EGT's for long periods of time is the culprit here.

Damn Sand Dunes ;)

Unless I just got unlucky and had a weak piston . 1 more hour and I will post some pics of piston w/ head off. And fingers crossed on cylinder wall damage. Will know soon.

John

Good luck with the build......what improvments do you plan on doing to it while its apart?

Rods and Pistons a minimum .

Thanks for the reply, I need some luck right now .

5 minutes from seeing cylinder wall . :)


John

well how is she?

The suspense is Killing me!!

ok man your 5 minutes are very up!!!

didn't your mom tell you not to jump your 12,000 lb truck. Looks like you are going to have some fun for a few weeks. Got a buddy up here with a Kodiak who wants compounds next year cause he is doing the trans this year. Good luck with the build and keep those pics coming

johnny i like the pics but i really like the truck your driving untill it is done

OK verdict is in pics coming now . Cracked Piston Cylinder #1

big crack with hole , left a quarter sized patch of aluminum on cylinder wall .

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Loading the cracker piston shots ..... coming in a minute .

John

here they are .....

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There is a quarter size patch of aluminum on cylinder wall . Other than that it looks good , no real scratches .

Now the ? is . What is the next step . Getting piston out and motor on the stand to turn over and get pan off. Tomorrow I will get this done.

More pictures to come.

And it looks like I have a cool new avatar pic :mad:
John

Lucky thing it is under warranty. JK Johnny.

That is exactly what you thought it was. High EGTs being the culprit??

That's a present you would like to give back. I can't tell for sure in the pics but do I still see crosshatching in the other cylinders?

yes cross hatching still in all cylinders , even cracked one .

Best Pictures of the day :D:mad:

http://www.dieselplace.com/forum/attachment.php?attachmentid=59114&d=1204424186

http://www.dieselplace.com/forum/attachment.php?attachmentid=59115&d=1204424186

http://www.dieselplace.com/forum/attachment.php?attachmentid=59117&d=1204424186

Oh well ,this is what you get when you flog 12k with a race tune ):h):h

Its not like I didnt know this could happen .

More pics of rods soon .

John

Nice pictures John, that's probably about what you expected to see. Hopefully the cylinders look decent, it's tough to tell from the pictures. Keep at it man :)

Nick

Was just over at Johnny's house before work...

Seeing that in person is something.

Johnny, let me know if you need any assistance Sunday-Wednesday.

Wow, thanks for taking the time during all this to get us all those great pictures. Can't wait to see it all go back together bigger and better! :thumb:

Cylinder wall looks good except for the small quarter size patch of aluminum on it. Hoping a hone and ball hone takes it off . And then " we'll see " is the answer of the day.

Rods are the next thing to look at . And then decisions on what to do next.

Blksmok , thought I should have something to show for all this work . So I broke out the camera .

John

So what all is different from your motor compared to a 3/4 or 1 ton. Any turbo dif. Are the up-pipes and DP the same or different?

What pistons are you thinking of going with?

Stock pistons cut down and radiused . Tim Z

And its the same motor as 2500hd Colby , the manifolds and up pipes are different but everything else is the same .

John

Stock pistons cut down and radiused . Tim Z

And its the same motor as 2500hd Colby , the manifolds and up pipes are different but everything else is the same .

JohnCool, who does that type of machining? Is there a company selling modded Stock pistons you know of?

Guy Tripp at SoCal Diesel Performance should be able to do this I think.

John

I am amazed at your progress Gasuout! You got balls for tackling that job. So what did that take you...a few hours? I'm impressed, and know that there are many more members equally impressed. Great job, sorry to see ya down like this.

Thanks , It was a chore and Im on my 4th day at it.

Making alot of headway though . Somebody had to tackle it . :lol:

Now if I can remember where it all goes.

Kept hoping it was all a bad dream . But no , would wake up and come out to reality at what I had done every morning . ):h ):h

John

John this was just your trucks way of saying I need compounds:D PLEASE. Maybe a modded stock unit mated with a GT45 or BIGGER

Wow man thats some carnage. Basically your attributing this to high egt's and general hot rodding the hell out of it?

Im open for any possabilities right now. This is the time to do it .

Twins is a good way to get egt's down thats for sure. But a nice single set up would be good also .

Still up in the air . Time will tell .

Anybody looking for a test truck for parts durability testing let me know . :lol:

John

Wow man thats some carnage. Basically your attributing this to high egt's and general hot rodding the hell out of it?

The high egt's Im running could have played a role here , but Im thinking more just the big HP cracked a piston . No erosion at all , just a huge crack and a hole where it blew through .

Not really sure , the rest of the pistons look fine .

Rods coming out tomorrow .

Guy Tripp at SoCal Diesel Performance should be able to do this I think.

John

I'll get you fixed up John. :D

Thanks Guy ,

Im going for it , got it torn down quick.

Not liking the cylinder bore . Doesnt look good . Hard to tell in pics .

Almost down to a short block .

John

Thanks , It was a chore and Im on my 4th day at it.

Making alot of headway though . Somebody had to tackle it . :lol:

Now if I can remember where it all goes.

Kept hoping it was all a bad dream . But no , would wake up and come out to reality at what I had done every morning . ):h ):h

John
man your slow john i did it a day :P now for that rebuild is going to take a while......

Sorry to hear about the truck John,Looks alot easier to work on then the 2500hd's, turbo swap would be alot easier with that tunnel removed.

Great pics... I know what a PITA it can be to try documenting as you go.
Hope you get everything rebuilt soon without major issues!

Never realized the 4500's have a doghouse either.

Hopefully she'll be back on the road soon! I assume having the truck for the drags/bbq this weekend in Fontana is outta the question?

Thank you for documenting this! Great truck you built, hope she is back in shape and on the road soon...

what kind of egt's were you seeing regularly? it must see higher normally just due to the weight over a p/u. could not imagine what a race tune will produce.

damn john.... wicked pics. keep em coming. hope your build goes well.... :D:thumb:

Piston is out and cylinder looks good except for the aluminum smeared on the cylinder wall . Have a pretty nice trophy . Piston is cracked side to side all the way through . Only held by underside of wrist pin area. Interesting how it blew out through the corner of the bowl in the piston . Hole is size of pencil. And cut it's way into area on side of piston at wrist pin opening . Another hole . This was a perfect way for the material to get mashed onto cylinder wall.

The flame cut a hole through the top of the piston and blew out the wrist pin area . Cut right through the oil ring. The pieces of piston are smeared on cylinder wall .

Trying to figure out how to get it off .

More pics in the morning .

John

wow, nice pics. hope to see that beast back up soon johnny. give me a ring if you need help in anyway im on nites so im avalible all day.

what kind of egt's were you seeing regularly? it must see higher normally just due to the weight over a p/u. could not imagine what a race tune will produce.


The egt's move much quicker than 2500 . Not unusual for me to see 16-1700 on a quick burst level 10 hot tune. Hotter if you hold it there.

I still think that I just had a bad piston . The rest of the pistons and even the one cracked look fine as far as heat goes.

It really looks like the piston is using the bowl as a contained explosion. And splitting the piston in 2 halfs. Doesnt make sense why this happened.
I was on flat ground getting on it much less than normal and had only been at 1600 for a moment when piston cracked. There is no erosion on any of the pistons at edge of bowl by injector spray patterns. Even the cracked one . Maybe it's the weight of the truck holding the piston back against the cylinder pressure.

i wouldent exatley call this flat johhny :)http://www.dieselplace.com/forum/attachment.php?attachmentid=57720&stc=1&thumb=1&d=1203472416 (http://www.dieselplace.com/forum/attachment.php?attachmentid=57720&d=1203472416)

What about water?
Running any filtration? separaters

In the days of old, a teaspoon full of water down the carb created a nice little explosion enough to clean out the carbon of the cylinders
Not sure if it would have a similar effect with diesel, Maybe?

Probably be quick job, if you didn't stop and take all the pics
Well appreciated though!!

i wouldent exatley call this flat johhny :)http://www.dieselplace.com/forum/attachment.php?attachmentid=57720&stc=1&thumb=1&d=1203472416 (http://www.dieselplace.com/forum/attachment.php?attachmentid=57720&d=1203472416)

:lol: No, but I would call that 5 seconds before ...... whoa whoa Johnny shut er down . We have a problem ...... may day may day .

With Tommy (fire0021)and Jason (lbzrcks)off to my right giving me the throat slash signal with thier hands . And a look on thier faces like they just heard something very bad happen . I put it in park and revved it a few times ... thump thump , and Tommy is giving me the hand signal a few more times like no really dude I wasnt kidding shut er down .

I do like that pic much better than these ones though .
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Definately a trophy piston here !! :lol:

John :thumb:

Been carefully performing Mac Gyver surgury on the cylinder wall. Been trying to get the aluminum off. I have it down to just a lttle line of it. Im thinking this last little bit is buried in a scratch on cylinder wall . Thought it was worth a try to see if I could clean it up. Giving the compressor a break for a few moments . Been going at this cylinder wall for 2 hours very lightly with a small soft wire wheel . Looking good except for what looks like a small scratch with aluminum in it. Going back at it in a minute and will know in a bit if it's terminal .

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It's even smaller now than in the pics.

I know its crazy to do this near the cylinder wall , but Im pretty good with the die grinder . If I could get this off the wall I could hone the hell out of it and get a piston to seal . The bore looks good except for this crap on the wall . There are some marks from piston but no scratchs . And It cant get worse than it is now . Going to machine shop with block either way . Figured Id give it a try to get aluminum off wall .

My guess at this point is terminal cylinder damage and a bore is coming .

If I see it is done for , I will have this motor down to a bare block by tomorrow . And on its way somewhere for an attiude ajustment to all 8 cylinders.

John

LOL and you said i was crazy for wanting to use a dremil tool l:D

Well Im done . The aluminum is deeper than the wall surface.

The wire wheel was a good choice , it didnt leave scratches in the cylinder .

That dremil if I even flintched would have marked it up in my hands.

I have a little trench about 3/4 by 1/16 with aluminum still in it below surface . You can feel the depression with finger , and see a edge of shined steel on one edge from the brush. I was actually feeling suprised at all the aluminum I was getting off. And it was looking good till this last little strip.

Well Im out , going to start taking apart for machining . No reason to mess with it any further . Great more parts to keep safe.

Sooner it's all apart the sooner it gets all the holes bored .

John

Awesome project John!! and thanks for taking the time to document the whole thing for all of us to see too!!!

what are you driving instead of your 5500?
we should have a DP museum where members display $hit that broke on their trucks and photos of what they put their trucks through
It should be based in northern TX

How do the Rods and Mains look?? Curious to see how well they hold up to extra HP.

since you wont be driving to truck night, at least bring part of the Kodiak... the cracked piston.

I'd offer my bus pass, but you got that niiiice dually to cruise around in.

:lol: No, but I would call that 5 seconds before ...... whoa whoa Johnny shut er down . We have a problem ...... may day may day .

With Tommy (fire0021)and Jason (lbzrcks)off to my right giving me the throat slash signal with thier hands . And a look on thier faces like they just heard something very bad happen . I put it in park and revved it a few times ... thump thump , and Tommy is giving me the hand signal a few more times like no really dude I wasnt kidding shut er down .

I do like that pic much better than these ones though .
5936859369593705937159372


Definately a trophy piston here !! :lol:

John :thumb:

How do you tell when this happens? Just curious because it sounds like I kinda drive like you.:D

How do you tell when this happens? Just curious because it sounds like I kinda drive like you.:D

when all your frends around you start yelling at you to shut off your motor becuase its making god awful sounds and smells like severaly burnt stank oil :eek:

the loud knockin noise and your friend freaking out....

edit: what he said ^^^^ :HiHi:

when all your frends around you start yelling at you to shut off your motor becuase its making god awful sounds and smells like severaly burnt stank oil

that pretty much sums it up...except for kyle and his buddy woody they were busy cleaning off all the sand on them..

Its hit or miss , Ive been doing this for a long time with no issues.

You just never know , sometimes pistons crack . Im going to fix it and go at it again .

Just know that it can happen randomly . When I broke I wasnt even doing my usual flog job to truck up big stuff . I was just playing around in the small dunes . Since there was no aparant erosion to piston from previous harshing , then my take on it , random piston cracking .

Have even heard of trucks with small tunes with cracked pistons.

Could happen to anybody Hit or Miss

John

Hope you get her back up and running again soon!!

That looks like it took a long time. Good luck!

What's the current status Johnny? Is the block at the machine shop?

Block is torn down , and the status is not good . Gouge in cylinder wall is deep . Looks deeper than .030 or .060 is gonna clean up .

Looking for a motor . Or a short block .

John

Man that blow's!!! Is that a definate or is there still a chance a 60 over bore will take care of it?

From my motor experience its to deep . But still going to check .

That blows is a perfect way to sum it up.

John

From my motor experience its to deep . But still going to check .

That blows is a perfect way to sum it up.

John

No punn intended, Hope your luck changes for the better soon.

Thanks , it can only get better :thumb:

Jokes are the best way to get through all this.

wow, well johnny i hope you get everything going your way soon. ooh thanks for the help today.

John sorry to hear about your truck, my Titan is still down from months ago blew a hole in the piston too much boost, well call if I can help you out-Peace.

Hey John..there is a guy selling his LLY motor complete with 28,000 miles on it.

http://www.competitiondiesel.com/forums/showthread.php?t=23502

Hey John..there is a guy selling his LLY motor complete with 28,000 miles on it.

http://www.competitiondiesel.com/forums/showthread.php?t=23502 (http://www.competitiondiesel.com/forums/showthread.php?t=23502)


SCORE !!!!

dude the guy is down to $3500

That's a lot of worK! Good luck on the build.

good luck on everything that sucks that the motor is shot hope you find another that is cheap

Sorry to hear that John. Good luck with everything.

:thumb: Thanks

All is good . I'll get her up soon .

Just a random part failure .

John

My gaser Titan has been down since September blew a hole in the piston, taking long cuz all parts had to be custom made all forged internals means more boost hint hint John !
http://memimage.cardomain.net/member_images/1/web/2689000-2689999/2689828_5_full.jpg

How about throwing in a 7.8 with twin turbos?

John is there any progress report on the surgery?

Hey John when pulling your 2 car trailer do you ever get bugged by the DOT guys??? I just bought one like yours thanks for the heads up!

john
saw you bein pulled back into camp when i was at glamis over pres weekend. now i know what happened! Hope all goes well with the new build and hope you dont have to do it again

has anyone tried to sleeve a dmax? id think it would be ok if you werent pushing serious hp... but thats obviously a last resort.

good luck with the build

has anyone tried to sleeve a dmax? id think it would be ok if you werent pushing serious hp... but thats obviously a last resort.

good luck with the build

Johnny talked to some people about sleeving it, but I guess most people aren't talking about it favorably.

Hey, so what's the status?

I have 2 different motors going together .

One with a short block from Tony Burkhart that I will put together myself and get into truck as soon as it gets here and I can get heads back on it .

And a short block with PPE that will be going to machine shop in the near future as soon as motor lb7 gets here from Kansas for me to tear down , and then some serious hard parts . Will be a while for this one to get done.

I plan on putting PPE GT40-94 kit on truck and interested in trying one of these bigger VVT's to see what set-up delivers best drivability vs. lowest egt's .

I want to get another one of these short blocks from Tony . I think these are a real way to go for guys in need of a motor . The motors have standard bore and all new parts . Cant go wrong with one of these .

A real good deal for the price , and from a reputable person .

Id really like to Thank Mike L . for all his help behind the scenes .

And Thank You to :

Tony Burkhart for the Short Block coming soon .

And Jonathan Goodwin from Hline Conversions in Kansas for the LB7 coming for block to be used for the PPE motor .

And of coarse Joe from PPE .

John

One more thing ,

Id like to thank all DP members for thier support .

And to all my Socal boys for keeping my spirits up through the ordeal .

Thanks Guys it's made it easier and less painful . :thankyou2

John

Has anyone else noticed how boring its been since the Kodiak broke... Give me a holler if I can be of any help Johnny!

I'll cruise by with a 12 pack and watch you guys work on it! haha, and i'll bring a Big Gulp or something for you.

Your killing me . Or what has it been boring .

Just got back from Super Chevy Fontana , usually run the kodiak there .

Killin me being broke . I havnt been able to smoke out tailgaters in so long .

Doesnt look like Im going to be back up for a while .


Anybody want to buy a kodiak .......... hahahaa .


Johnny

Well, your lucky that you can get a built motor, I would love a built motor.

I have to build it , and install it .

You are still very lucky :D

You are still very lucky :D


???? why? Spending thousands on a engine is lucky? Weeks of having your ride torn apart? :confuzeld

I guess that is true, but still it would be nice to have it afterwards.

You are still very lucky :D

A built engine is only nice when you have planned for it in advance.

hahahaha exactly . It's been too long now , and the truck is my $$ maker .

Kinda catch 22 breaking it . And bad timing .

Need $$ can't make $$ :smashfrea

Johnny

hahahaha exactly . It's been too long now , and the truck is my $$ maker .

Kinda catch 22 breaking it . And bad timing .

Need $$ can't make $$ :smashfrea

Johnny


what ?!? :eek:

you mean the dropped dually or the bike cant handle the trailer weight the kodiak could??? ...... get outa here :HiHi:

it dont matter when it breaks, its always bad timing..... :D

Was hoping you were coming to Fontana with Mike . mmlmm

They both just made it to second round . tommy and mike

where you at johnny? so did you make it out there to fontana?

Was hoping you were coming to Fontana with Mike . mmlmm

They both just made it to second round . tommy and mike


wanted to.... had to work yesterday. :( ... next time, i guess.

anyone gettin vids of the runs??

wanted to.... had to work yesterday. :( ... next time, i guess.

anyone gettin vids of the runs??

I got some from Friday.

whats an update on the truck?

whats an update on the truck?

X2

I got some from Friday.


gonna pput em up??


x3 on the update.

you broke this with the stock turbo??

you broke this with the stock turbo??


Well, you should see how he drives that poor truck...:eek::D

you broke this with the stock turbo??

Yep, he did

Well, you should see how he drives that poor truck...:eek::D

X2 and he wasn't even really beating on it too much when it happened:eek:

Yes the motor was broke with a stock turbo at 32 psi on my ppe level 10 tune with 2 cp3's . I was on it pretty hard when it broke but no real load on it . I was in 2wd doing a little brodie in the sand and boom it let loose and cracked a piston . Could of been a stuck injector maybe , we will never know . Would have broke about 20 minutes later probably , I was heading for the big sand hill to flog the hell out of it for some video's .

Instead broke it before we could get some vids and had a shortend trip that day .


Well the update on motor is ,

Recieved a good block from a friend in Kansas . Had a broken crank but block was good .

LB7 block .... same as LLY . Had my 7 pistons +1 new one cut down by Guy Tripp . Had the bowls opened up but didnt cut the tops . Using my old pistons and my crank in good block . PPE is doing the machining on it . Block was standard bore and my pistons are 20 over. Boring block as we speak and working on some rods . Wanted some carillo's but finances are tight. was offered some LBZ rods from Mcrat Racing that im going to use if I cant come up with carillo's . Pat has offered to donate LBZ rods to my project . Pretty cool of him . Thanks Pat . Not sure how long this is going to take , but hopefully sooner than later .

Been working on getting another motor that is stock used to get in truck and get it on the road again. Its been to long without it . Need my wheels back up and running .

Im working on getting something in it as soon as possible , going a little crazy now .

I will be putting a bigger turbo on it also and some head studs too.

Johnny

Hey Johnny, hang in there and keep your head up, Bro. We are all pulling for ya. That is good to hear that McRat is hooking you up. Good move on putting a different motor in the Big Rig so you can get back to work. Gotta make money to spend it, right. Thanks for the update.

Thanks Bro for the uplift , im trying to keep the head up . Just taking longer than I expected . Being without the truck has been a little difficult , but it'll come together soon.

Having support from my diesel brothers sure has made it alot easier thats for sure .
Im feeling a bit closer now , last month it seemed like it was going to be Christmas before I got it going .

Thanks for all the Support from all you guys

:thumb:Johnny

did you get the truck up and going again ?

I want to see and hear a video with the new turbo....When you get it all back together. Next time I am in Cali, we'll have to line em up!

For sure Jerry .... you know I love to race . About time it's a Kodiak .

Johnny

Have you checked out Nick's rods? (that didn't sound good)

Duramaxtuner

they're not free but they are cheaper than Carillo and quite nice.

That might be what I go with , I like Nicks rods.

or LBZ rods . ??? Need to make up my mind quick .

Machine shop waiting on me .

Johnny how's the truck coming along. Let me know if you need help? I'll bring the Tequila!!!!!!!!

Sup brother long time no see . Some tequila shots sounds good . Waiting on machine shop still .

Will post when im getting closer . If your ever in the area give me a call .

714-514-3675

Johnny

Glad to see your getting closer Johnny.

Thanks Chad

Hurry up and build your engine already!

Hurry up and build your engine already!

:D

YA !!!!

What he said !

yeaaaaa LOL happy bday johhny

Is today your B-Day Johnny, If so Happy Birth Day! :D

Thanks the 16th . Motor going together now .

Hope it all goes well Johnny, have fun and take your time. Everyone is just pushing cuz you have been out of the game awhile and we want to see that BFT move again. It is a sight to see haulin' ass.

Been trying to get some construction at house done . Done now .

Waiting on parts has been like waiting on the machine shop .

Have even thought about taking it back apart and putting Carrillo's rods in it .

Can still do them , heads are off . Easy to pop them in

Slow assembly sucks but is the right way to do it . I know Im not far out .

Plan is honestly to have running before end of month . Maybe sooner .

Hope it all goes well Johnny, have fun and take your time. Everyone is just pushing cuz you have been out of the game awhile and we want to see that BFT move again. It is a sight to see haulin' ass.


so true... may have to make another trip back to socal to see it run. hurry it the **** up will ya..... :D:p::cool:

if you want carillos why are they not in there?

You will regret it later on if you do not use them now.

I know a guy that wants those LBZ rods - :D

Keep Pluggin' Man...Your over the hump, and their's fire-in-the-hole at the end of the tunnel.

BTW...If your rods were OK for how you've been hammer'n it I'd stay the course!

Save those Carrillo's for the the next time...when you punch-it-out a few cubes, etc.

Definetly Head-Studz though...

Ciao

Keep Pluggin' Man...Your over the hump, and their's fire-in-the-hole at the end of the tunnel.

BTW...If your rods were OK for how you've been hammer'n it I'd stay the course!

Save those Carrillo's for the the next time...when you punch-it-out a few cubes, etc.

Definetly Head-Studz though...

Ciao

if i'm not mistaken this will be engine number 3 the kodiak will have.

Don't think he wants to do this again...

if i'm not mistaken this will be engine number 3 the kodiak will have.

Don't think he wants to do this again...

yea but #1 only blew a head gasket # 2 cracked piston 3rd times a charm keep what you have stop making exscuses put it togehter you dont need carillos. and you know it would have to go back the machine shop. get it going or i coming to the house taking your motor and buliding it for my self :D

HAHAHA . Come get it !

I'll put you to work with the torque wrench .

I at least upgraded to lbz rods from lly's . I will run them .

Back to work , putting on stand now .

johnny

HAHAHA . Come get it !

I'll put you to work with the torque wrench .

I at least upgraded to lbz rods from lly's . I will run them .

Back to work , putting on stand now .

johnny

good to hear buddy !

HAHAHA . Come get it !

I'll put you to work with the torque wrench .

I at least upgraded to lbz rods from lly's . I will run them .

Back to work , putting on stand now .

johnny

will see im on my way.
stew return my dang call :D

will see im on my way.
stew return my dang call :D

i tried, you don't answer for me :-)

Good To Hear Its Going Back Together........
Im Close So Let Me Know If You Need Any Help Buddy.....
Sam

Good To Hear Its Going Back Together........
Im Close So Let Me Know If You Need Any Help Buddy.....
Sam

you coming to the night of trucks this friday?

Im Gonna Have To Pass.. Its My B-day And My Wife Already Has The Night Planned....... You Guy's Meeting Every Friday?

HAHAHA . Come get it !

I'll put you to work with the torque wrench .

I at least upgraded to lbz rods from lly's . I will run them .

Back to work , putting on stand now .

johnny

Are you sure?:p:

he now has all the tools no more excscuses get tht dang thing done it sure looke dlike it was on the cherry pcker still thhis morning

Where and when are nights of trucks held???

Im Gonna Have To Pass.. Its My B-day And My Wife Already Has The Night Planned....... You Guy's Meeting Every Friday?

Where and when are nights of trucks held???


checkout the southwest section of this forum for more info.


1st and 3rd fridays of each month

we are currently meeting at imperial/beach at the southeast corner where walmart/panda express / baja fresh / pasta bravo....

7:00 pm

Any updates?

Been working 15 hour days . Just need to finish . I wish I had some better news for you guys . Even working the July 4th and Sat and Sun this weekend .

Soon , very soon . It will be back in action .

Johnny

Been working 15 hour days . Just need to finish . I wish I had some better news for you guys . Even working the July 4th and Sat and Sun this weekend .

Soon , very soon . It will be back in action .

Johnny

Johnny works as an Exotic Dancer......goes by the name...Big John.:p:

Come on Johnny, skip a few of the table/lap dances, and drop that motor in the truck.

John? http://www.greatlakesoffshore.com/greatlakesoffshore/images/smilies/pole2.gif:eek::think:

:lol2::lol2::lol2::lol2:):h

thats some funny chit there . :lol:

do you still use the stock injectors?

Yes I do . Until you exceed 500hp you would use stock injectors. When you go bigger you would still use the stock injectors with extruded nozzles . The reason to go with these is to shorten pulse width and get the egt's down some and quit chasing the piston down the cylinder with fuel . I will be going with extruded nozzles here in the near future . Brayden from Fleece Performance will them done as soon as I send them to him .

How's the new truck ?

Johnny

Johnny I have a friend that is getting married end of next month. If things are still tight let me know, I'm sure he could use some sort of entertainment for the bachaler party.




Ok I'm done with the stripper jokes.

I thought I saw him in a chipindales commercial. Or was it in the the thunder from down under commercial???? :nopics: Come on johnny. Put the tong or g string on hold for a weekend and finish it.

Funny chit in this thread.. but also sad at the same time..

Funny chit in this thread.. but also sad at the same time..

Yep...big John is a good guy with a great sense of humor. I knew he can stand a bit of joking around, and his motor is finally coming together! Can't wait until you get her back on the road and I am anxious about what all you are going to do to the finished product.

Alright , I have all my parts and the motor is going together now .

Should have the build finished by the weekend . I will take pics and post progress .

Then getting it back in the truck is next .

Hoping to make the sled pulls for August .

:lol: the thought of me in a G-String is just plain scary .

But if the Ladies are willing to pay Im game .

Johnny

yeah...... Pay to put it back on-:t:coolnana::D

Ya that would be about right ....... Ahhhhhhhhh !!!!!


Blinded by the white more like !!!



After reading this thread went and applied for an audition at Chip and Dales .

Figured what the hell , could use some extra cash .

They werent to impressed , it was more like a comedy act .

Tried to do the splits and sharded myself .

Then fell off the pole 3 times and just ended up leaving the smell of ass on it .

Lets just say I didnt get the job . :lol:

Im just going to stick with building the motor and racing . :D

damn, i got the willies just picturing that.... please stop, you're ruining my night. :D


definatley gonna need somepicxs of that big bastard up and runnin again :)

That would be scary wouldnt it . :lol:

Very soon Wes . Im working on it !!

That would be scary wouldnt it . :lol:

Very soon Wes . Im working on it !!


now when you say "it" what exactly do you mean?

The Motor Greg

Been getting it put together .

Wanna help .....

The Motor Greg

Been getting it put together .

Wanna help .....


good job buddy

I was about to cruise over... but i'm lazy.

i'd cruise.... i've been dyin to do some wrenchin lately. however, the 0500 wake up, the cold one in my hand right now and the 3 hour drive are kinda shuttin me down on that idea.....


if only i was closer. :D .......


i'm using this picture as the backdrop one my desktop.... love the way that truck looks. gonna have me one someday.

Wish I had some pics with that load with a better background .

Sounds like your on your way to getting it back up and running. Good luck Johnny.:cool:

Thanks Steve .

Working on it right now .

I'd sure help you with putting it all back together Johnny if I were not on the other side of the country. I always wanted to see a Kodiak tore down to the bolts!

good luck johnny. keep us posted.

Hopefully together by Monday .

Im going at it . Tyring to remember where it all goes . :lol:

thats the hard part, eh?!?! :eek::D .... few extra pieeces left over aint no big sdeal.... more stuf for next tim e.... :lol:

hahahahaha , lets hope not . Hmmm where'd this come from .... oh it's the oil pick up . :lol:

thats the hard part, eh?!?! :eek::D .... few extra pieeces left over aint no big sdeal.... more stuf for next tim e.... :lol:
Somebody's about half sauced.:D
hahahahaha , lets hope not . Hmmm where'd this come from .... oh it's the oil pick up . :lol:

I'm gonna hop on the: "GET THE TRUCK BACK TOGETHER" bandwagon.
:nopics:

Uploading todays pics in a minute . Got pretty far with Malibu795 's help today .

He showed up and we got it almost finished . He was a great help .

Johnny

Somebody's about half sauced.:D




no doubt.... i need to stay the **** away from computers when the boozin starts.
:D


cant wait to see it johnny.... glad its movin along for you.

Today made some serious headway .

Should be installing it by Either late tomorrow or Sat morning .


Here is the pics . Just need a 12 point 15mm , and a 36mm socket to finish heads , then adjust valves and bolt down valve covers .

Then it is going in the truck , and the rest is done in the chassis .

Special Thanks to Malibu795 today , he really kept me going and motivated . He came down from Ventura and we kicked some ass .

Really exited to hear it with the new Cheetah Turbo from Fleece Performance . Thanks Brayden and Chase . It's going to sound wicked . Cant wait to hear it .

Johnny

68863688646886568866688676886868869688706887168872 68873

Here is a few more .

6887468875688766887768878

WhooHoo !! Almost finished , Just a few more things .

Then she goes in the truck . :rocking:

Johnny

SWEEEEEEEEET!!! glad to see it gettin done..... :thumb: soon, real soon. break it in on the track?!?! :D

Way to go Johnny... Glad to see you two knocked quite a bit out today.:thumb:

Definately kicked some butt today .

Your funny Wes , break it in at the track . :lol: Or break it at the track .

And hell ya Steve . getting really exited to hear it with the cheetah .

It is a lbz turbo with from what I measure with the Mic a 69mm wheel or close to it .

tommy fire0021's sounds wicked and it is a lmm turbo with a 64mm wheel .

Should be a rocket . At least while I break it in i'll get to hear the F-16 under the hood .


Very Nice !!

Johnny

sucks when you have to stop due to missing tools:rolleyes:

Ya, but we got it almost all done .

Nice headway guys!

That's quite the makeshift workshop you've got set up. :)

Hope the rest goes smoothly,

Nick

You like that ..... amazing what you can get done with a screwdriver and a hammer .

Hillbilly Jim and his sidekick Boo boo . :lol:

Thats the open air workshop , not the most preferred but worked well .

You do with what you have and make the best of it .

A old door , and a card table make for a great work station . At least there was concrete under our feet .

I personally would have liked a clean room build , but this worked .

Clean , clean , clean is all I cared about . I slowed up the process a little being overly concerned about clean .

Youve been to my house Nick , you remember this well working on the slowlmm till 2am before Fomosa .:D

Johnny

You like that ..... amazing what you can get done with a screwdriver and a hammer .
if that is so... why aint it in the truck yet?!? :p:

If I would have turned my back to long you would have probably had it in the truck . :lol:

Thanks Again , and sorry to hear the Malibu chewed the lobes off the cam on the way home last night .

I need my motivator about now . Dammit

Johnny

If I would have turned my back to long you would have probably had it in the truck . :lol: thats is arguable correct :rolleyes:

Thanks Again , and sorry to hear the Malibu chewed the lobes off the cam on the way home last night .

I need my motivator about now . Dammit

Johnny
you been up for an hour or so... get off the PC you post whore.:rules:





:D im off to got pull the engine out

How many times did you hear .... wait wait Im cleaning that still .....

With you tapping your feet at me . hahahahahah

How many times did you hear .... wait wait Im cleaning that still .....

With you tapping your feet at me . hahahahahah
shit i sneezed.. let me re-clean it :rolleyes: frogs dont have hiars so quit looking for them :p:

Every drop of grit counts to keep out of the motor on the open air build .

You know you and I would build it on the side of the road if we had too .

How are you going to kick me in the ass 100 miles away .

Just got back from Simpson GMC getting o-rings , fly wheel tool , 36mm , 15mm and the copper banjo gaskets . Thanks Greg ..... your the best .

Then to Boyds for 2 torque wrenchs .

Ready to rock again .

Torquing heads and adjusting valves now ......

Johnny

J did you ever think about adding a tandem dually since it looks like you have the room for it??
I am currently looking for good tools so can you PM me on where you buy your pls!!!

4 times on and off torquing studs thru per ARP instructions .

Almost done and ready for last round thru to 125 ft. lbs .

18 studs , 6 around each cylinder and 4 bolts at top of head . 22 total per head .

4 bolts at 22 ft lbs then 25 ft. lbs. last round . Same as studs 4 times tighten loosen .

Then on fourth round torquing your done .

1 more round torquing then loosen one more time and final retorque . Getting old quick . Then onto valve adjustment and rocker assembly . Should have it done as planned for install today . we'll seee how long adjusting the valves takes me .


Back to it . .......

Johnny

4 times on and off torquing studs thru per ARP instructions .

Almost done and ready for last round thru to 125 ft. lbs .

18 studs , 6 around each cylinder and 4 bolts at top of head . 22 total per head .

4 bolts at 22 ft lbs then 25 ft. lbs. last round . Same as studs 4 times tighten loosen .

Then on fourth round torquing your done .

1 more round torquing then loosen one more time and final retorque . Getting old quick . Then onto valve adjustment and rocker assembly . Should have it done as planned for install today . we'll seee how long adjusting the valves takes me .


Back to it . .......

Johnny

The guy that built my motor told me the other day, if someone ever asks you to put headstuds in RUN!!!

Good luck with the build!

The guy that built my motor told me the other day, if someone ever asks you to put headstuds in RUN!!!

Good luck with the build!


Cause there a PAIN IN THE ARSE......

Cause there a PAIN IN THE ARSE......
not really just time consuming

good thread...........:beerchug: soooooo, how many beers on this project?:D

Man the studs were a pain , but I wasnt cutting any corners . All finished and torqued .

Heads bolts are all pre stretched now . 22 per head on and off 4 times .

18 studs and 4 bolts per head ...... wowzers

So lets see that 4x22=88 then 2x88=178 since you have to tighten and then break loose . And that just one head . So 178x2=356 times if you count tighten and loosen to do both heads. Is that right or not since the last time they stay on ..... :eek: ...... who cares , it's just a hell of alot of torquing .

Just really time consuming . Right arms a little tired too . :lol:

Rockers are all on and just need to do the valve adjustment now and get the valve covers on and buttoned up . Then she is ready to drop in .

Except I have to pull the flywheel and put the 2 pan bolts in that go thru the back plate . You can get one in but not the other with the flywheel on .

On most motors you can drop in more complete (2500hd) , but the kodiak and the way the motor sits under the cab you have to put it in bare ( no turbo , no intake , no fuel rails , no accessories ). The damn cherry picker needs to be really close to the top of the block to fit it under cab . Oh well just part of the process .

Gotta get back to it , just woke up . time for adjustment now .

Back later .......

Johnny

A few pics of the chore yesterday .

689256892668927689286892968930

Sure makes you appreciate your warranty and the dealer heavy line guys . :D

Really glad im doing myself though , I know its done right .

Johnny back to work :whip:

Man the studs were a pain , but I wasnt cutting any corners . All finished and torqued .

Heads bolts are all pre stretched now . 22 per head on and off 4 times .

18 studs and 4 bolts per head ...... wowzers

So lets see that 4x22=88 then 2x88=178 since you have to tighten and then break loose . And that just one head . So 178x2=356 times if you count tighten and loosen to do both heads. Is that right or not since the last time they stay on ..... :eek: ...... who cares , it's just a hell of alot of torquing .

Just really time consuming . Right arms a little tired too . :lol:

Rockers are all on and just need to do the valve adjustment now and get the valve covers on and buttoned up . Then she is ready to drop in .

Except I have to pull the flywheel and put the 2 pan bolts in that go thru the back plate . You can get one in but not the other with the flywheel on .

On most motors you can drop in more complete (2500hd) , but the kodiak and the way the motor sits under the cab you have to put it in bare ( no turbo , no intake , no fuel rails , no accessories ). The damn cherry picker needs to be really close to the top of the block to fit it under cab . Oh well just part of the process .

Gotta get back to it , just woke up . time for adjustment now .

Back later .......

Johnny

Just become a switch hitter and you won't have that problem):h

Looking good. Can't wait to see it finish.

:eek:Man you pretty dam good at reassembly
I can't even get to my wife head gasket in her mazda:D

Imports are just a pain period . I think they build the car around the motor with no thought of ever working on them .

Should have it fired up by the morning then right? Motor sure is looking good!

Wouldnt that be nice, drop us a vid of the initial fired up and run! I have seen many Harvesters initial startup, and they are a pain. Wanting to see if a new Dmax is the same.

Tony

Thats possible to do if I remember .

Just finished doing the valve adjustment .

Really enjoy doing this and the theory on how everything is timed .

6893368934689356893668937

Here is some pics of how awesome wireless is . And thanks to RIPMF for these valve clearance specs he posted in a thread I used . Valve adjustment only took me about a half hour . 12 thousandths back checked with a 10 to make sure none were tight .

It is fun to adjust valves , now back to valve covers and flywheel .

And thats about it , she'll be hangin from to picker next . :thumb:



Johnny

That thing is lookin good, if I dont chill out I will be there myself. We have the money, but I want to wait a little while longer before I dig inside. Because thats alot of effort you have in yours!

Tony

It sure does come apart fast when you disassemble .

Reassembly is a slow go . Dont want any issue and have to pull it back out .

Evev after going with out the truck for a while , I still wouldnt change a thing on my past abuse . To much fun !!

Definately worth the trade having some diesel ponies under the hood . And the possibilities of hurting it . Part of the trade off , ........ the risk .

And Damn worth it .


Johnny

Bad News on motor .

Just figured out Kodiak needs , a what looks to be , heavy duty block with completely different castings on side and front of block for mounts . Dont think it is just being lb7 .

There are no cast pads for my mounts on front side of block by cylinder walls , or a big ear sticking off side of timing cover area 1 inch thick on block by front for anther mouting point on mount . The kodiak motor is 4 point mounted . far front on block and sides of transmission . Different from 2500 hd . Never noticed my new block was missing some block compared to my other one sitting here .

Completely different . Not sure of a solution here .

Basically I have a brand new built sweet motor sitting here ready to go in truck with absolutely nothing to bolt front mounts too .

Awesome !!


Johnny

Bad News on motor .

Just figured out Kodiak needs , a what looks to be , heavy duty block with completely different castings on side and front of block for mounts . Dont think it is just being lb7 .

There are no cast pads for my mounts on front side of block by cylinder walls , or a big ear sticking off side of timing cover area 1 inch thick on block by front for anther mouting point on mount . The kodiak motor is 4 point mounted . far front on block and sides of transmission . Different from 2500 hd . Never noticed .

Basically I have a brand new built sweet motor sitting here ready to go in truck with absolutely nothing to bolt front mounts too .

Awesome !!


Johnny

Dude, that sucks. But, from a customizers standpoint, I have put many a motor in cars that they didn't come in. So far, I have not tackled a Kodiak, but there has to be something that can be fabbed to work with the stock mounting?

see the big mounting pads and big ear on block ,not on new one . Blank

68954

Nothing even here to bolt to on block .

68955

The rust covered part is whats missing from block . Over an inch thick with threaded hole .

68956

Here you see my finger is where this should be on the block .

68957

only way to do it is custom mounts .

here are some pics of differences in 2 blocks .

Just feeling a little discouraged right now about this dilemma .

Damn Johnny..I am at a loss for words. I saw 2 motors on ebay yesterday for a Kodiak....Still.....damn

The mount on old block is very strong to the block and far forward . Wait here I'll show you .

Its more like a front motor plate . very strong .

And on new motor there isnt anything there to bolt to on either side but air .

6896268963689646896568966

Im really stumped with nothing there to even bolt to .

The way the motor is mounted in truck with mount far forward on block and the two ears that are on my previous block . Makes the mounts work like a front motor plate .

The truck needs this for it to be strong and take the beating this truck takes , even just on the highway . Then add me off roading , and whatever I come up with must be strong . I just dont see how to do it or make it work .

Im really bummed and stumped at a way to do it .

Really feel dumb , building a complete motor that wont even bolt into the chassis .

Somebody come and shoot me LMAO..... what an oversight to have .

So much for bolting in the motor today , Im just sitting here staring at it with no answers or a reasonable solution to this dilemma .


Johnny

Man I feel for ya. I wish I had a solution..

I went out and looked at my Kodiak to see if there is an easy solution. I can't see see any way possible to get around not having the front motor mounts. All the holes in the front of the motor all ready have something bolted into them....so, unless there is an extra hole or two on the face of that block, I can't see how you can even fabricate a motor mount. Unless you can design a motor plate for the motor???? Now there is a idea...patent it and make millions!!

Why couldnt you make a motor plate to go on the front and make it strong enough so that you could make the mounts off of that?

Why couldnt you make a motor plate to go on the front and make it strong enough so that you could make the mounts off of that?
How would you do that and make it strong enough to hold up the motor and the dunes he attacks? I am not bashing in anyway, just wondering.

Im going for it plating the motor , I think I can do it .

Need 5"x 8" 1/2 plate steel , drill and bolted to 2500 mount holes .

Then bolted to old motor . Take mounts and have 1/2 " machine off mounting surface . Plenty of meat there .
Youve gained back the thickness of plate now . you should be able to bolt perfect to ear mount on old motor with plate bolted . mount will sit on plate and mark holes , mount to plate , for old pads location . From the it is cake I think once youve locate these holes . Now mount to new motor with mount bolted to plate and locate and fab pieces to catch ears locations .

Thinking of doing another plate on 4 bolt holes located on both sides of the block forward . Needs to be bullit proof . Use that to hit the ear location and incorporate it into original plate . Maybe out of 1/4 . Or 1/2 also .


The whole time Im typing this Im day dreaming about motors at Tony's with ears and pads on them . :D

Ok , been at it all day .

Came up with something . Off to a good start .

Just need to do some reinforcment and add more to get to ear mounts .


68994 give me a sawzaw and a uni bit and look out .

68995 drivers side mounted

68996 pass side mounted

68997 pass side

68998 drivers side

A good start and we'll see where I go with it tomorrow .

Johnny

Lookin good... Im crossong my fingers for you...
Jerry

Lookin good... Im crossong my fingers for you...
Jerry

Thanks Jerry , Im going to add some more , like another plate on the 4 bolt pads below the plate already made on both sides and stub up to the ear mount an attach both plates to each other somehow .

The ear mount hole on mount is open and needs to be used also . I need to do that tomorrow .

http://www.dieselplace.com/forum/attachment.php?attachmentid=68995&d=1216007496

The 4 bolt holes below the mount in this pic is my next place Im mounting to .

how much more if any is this going to raise the motor from the plate will the mounts align with the truck?not trying to be negative just helpfull.i dont know how you stay so calm i would have flipped out after all that work and this happened good luck.

Man, when I told my buddies yesterday about your deal, they TOTALLY got it as far as frustration. We were really bummed for you. On the positive side, it seems that you have got it figured out......watching this has been pretty cool..........hope your luck keeps getting better and you get that biatch fired up in the next day or two!!!!!! Keep us posted!!:ro):beerchug::beerchug::hail:

how much more if any is this going to raise the motor from the plate will the mounts align with the truck?not trying to be negative just helpfull.i dont know how you stay so calm i would have flipped out after all that work and this happened good luck.

My plan is to take the thickness of my bracket off the back of the pads on the mount . It had to push each down and out .

Was going to take mounts to a machine shop and cut pads on back down a 1/4" . This would make them the same .

Then if I ever use on normal block I just add a 1/4" spacer behind each pad . Not really worried about going up a hair . Just the mounts being wider .

Was going to maybe set motor in and see if mounts are to wide or not .

First I need to beef up mount and strengthen my custom plates . So far so good .

At least I feel like I came up with a solution . I was pretty discouraged day before . Felt very screwed . This was all I could think of to get this motor in truck .

Back at it today to make another 2 plates to hit the 4 bolt pads below mount and make it stronger and stub up to ear mount with a threaded mount .

Johnny

looking good johny :D

Ok getting farther .

http://www.dieselplace.com/forum/attachment.php?attachmentid=69111&d=1216141855
http://www.dieselplace.com/forum/attachment.php?attachmentid=69112&d=1216141855

http://www.dieselplace.com/forum/attachment.php?attachmentid=69115&d=1216141855

Adding more to drivers side mount , another up bracket behind ear mount same as front . Then boxing some stuff in and gussets .

We'll see if this is going to work . Wont run it if I dont think it's strong enough .

Johnny

http://www.dieselplace.com/forum/attachment.php?attachmentid=69114&d=1216141855

Another view of drivers side .

Lookin' good. Good for you for sticking with it. It appears that - if it works - it will be better than stock. You can gusset and strengthen areas you know will take a beating.

he cant do the whole truck in gussets:Dsorry i had to say it:(.looking good.i looked at mt truck today and it seems to have the mounting holes.wonder what ones dont have them?

Here is today efforts , almost there .

Doubled up lower plates 1/2 " now and uprights to ear mounts . Just need to gusset and start welding together . Split the 2 upright on drivers side and gussett between .

Hit the head with a bracket on pass side . Made it pretty bulletproof .

Just going to tack it all and start doing some overkill strengthening to make it Glamis and Drag Race Proof .

6913969140691416914269143

Feel like Im winning the battle .... just had to get down and dirty .

Looks like your making progress. I bet you cant wait to get that bad boy running. Just remember there is no such thing too strong, over done, when building motor mounts. Especially for what your gonna be putting it through.

Come on man, we wanna see this thing runnin!

Tony

How do you think I feel . Dieing to hear the turbo spoolin ... :D

Should have these mounts finished by tomorrow hopefully .

Just need to weld the crap out of them and add some gussetts . .

Crude but Strong . I think they will hold up to the abuse .

If I break them , i'll fix them .

Johnny

There ya go. Atleast you have the ability and time to be able to get out there and do it. I wish I had more time on my hands so I could also get out there and do more stuff as well.

I think with some gusseting , drilling and filling holes between plates will be all good on this one .http://www.dieselplace.com/forum/attachment.php?attachmentid=69146&d=1216179060

Im going to run something along the bottom edge and box in , and brace the front brackets , and gusset the bracket above to block and plate .



69146

damn Johnny.... sorry to hear bout the bad luck with the brackets!!! ill give you a holler tomorrow, and try to cruise by!

thats the good thing with doing it yourself, if it breaks you can fix it. and know what to do. they look good so far. a little welding will go a long way for strength. just don't over heat the steel.

Good luck with the build. Way to keep plugging at it. It will be worth it when you get to drive it!!!

stitch weld

Thanks Bobo .

No real choice but to keep at it .

These mounts will be strong, now that I figured it all out .

If anyone can figure this out its you John.....

Are you going to make it to this fridays meeting John????

Are you going to make it to this fridays meeting John????

He's always there Kodiak or no Kodiak;)

Maybe , finish motor install instead .

We'll see .

Mounts are done and it's ready to go in the truck .

Just need some help getting hood and radiator/intercooler assembly off truck .

Then cherry picker , new flywheel bolts and in she goes .

Hope everything goes good johnny.. gunna take it back to Olsmobile hill this next season for a good luck trip?? :lol:

Always if its running .