Spec Boxster Build

[thstone]

Sorry that I haven't updated this thread in awhile. There has been a LOT going on and I was waiting for everything to shake out.

** CAUTION ** TURN BACK NOW ** GRAPHIC ENGINE FAILURE PIC'S ** YOU WERE WARNED **

Unfortunately, my engine failed again during the first practice session at the PCA Willow Springs race. The engine suffered a catastrophic rod bearing failure. Since the complete rebuild in August, it only had 300-400 miles of street/freeway driving and 1.2 hrs of track time.

This was my 3rd engine failure in 5 months. To review; the first failure was in May - lifter failure. The engine was rebuilt but failed in June due to another lifter failure. Then the engine was then entirely rebuilt again in August using brand new lifters and lifter carriers to prevent a repeat of failure #2.

From my point of view while driving, it felt like the engine was low on power exiting Turn 3 and going up the hill into Turn 4. After coming down the hill and through Turns 5 and 6, the engine made a big bad noise, immediately shutdown, and spewed oil all over the track before the Turn 7 kink. The time between noticing low power and total engine failure was around 20 seconds.

This engine was a total loss (not rebuildable). And no, there isn't any warranty on engines used for racing. Ouch. That hurt. $eriously hurt.

As a result of the down time from engine failures #1 and #2, I had previously decided that I couldn't stand to be down for months due to an engine failure so I had already purchased a used engine (92K mile Tip) as a backup - I just didn't plan to need it quite this soon!

But being prepared for just this occurrence meant that the used engine could be swapped into the car in a couple of weeks rather than waiting 2+ months for a rebuild.

I specifically chose a high mileage Tip engine for two reasons; one, if the IMS made it this far, it is probably ok. Two, my theory is that Tip drivers may not rev the engine as much as a typical manual driver so the engine may have had a little easier life.

I plan to have the used engine dyno tested to see how the power compares to the original and rebuilt engines and will report back.

The replacement engine was also fairly cheap (around $4K including the labor to perform the swap) as compared to a full professional rebuild ($14K+).

With all of that being said, this update ends with the car running again and ready for more action.

Stay tuned for a special announcement coming in early December regarding 2015...



Intermix coming out the intake ports is never a good sign....



Lots of debris in the pan...



Missing a nice big piece of the cylinder and the case (directly above the missing cylinder)...



Broken camshaft, bent valves...



This is what was left of the rod and piston...



Crankshaft damage indicates a rod bearing failure...

[com3dorm3]

Whoa that hurts!!
I should have paid attention to the warning, but I had to see it...
Any insight on the possible cause of the rod bearing failure?
Sorry to hear about the kaput, but good that you have another engine lined up already.

[thstone]

Originally Posted by com3dorm3

Any insight on the possible cause of the rod bearing failure?

Unfortunately, with damage that severe it's impossible to know the cause.

I am finding that racing tests your level of commitment in many ways and some of them aren't on the track. No one said that racing would be easy and this is one more example of how racing is often seen as a microcosm of life.

Glad that this is behind me and really looking forward to 2015!

[stephen wilson]

I didn't see it mentioned, what oiling system mods do you have ?

[Topless]

Eeeeesh! That sucks the joy out of racing. Sorry Tom.

I do think "plan B" is wise though. When a motor grenades it stresses, wears, and deforms in unexpected ways and shiny bits get into everything, everywhere. A sound used motor with clean oil is not a 100% sure thing but probably a lot more certain than one that has been a metallic sausage grinder. I went through this in an earlier life with both a 350 Chevy and Ford 351 motors.

Best wishes for 2015 my friend!

[thstone]

Originally Posted by Topless

Eeeeesh! That sucks the joy out of racing. Sorry Tom.

I do think "plan B" is wise though. When a motor grenades it stresses, wears, and deforms in unexpected ways and shiny bits get into everything, everywhere. A sound used motor with clean oil is not a 100% sure thing but probably a lot more certain than one that has been a metallic sausage grinder. I went through this in an earlier life with both a 350 Chevy and Ford 351 motors.

Best wishes for 2015 my friend!

Thanks and yes, my thinking is that it was time to start over with an engine with only street use and no previous metal processing! I am hoping that this engine will last as long as my previous stock engine.

[thstone]

Originally Posted by stephen wilson

I didn't see it mentioned, what oiling system mods do you have ?

The engine had an EBS sump baffle but otherwise is stock. No Accusump. But I am seriously looking at options.

[jaykay]

Originally Posted by thstone

The engine had an EBS sump baffle but otherwise is stock. No Accusump. But I am seriously looking at options.

Wow that hurts. Three in one season is just crazy! Any over revs? What was did different about your previous engine/car? Diff. tires and tracks?

I never really understood the EBS baffle's specific value other than being metal and the incorp. of the small baffle sections....I guess I would have to get my hands there to see how it fits up. There is no reserve oil volume and it would appear oil can still "climb" the baffle walls. I would think a trapped volume oil via a windage tray (horizontal baffle and vert. baffles would be the way to go with a deep sump as big as your ground clearance goes...then Accusump? Anyway there a few good sumps on the market now.

Ahh I know a guy....think he looses an engine a season (M97)chasing mustangs and camaros....high revs then boom