Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby mof » Wed Nov 23, 2016 4:49 am

MACH6, the crank touched the sump near the oil filter from memory. If the block is getting CNC clearance, those machined locations will be your tell tale. Mine was a sheet metal sump, yours looks like cast ally?
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Wed Nov 23, 2016 6:36 pm

Yeah I'm still not 100% not sure Feety. I have not found a smoking gun cause but I can tell you what I have ruled out as the cause.

The block has been pressure and crack tested OK, the heads pressure tested OK and the exhaust manifolds pressure tested OK. That really leaves the head gaskets as the primary source of the coolant leaking into the cylinders and the exhaust gas leaking into the coolant path.

Something I found odd though was that the gas bubbling up through the coolant header tank would only happen at idle. When power was applied it would disappear and only come back when the engine had settled back to idle for a few seconds. After settling back to idle it would not come back with a surge suggesting the exhaust gas leak was stopping whilst the power was on. This kinda points to a slight head gasket leak but when I inspected the heads, head gasket and the block I couldn't find any signs of potential leakage.

I am thinking that after all the other stuff checking out OK that it is most likely the head gasket that has let me down.

Yeah I have so much good gear at my disposal: I got the engine out in about 10 mins with the gantry crane, I even used the crane to get the manifolds off because the are heavy and you need to support them as you unbolt. The sand blaster has just gone tits up though, I might have to chuck some of my own coin into it just to get it going again.

Juddy, I just checked the quote from the engine shop and they are Felpro marine gaskets that they are supplying me. I have noticed a few 350's with just silicone sealing the intake manifold down, I guess it will allow for a bit more gap filling with the slight misalignment as the heads or block are decked down.

Cheers Moffie. Yeah cast aluminium jobbie but I will check it out anyways.

Another lunch time of blasting away, I now need to under coat the suckers before they get a coating of rust...

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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby 82Juddcraft » Wed Nov 23, 2016 8:32 pm

A mate had a similar issues with his boat (400 Chev) it ended up being a porous block.

But it wasn't just a few bubbles, he was having trouble keeping the radiator cap on the bottle there was that much pressure.
I reckon your on the money with the gasket
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Sun Dec 11, 2016 9:28 am

So I got the engine back from machining, needed a re-sleeve and a new exhaust valve in No 8 cyl, everything else checked out good.

One of the engine mounts was corroded away by 50% so I thought I should chuck a bit more meat back on it so I don't have any problems down the track.

Ended up getting a performance kit which meant gaping every bloody ring and the oil rings were a bloody pain to put in as they were super tight in the bore.

Pots are in and I am about to set the timing after struggling to get the cam shaft in, engine guys forgot to chuck in woodruf keys so need to pass by them to pick them up friday arvo.

Have to make a tool to fit the oil pickup to the new oil pump, I reckon I will stuff it if I don't manufacture something to tap it in. Should have the engine pretty much together buy the end of the week.

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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby mof » Sun Dec 11, 2016 1:27 pm

Another good tip is fully prime the oil system before you fire it up. I chopped up an old dizzy, 'cause you need the bottom piece of the dizzy body to feed the oil from the pump to the rest of the block. I spun the pump with the old dizzy shaft in a battery drill till oil came out every rocker arm. A 360 deg rotation on the crank by socket while priming the oil system gives peace of mind when you crank it over in earnest, knowing the oil galleries are all full of the good stuff. Better than cranking the starter till you get pressure on the gauge. :wink:
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby lewy71 » Sun Dec 11, 2016 6:28 pm

Summit Racing have them nice a cheap the freight can be a deal breaker though.

https://www.summitracing.com/int/parts/ ... /overview/
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Sun Dec 11, 2016 7:29 pm

Sweet idea Mof, was thinking how I could do something like that but didn't have any idea of how to get the pump turning without cranking it.

Too late Lewy, just designed one up on CAD and will 3D print it at work tomorrow morning out of ABS plastic; should be plenty strong enough to run from a cordless.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Fri Dec 16, 2016 9:46 pm

She is starting to come together.

Designed and printed the oil pump drive adapter so I can prime up the oil before start, prob about $1 worth of plastic. Cheers Mof, great idea.

Also designed and printed a adapter plate to bolt up to the harmonic balancer and allow me to rotate the crank with a 28mm socket. It also held the degreeing template that I printed off and stuck to some Coreflute so I could degree the cam shaft. Bloody turned out a treat, all the guys at work were nay sayers but when they saw it fitted up they were impressed. Especially the fact that it cost $3 worth of plastic. It will probably end up in the workshops tool cabinet.

Had some issues reading the lifter rise with the dial indicator, 10 mins on the CAD and 40 mins on the printer and I had a adapter for the lifter so I had a flat surface to read from and I didn't have the dial fouling on the block

Measured 0.5deg advance on the cam when I checked it, added another 2 deg advance at the crank to get a bit more power down the lower rev range.

Fitted the heads, oil pump and lifters. Was hoping to reuse the old head bolts but it was not to be.... Went to fit up the rockers and fount that the rocker studs were 3/8 and I had rockers to suite 7/16 studs, another $100 worth of bits.......

And I checked the clearance for the sump against the con-rods, was a No-Go.... It was probably <1mm clearance from the rods in a couple of places. I marked all the areas and will have to get the die grinder out to take a good 3-4mm off the sump to have a min gap of 3mm. Another thanks to Mof..



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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby Dickj83 » Sat Dec 17, 2016 6:48 am

I gotta get me a 3d printer!
This is excellent. Great work mach6.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby mof » Mon Dec 19, 2016 6:47 am

For your oil pump primer, you need the bottom piece of the dizzy body. The oil passage comes from the pump into one side of the dizzy hole, goes thru the recess in the bottom of the dizzy before it goes to all the rest of the oil galleries. When you spin the pump, the oil comes out the hole and shoots straight back into the sump. Ask me how I know...
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Thu Feb 02, 2017 9:23 pm

Cheers Moff, what a bugger hey.......
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Fri Apr 07, 2017 11:44 pm

So...

Got the engine in a while ago, not without a few issues. Kinda forgot to put the oil pump shaft in before putting the oil pump on... and the sump... and engine in the boat.... Fudge........ Did learn the hard way :oops:

Engine out again, sump off, pump off, shaft in..... back together again... had it done in 3 hrs from driving in to driving out.

So we did a test run and all was good except for a hose clamp. We then went out to get some speed/rpm data to get a new prop and kinda backed into a sand bank... Double Fudge bags....

So ordered new prop that we needed anyway.

And it is now getting cold.... I think I will just need to harden up a bit.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby JBWake » Sun Apr 09, 2017 9:49 pm

Nice update and 5 blade looks fancy!!

Will be interested to hear how it goes.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby Alastair » Mon Apr 10, 2017 8:03 am

Can't remember seeing any, but you should throw up some wake pics if you have any with a rider in the trough of the wake for comparison.

engine over haul looks like it went well.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Thu Apr 13, 2017 4:12 pm

Yeah the 5 blade is the gear, should be able to load the bageezes out of it and still be able to pop out of the hole easy. Dropped it from a 17.5 to 15.5 pitch and increased the dia from 13.5 to 14.5inch. Hopefully the math works out but I'm yet to test it though, maybe this weekend.

Engine is sweet but I am having problems starting it. We replaced the starter with a geared one from a big block because the old one couldn't handle the compression and we were starting to cook it. We now have to prime the engine with a pump from the throttle to get a dash of fuel in the manifold before every start.

I am about to reset the idle jets and see how that goes, might have to make it a bit rich at idle to get it to start nicely.

I will try to remember to get a couple for ya Al.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby Dickj83 » Thu Apr 13, 2017 4:41 pm

MACH6 wrote:We now have to prime the engine with a pump from the throttle to get a dash of fuel in the manifold before every start.


Is that just for cold starts or hot starts also?
My carbed LS1 is the same for cold starts. I always give the throttle a pump before the first start of the day. No need to give a pump after that unless it has been sitting for an hour or so. I always assumed this was just a carby thing?
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby 82Juddcraft » Thu Apr 13, 2017 5:20 pm

Dickj83 wrote:
MACH6 wrote:We now have to prime the engine with a pump from the throttle to get a dash of fuel in the manifold before every start.


Is that just for cold starts or hot starts also?
My carbed LS1 is the same for cold starts. I always give the throttle a pump before the first start of the day. No need to give a pump after that unless it has been sitting for an hour or so. I always assumed this was just a carby thing?

Yeah we always had to give the old 308 a few pumps on a cold start.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Fri Apr 14, 2017 12:17 am

Yeah both cold and hot starts. It was being a jerk with the electronic choke mucking with the AFR and it would idle all over the shop.

So reset the idle mixture to default and did a idle AFR adjustment as per the manual and subtracted a extra turn out per jet. Starts nice when hot now but will need to try it cold.

Exhaust smells a bit rich but will need to try it idling in gear whilst wet. I know enough about it now to adjust whilst on the water.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby MACH6 » Sun Apr 16, 2017 5:07 pm

I had it all lined up to take the boat this weekend but it looks like something is conspiring to keep me from getting some barding done.
After setting the idle all good on Thursday arvo, my left knee started being a bit sore for no good reason, i couldn't walk next day and 24 hours later I was in emergency getting getting a infected knee drained. Now I have just come out of the first of a couple of surgeries to clean the sucker out. Looking like a week's stay in hospital. WTF! On a long weekend too.
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Re: Plate Aluminium Wake Boat - Engine Rebuild

Postby will » Tue Apr 18, 2017 8:52 am

MACH6 wrote:I had it all lined up to take the boat this weekend but it looks like something is conspiring to keep me from getting some barding done.
After setting the idle all good on Thursday arvo, my left knee started being a bit sore for no good reason, i couldn't walk next day and 24 hours later I was in emergency getting getting a infected knee drained. Now I have just come out of the first of a couple of surgeries to clean the sucker out. Looking like a week's stay in hospital. WTF! On a long weekend too.



NOOOO! Mate, that's terrible! I'm getting older so I always seem to have an injury coming on when there's a big weekend afoot, but I've never had something that serious happen! Hope the recovery is quick! It will make getting out on the water all the sweeter! Keep us up to date.
Enjoy the ride. Any time on the water is good time!
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