[6pack] New Engine AUTOpsy

[Foster, Stan]

Kendall, can you confirm that you had oil in this engine and that you had oil
pressure ?. For an engine with only 5 hours on it I would expect to still see
signs of assembly lube but the conditions of the journal and the bearing
failure make me wonder if there was any oil in the engine at all or if the
pump was working or installed incorrectly.. Did you verify at startup that you
had oil supply to the head because again, I would have expected a liberal
coating of oil on the rocker assembly and the top surface of the head but I
see none and the front rockers are rusting !.

Stan

-----Original Message-----
From: 6pack-bounces+stan.foster=hp.com at autox.team.net
[mailto:6pack-bounces+stan.foster=hp.com at autox.team.net] On Behalf Of Kendall
Larsen
Sent: Monday, September 08, 2008 5:47 AM
To: 6pack List
Subject: [6pack] New Engine AUTOpsy

List,

I've been putting off this email for awhile now. It was actually way back at
new years eve '08 that my new engine started making very bad sounds. It didn't
really start rattling until I had been on the freeway for 40 miles or so, the
longest trip that I had taken the new engine on yet.  The problem likely
existed much earlier but when oil pressure was up I didn't hear any knocking.
After towing the car back to my apt I didn't open the engine for awhile
because I didn't have the time or money (or motivation) to get into it. I've
since secured a garage to work in and now need to finish the job before the
TR6 wears out its welcome!

Here are some pathology pics of the damage. Cylinder 1 rod bearing spun.
http://picasaweb.google.com/kendalll/TR6Engine08#

So we now know what what the loud noise was, but the question is why, and what
do I do to keep it from happening again?

The rust on the rocker arm is curious. But the car sat for quite awhile after
the tow home, and I had to start it up and run the engine for a few seconds to
occasionally move the car. Seem like there was no oil on the rocker arm to
keep the rust off it.

What are the possible causes for a rod bearing to spin? This engine probably
had less than 5 hours on it.

I had the machine shop put the bottom end together, because I didn't want to
screw up a ring or something. I did the rest of the engine assembly, cam
timing etc. How likely is it that this is the result of a mistake on their
end?

Interested to hear what you guys have to say. This is late night email for me
so hopefully it's coherent!

Kendall
San Clemente, CA