Carnage with pics

[TCluff]

DOES ANYONE KNOW HOW FAR YOU CAN BORE A BLOCK ???

 

[PRattenbury]

. 020" Iirc

 

[lmills]

DOES ANYONE KNOW HOW FAR YOU CAN BORE A BLOCK ???

1 mm or . 040 over is the max limit.

 

[Jim Fulmer]

1 mm or . 040 over is the max limit.

For us, . 040 is correct!



Jim

 

[ENafziger]

This is from the '06 factory service manual. It looks like if more than 1. 00 mm is needed to clean up the cylinder, the engine can be sleeved. --Eric





STANDARD PROCEDURE—CYLINDER BORE REPAIR

Cylinder bore(s) can be repaired by one of two methods:

² Method 1:—Over boring and using oversize pistons and rings.

² Method 2:—Boring and installing a repair sleeve to return the bore to standard dimensions.





METHOD 1—OVERSIZE BORE

Cylinder bore(s) can be repaired by one of two methods:

Oversize pistons and rings are available in two sizes - 0. 50 mm (0. 0197 inch) and 1. 00 mm (0. 0393 inch).

Any combination of standard, 0. 50 mm (0. 0197 inch) or 1. 00 mm (0. 0393 inch) overbore may be used in the same

engine.



If more than 1. 00 mm (0. 0393 inch) overbore is needed, a repair sleeve can be installed (refer to Method 2—Repair

Sleeve).



Cylinder block bores may be bored twice before use of a repair sleeve is required. The first bore is 0. 50 mm

(0. 0197 inch) oversize. The second bore is 1. 00 mm (0. 0393 inch) oversize.

After boring to size, use a honing stone to chamfer the edge of the bore.



CYLINDER BORE DIMENSION CHART

DESCRIPTION MEASUREMENT



BORING DIAMETER DIMENSION 1st. REBORE - 102. 469 mm (4. 0342 in. )



2nd. REBORE - 102. 969 mm (4. 0539 in. )



HONING DIAMETER DIMENSIONS STANDARD - 102. 020 ± 0. 020 mm (4. 0165 ± 0. 0008 in. )



1st. REBORE - 102. 520 ± 0. 020 mm (4. 0362 ± 0. 0008 in. )



2nd. REBORE - 103. 020 ± 0. 020 mm 4. 0559 ± 0. 0008 in. )



CHAMFER DIMENSIONS Approx. 1. 25 mm (0. 049 in. ) by 30°

 

[lmills]

For us, . 040 is correct!



Jim

true, but the pistons will be marked 1mm

 

[RobertP]

yea all it takes is a little bit of debris to hang a injector open and cause big problems, ditch your fass 200, and go back to the 150 with micron filtration.



the 200 is too much for the racor filter. sounds to me like it was passing debris, do you have edm'ed transfer tubes? or stock?

 

[TCluff]

yea all it takes is a little bit of debris to hang a injector open and cause big problems, ditch your fass 200, and go back to the 150 with micron filtration.



the 200 is too much for the racor filter. sounds to me like it was passing debris, do you have edm'ed transfer tubes? or stock?

i still have the stock tubes,

 

[catoiler]

Man that is like mine but yours went down the side of the piston,mine stayed on the top and the cyl was saveable. sent the injectors out to be checked and they found "no problems" with them,put them back in and the same problem! took them all apart and checked the tips and found 3 cracked! So much for waisting 250. 00 on checking them! got stock sticks in now and don't plan on changing anytime soon.

 

[Signal73]

what shop makes them 3 flows?

 

[TCluff]

what shop makes them 3 flows?

INDUSTRIAL INJECTION.....







NOW, WHERE IS THE BEST PLACE TO GET PISTONS, IM NOT SO SURE . 040 OVER IS GOING TO CLEAN THAT BORE UP..... I USED STOCK COMMON RAIL PISTONS ON THE LAST MOTOR, THE OTHER FIVE STILL LOOK BRAND NEW... .

 

[JasonCzerak]

INDUSTRIAL INJECTION.....







NOW, WHERE IS THE BEST PLACE TO GET PISTONS, IM NOT SO SURE . 040 OVER IS GOING TO CLEAN THAT BORE UP..... I USED STOCK COMMON RAIL PISTONS ON THE LAST MOTOR, THE OTHER FIVE STILL LOOK BRAND NEW... .

Tho from what I read you can mix and match piston sizes. Something I wouldn't do in a motor you beat the crap outa. Why not just sleeve that cylinder and get one new piston of the same size of the other 5 if they are in 'new' condition?



Coat all the barrings and what not as you need to get the block dipped now since you got metal everywhere.

 

[TCluff]

I Am Having The Block Cleaned And Hot Tanked, I Think I Am Going To Just Sleeve The One Hole... . i Need To Have The Crank Shaft Checked And Prepped For Rebuild Too

 

[tp0d]

Does Cummins have a coolant bypass for the CRD available that flows out of the back of the block where #6 is, like on a 12valve? Or do you already have that in place... ? Might be something to investigate...

-j

 

[jwilliams3]

Another issue to look out for when you trash a cylinder is cracking of the cylinder walls. Seen it many times... .

 

[TCluff]

also what color of paint will give me the most h. p. , the plan is a cammed twin injection pumped large injectored, motor with valve springs so i can rev to at least 4500 rpm, i dont want to fly cut the pistons yet so the cam will be mild, i dont want low compression, its going to be able to be a daily driver... .

 

[TCluff]

Another issue to look out for when you trash a cylinder is cracking of the cylinder walls. Seen it many times... .

I WILL HAVE THE MACHINIST DYE CHECK IT, HERE IS MY BASIC PARTS LIST WITH COST...



CAM BUSHINGS 2 EA- 6. 39



MAIN BEARING SET - 79. 35



ROD UPPER BEARING 6 EA- 6. 16



ROD LOWER BEARING 6EA- 7. 74



REPAIR SLEEVE 1- 46. 40



PISTON KIT 1 - 144. 65



LOWER GASKET SET- 288. 00



UPPER GASKET SET- 181. 14



MACHINIST WILL CHARGE 340. 00 TO INSTALL CAM BUSHINGS, SLEEVE, AND FREEZE PLUGS...

 

[LowFly]

yea all it takes is a little bit of debris to hang a injector open and cause big problems, ditch your fass 200, and go back to the 150 with micron filtration.



the 200 is too much for the racor filter. sounds to me like it was passing debris, do you have edm'ed transfer tubes? or stock?

If he had the Racor on the pressure line of the FASS, it only flowing what the engine is using. You are not running 200 GPH through the CP3 and Injectors. NOW if he had the Racor on the return line of the FASS... thats a differant story..... you got some serious volume moving throught that line..... BUT most filters are rated for a fair amt of volume... ...

 

[TCluff]

If he had the Racor on the pressure line of the FASS, it only flowing what the engine is using. You are not running 200 GPH through the CP3 and Injectors. NOW if he had the Racor on the return line of the FASS... thats a differant story..... you got some serious volume moving throught that line..... BUT most filters are rated for a fair amt of volume... ...

HOW DO I REDUCE THE PRESSURE MY FASS 200 IS PUTTING OUT, IT AS AT 50 PSI I WANT TO TAKE IT DOWN TO ABOUT 25 PSI

 

[nickleinonen]

i believe the fass pumps have a bypass spring loaded check. trim the spring or change it to a lighter spring...

or

get a bypass regulator