The engine didn't "blow up", saying that means it failed. Ben says the spark plugs burnt the ends off. That is a "tuning" issue. The problem for me is I tuned it and I know how soft the tune was that it left here with. I can say with complete certainty that it there is no way in hell it could burn the plugs off (detonate) with the tune I had in it, just not happening. 27 psi of boost peak falling to 22 psi, 9 degrees timing going up to 13 degrees on a decent sized turbo, big FMIC, great cams and E85, AFR's in the 11.7:1 range. That is not hurting an engine end of story. Knock control was set up very aggressive allowing the engine to add 15% fuel and pull 10 degrees of timing. I set this car up conservatively to make sure it was going to run a good long time.

Something changed. FPR hose blew off, double pumper somehow didn't trigger, tune was changed, turbo flows more than the last one..........I don't know. I do know the engine stayed together and there is no explanation for the tune to run two 20 minute sessions one week perfectly and then melt the plugs off in less than 10 laps.

I have offered to fix the car out of my pocket if Ben wants to bring it back here. I am beyond pissed off this has happened. I think the next time this car goes to the track I am going to arrange to be there.

 

Be nice to know what failed on the car, so you don't go building a new engine to have it happen again.

 

I have always been impressed with your honesty and constant dedication to fixing some problem that may have not been caused by your work! Great job David. You are a honest man. I wish you the best Ben. I am glad I did not get caught in the middle of this fiasco back here at home. It would have not been nice, I am sure.

Damn what a bust. I wish you guys the best. Sure it will get resolved correctly.

James

 

Holy crap, what a night mare Sorry to hear!

 

Yes, it would be nice to know for sure but burnt off spark plugs are only caused by so many things and I am comfortable ruling out the tuning since I did it, I have the logs and know what the engines can withstand.

I spoke to Ben on the phone. I think he is going to take me up on my offer of fixing it, hard to pass it up. I want to be involved with the car and see it fly. He just has to get it here and the drive SUCKS!

 

dave were you able to get a log?

 

I did get a log, as I stated earlier but for some odd reason it is low speed driving and idling, no boost at all in the entire log or rpm over about 4,000.

 

yeah i read that, was wondering if you got the correct log you were looking for.

thanks

 

im guessing that the turbo was already on the way out by the time you received the car for the rebuild. it sucks that hes having such bad luck so far. but at least hes in very capable hands with you Dave. Hope you guys get it running right again, would love to see what its capable of on the track.

 

This was a whole new turbo, but thumbs up to db for taking care of a customer.

 

whoops, shoulda been more clear that i was referring about the 1st turbo in my post.

 

One thing changed since Dave tuned it last... the turbocharger.

It's obvious that the turbocharger was damaged when you tuned it Dave. Explains the difference in the tune, the 2nd engine failure, the lack of response on your dyno (why the EFR spools slower in 4th gear than the HTA3076 did in 3rd gear), etc.

It's a shame eyecrometers don't accurately measure radial and axial shaft play.

I hope to see Ben's car out and running soon.

 

Yup. I am really hoping that BorgWarner will state what the cause of failure was in the turbo when they receive it.

 

Probably the last thing on his mind, but if he wants to test an 8374 on his car on the dyno id send it over.

 

The first turbo failure is most likely due to the FIRST engine failure putting rod bearings and oil pump pieces through the CHRA via the unfiltered oil feed line to the turbocharger.