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Discussion Starter #1 (Edited)
Here is a little background so you can see what I've been up against:

When I had a few thousand miles on my truck, I bent a rod from a bad injector. The dealer fixed it under warranty and sent me on my way. I could not get the truck to run properly after the new rod was installed. The truck would begin to miss under load or over 70% throttle. I had the truck into the dealer for reflashes and updates about 5 times. Truck had all stock parts on the motor including the cat. I ended up installing a EGR blocker plate to help with the issues, but it was not 100% fixed. I had to load a predator 40hp tune with the EGR blocked to get it to run right. Fast forward about a year....

EFI was released and I began to do my own tuning last winter. My truck never smoked at idle or missed a beat...as long as it was tuned. In October 06 I noticed as the weather got colder, my truck had a haze of smoke at idle. I bought and installed twin turbos soon after this because I had been waiting for them. Once they showed up, I could not help but put them on(with the help of Billy17, thanks!). The smoke at idle stayed the same, but the cold weather caused some hard starting issues. In early November, I installed my ATS twin CP3 kit. I paid the dealer to do a compression test on the truck and it came back fine before the CP3 install. The weather got very cold and the starting issue was bothering me. I decided to do my own compression test. It looked fine. I had Smudge and BigStriss helping me work on the truck and we were all wondering what could be the issue. I used spare parts off Smudge's LLY to test on my truck. Nothing seemed to fix the issues. Stock tuning was not helping me any since I knew it didn't run right when it left the dealer. I used the 40hp Predator tune and it still wasn't running right. About this time, I got in contact with an injector specialist, Don M. He agreed to test my injectors and make them flow better for me. I installed the injectors hoping that would fix the issue, but it was still the same. Knowing the mods on my truck, its potential, and not being able to drive it for the past 4 months because I was scared it was going to blow up took its toll on my wife, my friends that helped me build this truck, and myself. With some help from my friends, I decided to take it to Merchant Automotive in Holland, MI (thanks for the tow, Nodmax) and have Eric and his team fix it. Eric had Volker from MDE make some changes to the tuning to get rid of the smoke, but that did not tell us if there was an internal issue. I finally decided to have the motor gone through and have some upgrades done to be sure this don't happen in the future.

Today:

Merchant pulled my motor. It should be taken apart sometime in the next couple days. I'll keep you all tuned in as to what he finds.

Planned upgrades for now:

Merchant is installing head studs. He is also installing a set of connecting rods I bought from Huckstorf Diesel. The rods come from TTS. Merchant has a great team and one of the techs (TouchRacing) in his shop worked in a machine shop for several years running all sorts of equipment. Merchant bought the equipment that is needed to do most of the engine build in house. He can now key cam's, cranks, custom fab most any part, and do valve clearances and piston modifications. I am having my pistons decked to lower the compression to 15:1. Merchant is blueprinting my motor to insure all the tolerances from GM are improved upon in this build. I'm having the crank and the cam keyed to improve on that design flaw also. I'm going to be running the thickest gaskets available from GM and the ARP headstuds should keep things nice and tight. I am not doing any upgrades to the heads or cam at this time. The only part of the motor build that is not being done in house is the balancing. This is done at a local machine shop. My goal is 700RWHP in a daily driver that is as dependable as a stock truck. I'm hoping the lower compression does not hurt my fuel economy too much, but I'll report back on that after I put some miles on it.

Check back for updates:

The goal is to have my truck up and running by next Friday, the 23rd of Feb. If the motor tear down don't bring up any surprises, Merchant is confident that the build should be complete by then. My rods were shipped out today. They should be at MA on Monday or Tuesday pending any weather related delays. I'll keep you updated and wish us some luck! Thanks to everyone who has helped me along the way. You are all listed in my signature for a reason! I should have a good running truck we can go play with as soon as this is all taken care of! I might even post some pics of the progress if Eric has time to take some. Stay tuned:cool: !!!

THANK YOU ERIC AND THE MA CREW!!!
 

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Good luck
 

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Good luck!!
Hope to see you in the Badger pulls this year, someone has to give John a run for his title!!
Jon
 

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Discussion Starter #4
big_jon00;1595872; said:
Good luck!!
Hope to see you in the Badger pulls this year, someone has to give John a run for his title!!
Jon
If I tune your truck, I might beat you!
 

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Bob,
If you do as good as job as you did on Tim's truck I am might be able to make into the top 3..
At the very least I want to see some sh** brake this year!! It will be interesting to see the outcome of your tear down.
The injectors from MDE sound like they may be the way to go.. Should be a good year for working out the kinks.
Jon
 

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thats sweet...good luck MA crew and bobo on the new power plant
 

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Sounds good Bob, I can't wait to see what a Twined and built, LLY can really do!:D
 

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Sweet...can't wait to see her run after being built up a little bit...she ran good at the drags last year though
 

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After much throat chaffing ..
...the build begins...
 

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sounds awesome bob, Id be really curious to see what the issue turns out to be. Slightly goofed cam gear pin maybe? Timing is ever so slightly off that it messes with the valve overlap and causes smoke? Did you do both a compression and leakdown test? Maybe back when the injector hung it washed down the cyl walls...be curious to see what teh rings/keystone/etc look like. But then I guess you'd have lots of blowby...

hmmm...anyway, its over and done with now, should be sweet when its back up and running.

make sure you wear that t-shirt design I sent you the first time you drive it. Should bring good luck :D

ben
 

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Good luck! Can't wait to see it done, Eric is one of the greatest!
 

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Can't wait to take a ride in a twinned truck:D I'm sure Eric and Blake will have you up and running in no time. Plus it will be nice to see what is wrong with this bad boy. Roger
 

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Good luck with your build. I hope you find the problem to put your mind at ease.
 

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Discussion Starter #15
Merchant called an hour or so ago. He found the problem!! I'll post pics as soon as I get some. Anyone that needs 8 short rods or blown head gaskets, I have some for sale!
 

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Will you throw in the blown head gasket if I buy all 8 short rods?
 

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So do you think all this went back to before you were even modded? You never ran nitrous correct? It would be really interested to know at what point your rods shortened.

I guess I should put mine back to stock tuning and see how it runs. It looks like rods are going to be a mandatory upgrade for any 500+hp tuned truck maybe less. :(
 

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Discussion Starter #19
When it first started smoking, I'm sure it was showing signs of rods bending. This truck has been my test bed. I knew it was going to be doomed, but how can you learn if you don't try? I never sprayed it. I believe the head gasket might have been an issue for a while. I never seen any coolant issues, so I can't say it for sure. I was pegging the 60 psi boost gauge after the twins install. I also turned the fuel and timing up when I was pissed that the truck wasn't running right...just to try and blow it up. Whatever the reason, I'm glad Smudge, BigStriss, Toman and Farmboystoy said not to run it at all. They saved me from having to buy a new block from the looks of things.
 

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Can't wait to see that thing rip!
 
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