Fun with Ted, Todd, Bill and Paul…Resurrecting an Ultimate Rebuild.

[Paveltolz]

.... Like to see it upon completion.

You and me both.

Fun Fone Fotos came to me yesterday. Crank is in as are the pistons.




Unfortunately, seems I have some clearance issues (Ted will have to chime in):mad2: Therefore, I'm not celebrating the 'progress', rather, taking a :chillpill: instead.
In fact, I'll take two :chillpill::chillpill: as they are small. So, some double checking is in order and worst case scenario means new pistons and balancing the rotating assy...again. What is it they say, 'Third time is the charm?" Joy:nonod:

More joy, the starter decided to die with no warning what-so-ever. Just turn the key with everything normal up to that point and then....nothing. Batts, grounds, fuses, relays etc...everything fine. Glad I didn't stop and sleep in that campground the night before. I'd still be there. Turns out it just needed a 12 oz motivator tap to get going again . But, it wouldn't restart after shut down without that 12 oz motivator assist again. So, new "rebuilt" unit to get it through the next couple of months.

 

[Paveltolz]

635 Update: So much for parts "present and accounted for." Ted went on a 'Where's Waldo" search of the shop for the Turbo Heatshield, brackets and just where is that ECM anyway? Found what he needed at a local "Foreign Auto" parts yard. Had a running 6.5 out of a 99 Burb that got knackered in the passenger fender (K-47 toast). So, tomorrow it gets buttoned in and will probably be driven out of the shop on Saturday.

Of a fun note: Wasps, Hornets and Bees will build a bunch of nests in your K3500 under the flares, inside the bumper, fender well and bed mounted tool box if you let the truck sit for over a year in or near a meadow. Also, Brake Cleaner will put a hurt on them in as much of a hurry as Wasp Spray, if you run out of it. Cheaper too, just don't have the range.

Anyone got some IP nuts laying around. I understand they are getting hard to come by. Will pay you plus S & H.

 

[ak diesel driver]

I got one in my hand if no one closer speaks up.

 

[NVW]

I got one in my hand if no one closer speaks up.

S&H will make "one" nut pretty costly IMO.

 

[ak diesel driver]

I would think you could get a washerhead 12 pt nut from fastenal or similar store

 

[Paveltolz]

I would think you could get a washerhead 12 pt nut from fastenal or similar store

So did Ted. He ended up ordering them from a couple of places back east...I'll try locally as well, I just thought I'd ask, thanks.

 

[NVW]

Paul, if someone from the US doesn't speak up I would have a set if I can find them. I'll be away this weekend so next week would be the earliest I could send them.

 

[OrionThade]

Paul, I *might* have a set from the 6.2. I'll have to run out and check my drawer.

 

[OrionThade]

Paul, I *might* have a set from the 6.2. I'll have to run out and check my drawer.

That's an NG. I wonder if I left them on the studs of the timing cover? Maybe have Ted check the one I sent up there?

 

[handcannon]

Of a fun note: Wasps, Hornets and Bees will build a bunch of nests in your K3500 under the flares, inside the bumper, fender well and bed mounted tool box if you let the truck sit for over a year in or near a meadow. Also, Brake Cleaner will put a hurt on them in as much of a hurry as Wasp Spray, if you run out of it. Cheaper too, just don't have the range.

WD-40 and ether will also make them curl up and croak.

Don

 

[Paveltolz]

Paul, if someone from the US doesn't speak up I would have a set if I can find them. I'll be away this weekend so next week would be the earliest I could send them.

Thanks. There's no hurry so I very much appreciate the assistance all. :thumbsup:

WD-40 may not be the best for around the house but I'll consider the Ether. I may still have a can laying around from days long gone by.:rof:

 

[Paveltolz]

Fractured Fairy Tails...

I feel like I'm in an upside down kid's story book..."These Pistons are too tall..." :nopity:

So, the stock compression pistons are too tall for the block, or, what's left of it. Bill called Dumb and Dumber Diesel today and asked Benny what they had taken off the block to begin with. "Oh, enough" Gee thanks.:skep:

So, Pistons and rotating assembly are out, measurements will be taken and pistons that don't protrude from the top of the cylinders will be ordered.
May be as low as 18:1 but what the actual compression will be once install is anyone's guess...who knows? Regardless, it is back to the machinist for another round of balancing with the new units and, of course, another invoice to be paid. Brings to mind the line, "It never ends this way too!":nonod:

In the mean time, despite being told not to by Bill, Ted and myself, Joe moved all the parts around the shop so now there is no telling where the $%^&* Ted's or my parts are. Ted not happy as he's the one having to go on the treasure hunts to find bolts, clamps etc. for his truck and trying to work as project manager for my motor... I'll stop as my rant switch is on a hair trigger.

Well, with the extra time I finished the lower intake, shined up one of the sandblasted valve covers and got the timing cover to the 90% point. Once these pieces are done I'll strip the oil pan and then the bumper.





A little bit here, a little bit there, a few steps backwards and before you know it, the transmission will fall out!

I did order a Mag-Hytech differential cover as a Birthday present. Might as well be optimistic.:agreed:

 

[3500GMC]

So, the stock compression pistons are too tall for the block, or, what's left of it. Bill called Dumb and Dumber Diesel today and asked Benny what they had taken off the block to begin with. "Oh, enough" Gee thanks.

You. have. GOT TO BE KIDDING!?!

Do what you can to get these A-holes out of business. They are no longer of service to anybody or anything. There's no excuse for an engine machinist to make that kind of mistake- or rather, these KINDS of MISTAKES.. PLURAL...

 

[Paveltolz]

You. have. GOT TO BE KIDDING!?!Do what you can to get these A-holes out of business. They are no longer of service to anybody or anything. There's no excuse for an engine machinist to make that kind of mistake- or rather, these KINDS of MISTAKES.. PLURAL...

Sorry, I can't blame the machinist for doing what I asked him to do. To my minds recollection, there's too many mitigating circumstances that take the burden off of him. Rich may be a bit slow but, he's a one man band at his shop. Too many separate tasks without the comparative parts available which is my fault. He has never had the block and the whole rotating assy together at any time during this whole process.

No, with my own culpability in clear focus, I'm going to put the blame for this sequence of "Oh Just Shoot Me" events straight on to the shoulders of Bennie and Jamie Avante at Diesel Depot (DD or Dumb and Dumber) and Avante Salvage of Sandersville GA. “Just Desserts” for them though, their web page has been down for a while.

Had DD kept their word, honored the warranty, shipped the right parts at the same time along with the $$ to cover a small part of the work LAST MAY (2011), the chain of events that has led to this series of seemingly never ending mistakes/issues would have been mitigated. Then again, had they just spent $8 more on the one main bearing....just half of one of them even, this thread wouldn’t have even started. Fast forward to now and if I had compared specs on what was left of the deck height and old pistons, I wouldn't be in the current jam either.

Short catch up…The block was delivered to the Machinist in November where it sat while Ted waited for the rest of the parts, namely main bearings, cam, cam bearings, Pistons, Rods etc to show from Dumb and Dumber.

Those parts showed up weeks apart from each other over the next four months...pistons w/o rings etc. The crank, flywheel and 'reconditioned' heads (nothing but scraping some of the ceramic coating off during shipping) etc. had arrived but only in separate shipments and then only after days of phone calls to DD without the promised return calls.

So, the pistons arrive, but are left in the box without being inspected (oops on my part) and with their original 'specs' in mind, the block gets the full treatment at the machinists and it is confirmed good, and is decked .010. He doesn’t have the pistons and rods because we’re waiting on the wrist pin bushings to arrive (DD pressed them in without matching oiling holes). So, Later, the rods get the bushings pressed and measured but the pistons aren't with them cause it was then that they were found to be JUNK. The block returns from the shop and placed in a corner waiting for place on an engine stand and the rods get the wrist pins pressed and measured while waiting on serviceable pistons. New pistons were ordered from Mahle and here is where I take responsibility for the piston mistake.
1. I was asked what compression I wanted...Stock.
2. I answered without confirming the current specs on the block or the old pistons. Just that .030 would fit in the hole, not cylinder height…my bad.
3. I had the rotating assembly balanced with the new pistons that I thought (wrong) would be just perfect without confirming specifications.
4. There was at least two or more weeks between all this 'stuff' happening and I just can't blame a machinist for not remembering what was what. Maybe he should, I don’t know, I’ve not done this before but I have shop manuals and have stayed in a Holiday Inn Express….
So, again. Diesel Depot gets the blame for setting the chain of events in motion. I take responsibility for ordering the wrong pistons.

 

[jhornsby3]

You know, Paul, that one day this thread will end. Everything will come together and fall into place. Then what the heck are you going to do? Let me know when you have everything done so I can sell you another project to go adventuring on.:thumbsup: :rof:

 

[Paveltolz]

You know, Paul, that one day this thread will end. Everything will come together and fall into place. Then what the heck are you going to do? Let me know when you have everything done so I can sell you another project to go adventuring on.:thumbsup: :rof:

RE: Thread ending...sooner than you think. Once Ted's 6.5 engine is running, this thread is finished in it's current state. Honestly, this one has run its course and, as you alluded to during our GTG a while back, one want's to slit their own wrists after reading it...its about that depressing. Besides, all I'm really reporting is parts getting cleaned up to bump the thread and who really gives a hoot about that. So, as a public service, this one needs to have a stake driven through it.

RE: Parts coming together. Ted will deliver the motor in as many pieces as it is in and any he can find around the shop, especially the ones I've ordered AND paid for, to my home. Probably in October before the Vegas NHRA event. Hopefully sooner. It will get built and stuffed in the truck and the progress will be listed under a different thread.

Hope all is well with the family and the training. Would be good to have you all down this way when you're done but you gotta do what's best for the family.
Hang in there.

 

[OrionThade]

Sorry, I can't blame the machinist for doing what I asked him to do. To my minds recollection, there's too many mitigating circumstances that take the burden off of him. Rich may be a bit slow but, he's a one man band at his shop. Too many separate tasks without the comparative parts available which is my fault. He has never had the block and the whole rotating assy together at any time during this whole process.

I think he was referring to Dumb and Dumber ...

This whole thing has been unfortunate.

I'd say don't replace the pistons or anything ... just have Ted bring back the 6.2 block I sent up. We'll take it over to Strassburg and have him take care of it. That block is original ... it's had no machine work at all.

But I've been advocating that since you told me about this joke of a block a couple weeks ago.

 

[jhornsby3]

Hope all is well with the family and the training. Would be good to have you all down this way when you're done but you gotta do what's best for the family.
Hang in there.

All has been great. Just finished up the HEO101 class(backhoes, skidsteers, excavators and rollers) and will be headed to HEO103(dozers, scrapers, frontend loaders and motor graters) on tuesday. Then I'll have three weeks after that of CDL to look for work. Hoping that I can find something over there. Twood be nice to be in that part of the country. That copper mine is sending guys to Perth for work right now. They are looking for 200 operators to work for a measly 300kusd a year and sign a 2 year contract working 3 on 1 off. (weeks that is) and they will fly you out on your 1 off to anywhere in the world. I'm watching three mines in Nevada and two in Ut to see where they are going. Plus there is a couple of "smaller" outfits over there in your neck of the woods that are looking for guys year round. So the options are there and we'll see where they lead me in three weeks from now. There is nothing here in Boise that can be found.

And to keep things on topic, i have a new set of heads for the pick up. Need to get over and pick them up wash them and get them on. Maybe then I can stop this coolant leak and white/gray smoking issue I've been having. Now it's leaking oil at the back of the block, but I think that is the CDR plugging with condensation.

 

[Jamin6.5]

It sounds like you two have been having fun sense the GTG. I hope all goes well for you both. Let me know if there is anything I can do to help. jhornsby3 if you need anything from Utah I can bring it up for ya. And Paul Let me know if you need help on the truck down here.

 

[Paveltolz]

I think he was referring to Dumb and Dumber ....

I'm positive they were a very large part of the comment but I wanted to absolve Rich. He's not been speedy but he's done all that was asked of him.

There's no excuse for an engine machinist to make that kind of mistake- or rather, these KINDS of MISTAKES.. PLURAL...

I'd say don't replace the pistons or anything ... just have Ted bring back the 6.2 block I sent up. We'll take it over to Strassburg and have him take care of it. That block is original ... it's had no machine work at all.
But I've been advocating that since you told me about this joke of a block a couple weeks ago.

As for the block, trust me, last night I was ready to get in the truck and head up there and do just that. However, it's a mixed bag of nuts as having Rich tank it, magniflux, confirm the main's center line, hone the cylinders and deck it is about as much as he'll charge to re-balance the rotating assembly. Plus, he'll do it for a lot less than Strassburg. I'm not so sure Bill will charge me for the pistons either as he will be able to re-use them eventually. Don't get me wrong, that block is still a very viable option I have not discounted. I agree though, in hind site, it probably would have been a wiser course.

"Why do you keep banging your head against a wall?"
"Because it feels good when I stop!"