Away at work rebuilding an engine.. Big engine

[SwagWagon]

Just thought I'd throw this up here, I don't post often... well ever really but I do troll a lot and find useful information all the time as well as get good laughs.

I'm currently at work in Alaska during the fishing offseason and we're rebuilding our main engine and I thought I'd share the pics and the process of rebuilding this massive thing.

The engine is a Cummins KTA38, it's a 38 liter v12 diesel that's currently set up at 1200 horse and pushes our 100 foot trawler around. The rebuild is being done by a cummins mechanic, myself and a buddy helping.

Anyways here is where she started, well really close




At the end of day one



This was about half way through day two, got the whole exhaust side off



And by the end of day two we had all the heads off



Day three was a little slower but we still managed to get quite a bit done. The parts on this thing are massive and we're having to take them all out a flight of stairs that you can see on the right of the pictures.

Here is day three, today

This is the oil pickup



Pulling the pan was fun, the thing weighs about 120 pounds and it's aluminum



And here is how she sits now

Tomorrow we have to pull the front cover and cams and the flywheel before we roll it over and pull the rods, pistons and crank shaft out



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[auaq]

Love watching big stuff being taken apart and rebuild. I have watched videos of mechanics actually crawling inside a huge crankcase through tiny tiny access holes where the connecting rods are probably about 6 foot tall and is right in your face with little room to breathe. I can imagine the thoughts of just getting crushed and be overwhelmed by these 'giants'.

Keep us updated!

[SwagWagon]

Love watching big stuff being taken apart and rebuild. I have watched videos of mechanics actually crawling inside a huge crankcase through tiny tiny access holes where the connecting rods are probably about 6 foot tall and is right in your face with little room to breathe. I can imagine the thoughts of just getting crushed and be overwhelmed by these 'giants'.

Keep us updated!

This is obviously not that big haha. Nor would I want to really be a part of that


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[SwagWagon]

Here is the progress from today

Pulled the front cover off



Then the back half of the front cover



Had to flip it on its side to gain access to the rods/ main bearings



Hanging out with terry! This dude is awesome and really knows his business



Pulling the pistons/ rods



And the massive junk we pulled today, cams, main bearing caps and piston/rods



We also pulled the sleeves out of the block and the cam bearings and a couple other things, pics of that will come soon


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[geargrinder]

Yeah , cool stuff.

[auaq]

Quick question though ... are you going to run E85? What size turbo? Megasquirt? ARP mains and heads? Planning to run 8 seconds?

[geargrinder]

What size turbo? Megasquirt? ARP mains and heads? Planning to run 8 seconds?

Ha ha... Looks like he has twin-scroll Holset's now. Definitely should upgrade to billet wheel EFR's. Needs a purple and lime green anodized dress up kit too. Couple of nice loud whistle-BOV's maybe.


I bet that thing takes 8 seconds to rev to redline at no-load.
On the other hand it could tow your house off it's foundation.

[auaq]

Ha! It could tow it under 8 seconds .... Probably beat those tractor tow rig competition.

[SwagWagon]

Haha it's actually pretty quick to redline but it's designed to tow a net that's about a quarter mile long, and the boat maxes out at about 10 miles per hour if you're really pushing it.

As far as the hardware it runs hardened steel bolts, the mains get torqued to right at 600 ft lbs and the heads to 450. The thing is pretty insane.

I've seen a lot bigger in this industry just never torn anything else down like this.

Considering this is just 1200 horse and about 1600 ft lbs of torque.

Today being Sunday was a half day so we just cleaned the side of the block facing up and threw the new cam bushings in




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