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01-04-2014, 01:06 AM | #1739 | |
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01-04-2014, 01:36 AM | #1740 |
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01-05-2014, 01:51 PM | #1741 | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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Great Bearing Measurements of 2014
Great Bearing Measurements of 2014
Preparation for clearance measurements I wanted the clearance measurements to be as controlled as possible. To me, this meant following the manufacturer’s specification and maintaining a proper and controlled temperature environment. Each bearing was installed in the rod and the rod bolts were properly stretched. The fitted rods were placed out on an open table along with the measuring equipment for two hours before measuring. The room temperatures were set to approximately 74-77 degrees Fahrenheit to match the conditions at Van Dyne Engineering during the original tests. (To be honest, I didn't have my portable weather gauge with me at Van Dyne during the original tests, so I'm only guestimating the original temperature.) I am hoping these procedures will gain uniformity between all of the temperatures, measurements, and measuring equipment. Selecting bearing pairs to match rod bearing bores I wanted to simulate the possible effects of tolerance stack up. So before beginning to assemble the rods and bearings, I had previously measured all of the rod bearing bores. These measurements were as follows:
To simulate the tolerance stack up, I wanted to select bearings as described below. Since it might not be possible to simulate all combinations, the following table describes my order of preference.
Using these criteria above, I came up with the following rod/bearing combinations.
Stretching rod bolts and installing bearings Both sets of bearings (702/703 and 088/089) were given new rod bolts so the tests would be as equal as possible. New S65 rod bolts must be stretched before use. The stretching procedure is very specific. You must torque and release two times prior to final torque and use. The following procedure is documented in the BMS TIS guide for building the S65 engine.
This procedure would normally require two different tools. First you would need to use the torque wrench to torque to 6 NM then 20 NM. Second you would need to change to the torque angle gauge. The pictures below show the procedure with a normal (albeit electronic) torque wrench + torque angle gauge. The normal procedure shown above is good, but is prone to minor errors. That type of torque angle gauge is can slip a little -- making the torque angle less accurate. This error happened to me repeatedly while stretching the rod bolts. So before the final rod bolt stretch, I decided it was time to upgrade my torque wrench anyways. I bought the all-in-one electronic Snapon ATECH3FR250B TECHANGLE torque wrench/torque angle gauge. This is a very nice torque wrench that is capable of switching between torque and torque angle. The electronics in the device make it possible to switch between units of torque at the press of a button (ft-lbs, in-lbs, Nm, dNm, Kcgm, and torque angle). The wrench supports different pre-sets too. So I was able to set the 20 Nm on one setting, then hit the button and switch to 130 degree torque angle. With this tool, there is no need to switch between two different devices. Before the final stretch, all the rod bolts were completely removed. Each bolt was re-oiled, and the rod bolt under-cap was re-oiled as well. This ensures no galling could take place and an accurate final setting. The vice is also fitted with hard rubber boots to prevent damage to the connecting rods when they are clamped in. Final Preparations I'm almost ready to begin measuring. There's just a few more things I need to do. I promised to provide eccentricity measurements, so I need to mark the connecting rods at 5, 45, 90, 135, and 175 degrees. Before measuring, I let all of the rods sit for two hours in the open air room temperature with thermostat set to ~76 degrees. The measuring equipment sits at the same location at the same temperatures. The Kestrel 4500 portable weather station is the small green device sitting on the lower left near rod #5 in the first photo, and upper left near rod #1 in the second photo. You see these on TV shows like Deadliest Catch. They are very nice and very accurate. This particular model will data log all environmental conditions and allows me to take individual snapshots in addition to a continuous data logs. Last but not least, after letting everything sit for a few hours, I re-measured the crankshaft journals. No surprises here, they measured exactly the same as before, although in a different order. By that I mean, the measurement spread was identical to before, but the measurements seemed to change order on the journals. When you're talking about measuring tenths (0.00010 inch) and half-tenths (0.00005 inch), I'm told this is quite normal. Just to make sure, I called Van Dyne for advice. Van Dyne told me: "If you try to understand it and don't ignore it, you'll never get anything done."
The Results: 088/089 Bearing Clearances Calibration and set up:
Official 088/089 Bearing Thickness and Clearance Specifications
Notes: (1) Includes previous measurement results from Van Dyne Engineering When comparing to the original Van Dyne measurements, there seem to be no surprises here. The crankshaft journals measured within the same ranges, as did the connecting rod + bearing assemblies. With the addition of the newer virgin 089 bearings, I have changed the "official" estimate of 0.00125 inch clearance to 0.00140 inch clearance. That's a 0.00015 inch increase over the previous nominal measurements. That increases the nominal clearance-to-journal/inch ratio from 0.00061 inch/inch to 0.00068 inch/inch, which is still lower than the minimum Clevite recommendation of 0.00075 inch/inch. 702/703 Bearing Clearances Calibration and set up:
Official 702/703 Bearing Thickness and Clearance Specifications
For me, there were no surprises here as well. Kawasaki00 had measured a full set of 702/703 rods with better equipment and detected a 0.00030 inch increase in clearance. The measurements above confirm that, and found a 0.00025 inch increase in clearance (effectively the same thing as kawasaki00's findings). Conclusions This was an enormous amount of work. I tried to be as meticulous as possible. I was willing to let the data show, what the data shows. There are some slight inconsistencies and deviations from the previous measurements, but those deviations are in the noise (0.00005 differences). All in all, everything turned out the same. Putting together the charts and tables is very time consuming work. There was a lot of cut-paste from one table to another. Even though I tried to cross reference very data entry with photos, it's very possible I made some mistakes here when I cut-paste some entries. If any such errors are found, please point them out and I will fix them. The front page clearances have been updated to reflect these new findings. Still to come:
Last edited by regular guy; 01-05-2014 at 07:46 PM.. |
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01-05-2014, 04:21 PM | #1742 |
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WOW!!!
Thanks for all that CRAZY work and the work you have planned ahead. .
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Let me get this straight... You are swapping out parts designed by some of the top engineers in the world because some guys sponsored by a company told you it's "better??" But when you ask the same guy about tracking, "oh no, I have a kid now" or "I just detailed my car." or "i just got new tires."
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01-05-2014, 05:15 PM | #1743 |
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I'm a bit confused here. From your logs it seems there is a .00081" per inch rod clearance, which is in the middle of the Clevite recommendation.
Isn't this whole thread based around your claim that the clearance was way out of the Clevite 'Best practice' spec? Nice torque wrench BTW |
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01-05-2014, 07:32 PM | #1744 | ||
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You already know the answer; why pretend like you don't? It's even the second or third time we've discussed it. Why don't you tell me the answer this time? Quote:
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01-05-2014, 10:18 PM | #1745 | |
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Nice work RG, a few comments, suggestions and observations.
But first... Quote:
Also (as suggested prior) since Clevite is not the manufacturer for these bearings we really should not even be holding them to the exact same standard. Either way the notion that the S65 (rod bearing) clearances are radically tighter than this "norm" should now be pretty well laid to rest as false. Unfortunately, the flip side to this is that BWM did either design in (most likely in my opinion or perhaps accepted as a consequence of manufacturing) a 20% increase (dead between my prior 15-25% estimate based on bearing thicknesses alone) in bearing clearance along with the update from the old (088/089) to new (702/703) bearings. Unfortunately, we'll most likely never know if this was some preemptive effort against premature bearing/engine failures. It seems reasonable that the material itself may simply have required a different actual clearance that is some way is more like the same initial clearance. RG: -Good job choosing bearings/bores etc to maximize variations. That was smart. It is interesting to note that even despite this choice the worst case clearance ratio for the 702/703 bearings was still larger than the minimum Clevite specification. -"Official" really should not be used as a term. This is not a number off of a print, it is an observed sample population mean. -"Nominal Bearing Clearance" also is not a nominal value, a nominal value is a print/design value simply without a tolerance". This should simply be called a Measured Clearance. -What are Min and Max Stack Up Clearances? Are they just to account for the additional variation of +/- 0.0005 on the crank? -Lastly it is a bit odd to also include the Van Dyne measurements here most notably because in the final white/grey tables some include those efforts and some don't. Observations: Not to much surprise the difference in the thicknesses of the bearings at 90° to parting directly contribute to the same reduction in installed bearing diameters and clearances. The observed old/new bearing total size difference was about 3.5 tenths difference and the old/new average clearances are different by 2.5 tenths. There is no overlap in the clearances (total range with min/max values) in the tables for the old/new bearings. Also there is a similar and very large ratio of the difference in the mean clearances for the old/new compared to the standard deviation thus leaving no doubt that the consistency of the measurement is not an issue and is fully capturing a real difference in the assembled parts. Again, the notion that the S65 (rod bearing) clearances are radically tighter than the Clevite recommendation should now be pretty well laid to rest as false. The obvious big remaining question then what is causing the failures on the later model cars that had the newer 702/703 bearings. Perhaps, it's just simple statistics and an unavoidable result of building an engine like the S65 for a mass produced sports sedan and the number of failures/total probability of failure is more or less in the noise (basically my contention all along old or new bearings...)
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01-05-2014, 10:22 PM | #1746 | ||
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01-06-2014, 11:31 AM | #1747 | ||
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http://www.m3post.com/forums/showpos...4&postcount=32 Quote:
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01-06-2014, 11:42 AM | #1748 | |
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01-06-2014, 11:45 AM | #1749 | ||
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Here it is: http://www.m3post.com/forums/showthread.php?t=931268
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01-06-2014, 12:04 PM | #1750 | |
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16 F82 M4 DCT - ZCP - JB4 - 556WHP / 570WTQ
08 E92 M3 DCT - Bolt Ons - 60-130MPH 10.71s - 11.88 @ 118MPH - 377WHP ESS VT2-625 SC 60-130MPH 6.80s - 11.30 @ 129.3 MPH 586WHP / 379WTQ ESS VT3-750 - 60-130MPH 6.14s - 10.81 @ 135.13 MPH 690WHP/463WTQ Shift-S3ctor E92 M3 - 1/2 Mile Trap Speed WR - 174.13 MPH |
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01-06-2014, 12:11 PM | #1751 | |
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Since none of us work at BMW and have direct access to the information, that means ALL of our opinions are speculation...your above opinion as well. Yes "it" was changed. The list of allowed oils changed from strictly TWS-10W60 to TWS-10W60 + all LL01 oils. |
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01-06-2014, 12:13 PM | #1752 | |
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01-06-2014, 12:14 PM | #1753 | |
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"2) BMW changed spec on oil to 0W40 in August 2013." There is a difference between CHANGING the spec, and ADDING oils that are approved for use on this engine. It may be a coincidence, or it may not be - this is what I stated in my reply in the other thread linked. Edit: I see what you are saying about "changing" the spec. Yes - it was changed. I was only clarifying that it was changed to add more oils, and that the oils previously allowed have not been changed.
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01-06-2014, 12:16 PM | #1754 | |
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16 F82 M4 DCT - ZCP - JB4 - 556WHP / 570WTQ
08 E92 M3 DCT - Bolt Ons - 60-130MPH 10.71s - 11.88 @ 118MPH - 377WHP ESS VT2-625 SC 60-130MPH 6.80s - 11.30 @ 129.3 MPH 586WHP / 379WTQ ESS VT3-750 - 60-130MPH 6.14s - 10.81 @ 135.13 MPH 690WHP/463WTQ Shift-S3ctor E92 M3 - 1/2 Mile Trap Speed WR - 174.13 MPH |
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01-06-2014, 12:16 PM | #1755 | |
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"Pretty clear where I'm sitting that BMW didn't think all was well, and that increasing clearance alone didn't fix whatever they were chasing. The question begs back to BMW: if it ain't broke, why did they try to fix it...twice?" My apologies if I read this the wrong way.
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01-06-2014, 12:16 PM | #1756 | |
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16 F82 M4 DCT - ZCP - JB4 - 556WHP / 570WTQ
08 E92 M3 DCT - Bolt Ons - 60-130MPH 10.71s - 11.88 @ 118MPH - 377WHP ESS VT2-625 SC 60-130MPH 6.80s - 11.30 @ 129.3 MPH 586WHP / 379WTQ ESS VT3-750 - 60-130MPH 6.14s - 10.81 @ 135.13 MPH 690WHP/463WTQ Shift-S3ctor E92 M3 - 1/2 Mile Trap Speed WR - 174.13 MPH |
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01-06-2014, 12:19 PM | #1757 | |
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01-06-2014, 12:24 PM | #1758 |
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I'm not trying to "get you".... There is no reason to be aggressive. I think clarification on this point is important, that's all.
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01-06-2014, 02:58 PM | #1759 |
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I don't see the point in carrying on the same conversation in two different threads by pulling quotes from another thread and bringing it here. If clarification is so important, then you can ask and wait for an answer or send a PM. It's usually impolite to pull comments from one thread and bring them over to another. Most people might consider that an aggressive move; but it doesn't bother me to be honest.
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01-06-2014, 03:15 PM | #1760 | |
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