Well guys, here is the deal. There are a number of people now getting into the 20+ psi range and we are all starting to run into this and that of the problems. I've had the great opportunity of getting to talk to race teams, other shops, as well as other members on here who are boosting up high. What I want to do is use this thread for an any and all "concerns" of dealing with the high boost. So first of all, a list of things that I see as hurdles as I work to have my motor done for March with a consistent 21-24 psi of RACING as well as occasional street use.
Tensioner belt - Rumor is that the acceleration of the high powered motors can cause the belt to jump.
Solutions: Dowel pin the tensioner or use a heavier spring for the tensioner
Sources for solution: None at this point past your machine shop
Rings - Rings obviously need to be upgraded. I received an informed opinion that the 21+ boost may be a little much even for the Total Seal TS1 race rings from a heat standpoint.
Solutions: Total Seal recommends their Max Seal (gapless top ring). These will handle the heats, but will eat your bores up. I'm working on an estimated 30K lifespan or slightly better with these rings.
Sources for solution: Total Seal, Summit Racing, Mental Addiction Motorsports
Piston Domes - obviously we are all forged if we are up in the range, but there is the risk of melting parts of the piston domes due to the excessive heat that can occur from mild detonation if a tune or gas goes bad.
Solutions: Ceramic or other coating to improve heat resistance and or dissipation of the top of the dome.
Sources for solution: None at this point, but several coaters are out there. Please update me with some sources for this.
Bearings - Apparently the racing teams have had trouble with wearing the bearings. Our pumps don't produce high enough oil pressure and running a traditional 20-30 thousandths clearance on the mains is too loose and rapid wear is occuring.
Solutions: Run Toga HP Main bearings, and run tighter bearing tolerances per rod manufacturer.
Sources for solution: www.importperformanceparts.net
Transmission - apparently at as little as 15 psi some teams have been destroying gears.
Solutions:Hardened gears, upgrade tranny
Sources for solution: MazdaMotorsports WCC hardened gears (1,000 dollars per gear)
Valves - The higher heats and exhaust volumes can do some definitive frying of the valves.
Solutions: Upgrade or coat valves to protect against heat
Sources for solution: None
Head Gaskets - Obviously boost can be hard on gaskets, there are schools of though toward both aftermarket MLS gaskets as well as the solid copper variety
Solutions: Due to the sealing issues many have with the copper a more advanced MLS may be the better route for this fix. Cometic should be offering a head gasket option.
Sources for Solution: Cometic, Mental Additiction Motorsports, MP3Racer (Tom)
Weak head - Rumor of a weak head that warps under massive boost which is then a contributing factor toward gasket failures. I'm researching tempering methods to strengthen things, but haven't been able to positively ID the head's alloy.
Solutions: No identification of the head alloy has been possible, thus no strengthening method can be identified yet.
Crank Walk: At high boost the crank can "walk" - move laterally in the block - and this can cause damage and wear to all components.
Solutions: Fill in/gusset the mains as necessary (focus on the thrust bearing main). Also, may be possible to cut crank and mains to add an additional thrust bearing.
That's my list at this point.. but please add and discuss so that we can make sure that even at forged levels we aren't popping motors constantly and costing all of us far too much money.
Thanks!
Steve
Tensioner belt - Rumor is that the acceleration of the high powered motors can cause the belt to jump.
Solutions: Dowel pin the tensioner or use a heavier spring for the tensioner
Sources for solution: None at this point past your machine shop
Rings - Rings obviously need to be upgraded. I received an informed opinion that the 21+ boost may be a little much even for the Total Seal TS1 race rings from a heat standpoint.
Solutions: Total Seal recommends their Max Seal (gapless top ring). These will handle the heats, but will eat your bores up. I'm working on an estimated 30K lifespan or slightly better with these rings.
Sources for solution: Total Seal, Summit Racing, Mental Addiction Motorsports
Piston Domes - obviously we are all forged if we are up in the range, but there is the risk of melting parts of the piston domes due to the excessive heat that can occur from mild detonation if a tune or gas goes bad.
Solutions: Ceramic or other coating to improve heat resistance and or dissipation of the top of the dome.
Sources for solution: None at this point, but several coaters are out there. Please update me with some sources for this.
Bearings - Apparently the racing teams have had trouble with wearing the bearings. Our pumps don't produce high enough oil pressure and running a traditional 20-30 thousandths clearance on the mains is too loose and rapid wear is occuring.
Solutions: Run Toga HP Main bearings, and run tighter bearing tolerances per rod manufacturer.
Sources for solution: www.importperformanceparts.net
Transmission - apparently at as little as 15 psi some teams have been destroying gears.
Solutions:Hardened gears, upgrade tranny
Sources for solution: MazdaMotorsports WCC hardened gears (1,000 dollars per gear)
Valves - The higher heats and exhaust volumes can do some definitive frying of the valves.
Solutions: Upgrade or coat valves to protect against heat
Sources for solution: None
Head Gaskets - Obviously boost can be hard on gaskets, there are schools of though toward both aftermarket MLS gaskets as well as the solid copper variety
Solutions: Due to the sealing issues many have with the copper a more advanced MLS may be the better route for this fix. Cometic should be offering a head gasket option.
Sources for Solution: Cometic, Mental Additiction Motorsports, MP3Racer (Tom)
Weak head - Rumor of a weak head that warps under massive boost which is then a contributing factor toward gasket failures. I'm researching tempering methods to strengthen things, but haven't been able to positively ID the head's alloy.
Solutions: No identification of the head alloy has been possible, thus no strengthening method can be identified yet.
Crank Walk: At high boost the crank can "walk" - move laterally in the block - and this can cause damage and wear to all components.
Solutions: Fill in/gusset the mains as necessary (focus on the thrust bearing main). Also, may be possible to cut crank and mains to add an additional thrust bearing.
That's my list at this point.. but please add and discuss so that we can make sure that even at forged levels we aren't popping motors constantly and costing all of us far too much money.
Thanks!
Steve
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