Anyone have a cylinder mysteriously rust?

[DirtbikePilot]

The liner on my 6/1 rusted.  WTH? I think maybe some coolant got in there and caused it, but I don't know. I took it apart because I had coolant coming out the top of the cylinder studs. It wasn't a big leak, but the top of the nuts got covered with coolant after a day or so after wiping them off. It also started to slobber oil out the exhaust and it didn't do that at first. I pulled the head and found that the liner is rusted. It is worse at the top, then tapers back to almost no rust at the middle of the liner (top of the piston when the piston is all the way down in the stroke). It's getting a new liner, piston, rings, head gasket, blah blah.... This sucks though. Has anyone else seen this?

[hotater]

DBP---

It sounds like what happens to my headgaskets on a regular basis.   

Look really close at the seal ring on the head gasket.  You'll find an area maybe .010 wide that's wrinkled or collapsed.  The fiber center might be missing in spots, too.

As posted on another thread--  I'm currently running a head gasket that I treated with a 2:1 mix of Permatex Aircraft Gasket and alchohol to thin it.  I carefully peeled the Indian copper back and painted the sticky goo on the fiber portions of the gasket.  It soaks it up!   So far so good.

Buy a new combination sharpening stone of at least six and preferrably eight inches in length and stone the head to be sure of flatness and cleaniness.   Mine changed some after initial run-in.
 Use fuel as a cutting oil and dunk the stone often to flush the crud out. 

JUST to be sure--- degrease the head with brake clean and dry it completely without the valves and injector installed.  Paint on a little gasoline and watch it dry closely.  Watch for cracks where gas leaks out after the surface is dry.  That's just to be sure there's not a cracked head letting water in.

[Doug]

Wow that gas trick is a good idea!!

Doug

[DirtbikePilot]

Thanks Jack. I check the head and get a new one of those too if it's cracked. I'm going to get a "real" composite head gasket for this thing from Eric. These indian things are garbage.

Did your liner ever rust any? What did you do with it? Mine's rusted bad enough to erase all traces of the honing.

[DirtbikePilot]

Doug, you have the most random signature ever buddy.... lol

[Doug]

It was that or "You can't sqeeze cheeze from a caw before it hatches".

There was an old TV series here In Canada imported from England called "the prisoner". Thats where I lifted my signature, I'm just not that creative......
The cow thing is classic "Ren and Stimpy", I'm also not very sophisticated....


Doug

[solarguy]

Dear Dirtbike,

What were you running for coolant???  Proper concentration of ethyl or proply glycol shouldn't really make it rust, should it??

Yeah, we gotta fix this whole weepy gasket thing.  My next attempt, as described on another post, will have the fiber part of the head gasket doped with sodium silicate based antifreeze stop leak.

The permatex thing also sounds promising.

Everybody keep everybody posted.

Finest regards,

troy

[hotater]

  Mine's never rusted to where it starts covering the honing marks....but its' never off long enough to do that, either.

A leaky headgasket can put a prodigious amount of water in the cylinder....and STILL crank and run, but not on the first try! 

My plan was to make a two piece solid gasket from sheet copper but that material is not available without special order.   The Permatex stuff is working great so-far.  No weeps, leaks or stains.

[Jim Mc]

The liner on my 6/1 rusted....

What brand of engine was this?

[Tom]

Oh no my Ashwamegh 6/1 is doing the same thing.  I retorqued the head last weekend and it seems to have stopped. Exactly what was the failure?

[DirtbikePilot]

This is my ashwamegh. No problems yet with the satyajeet.

I looked at the gasket very closly, and saw no problems with the cylinder sealing ring. This may have been rusted from the start, but I don't know. It ran perfectly when I first got it. The rust is not uniformly distributed in the liner. It's mostly on one side near the top, tapering to clean metal near the top of the piston when it's as far down as it goes.

The coolant mixture was more water than antifreeze with a ratio of around 1:4 or so, but that definitely would not make the inside of the liner rust.

[listeroidsusa]

If I were to build a die and punch some solid copper head gaskets do you think I'd be able to sell enough to come out on it? I have the equipment to manufacture these but I'd need to build a die set to stamp them. There are two different head gaskets, one for the original configuration and one for the engines with liners and only one small stud. The water passages are different so they are not interchangeable. Prices would be considerably higher than the Indian parts primarily due to the current astronomical price of copper. After the copper and the labor to build the die set are figured in the head gaskets would probably be in the $20-30 range. A gasket made of a material other than copper would be less. Fel-Pro makes some good gasket material too.

Mike

[kyradawg]

Peace&Love , Darren

[DirtbikePilot]

Yeah. I have heard that folks who have tried solid copper head gaskets in cummins engines have constant coolant leaks. It leaks out and runs down the block and also gets in the oil. I keep telling everyone to just use the same kind of head gasket that is used in every other application. Eric at RMPS has them custom made and that's what I'm getting.

[SHIPCHIEF]

Hey Dirt!
I recall your engineroom picture on the coppermine; you have the 20/1 and the 6/1 exhaust pipes joined to use the same uptake out of the engine room. When you run the 20/1 the exhaust goes right thru the Tee from the 6/1. Some exhaust must be going into the 6/1 and the corrosive cool gasses are rusting your liner. You need an exhaust cut off valve, or separate uptakes. Diesel engines usually don't share an exhaust pipe.
Scott E