Blown FD @ KDRotary
 

I have a worked FD3S. I have all the mods you can think of, from the Greddy T88 kit to the Apexi PFC (too many mods to list). My car was at KDR a month ago for the 1600 injector kit installation and tuning. It turns out my car was tuned too rich, where my car drove poorly, mileage was terrible and the whole rear of my car was carboned up. So Dave had to fit me in for retuning on the Dyno a week later.
Guess what happened next? On Daves second run my engine blew up. Nice, huh? There was supposed to be a knock sensor hooked up to the car during the dyno run, I don't know what happened to that. The car was also running rich, so I also don't understand how the engine blew @ 4500 rpm (16 psi).
Now I had to wait 2 weeks for Dave to tell me the engine was not rebuildable. I had to go through Malloy Mazda, and get a new engine sent to KDR for a swap.
2 months and about $4000 dollars later, I went to pick up my car with the new Mazda rebuilt motor. I headed up to KDR from Jersey. I went into the garage where they work on the Rx7's to see white smoke everwhere. I couldn't even see the end of the shop. I found out that that was from my new engine.
Italked to Dave about the problem, and he stated "The cars is in perfect work order, everything but the turbo."
I was like WHAT!!! The turbo was about a month old. He said that when the engine blew, the apex seals broke and sent debris into the tubo desroying the oil seals. He stated "that i s the reason for the massive white smoking."
If I remember correctly, a turbo wouldn't create a problem like that, especially a new Gredyy T88.
In other words, Dave was telling me, because my car blew up on his dyno, I now have to bite the whole bill for the motor and now the turbo (a month old turbo) WTF!!!
I sent out the turbo to Majestic turbo for a rebiuld, and guess what Kevin (a representative of Maj Turbo) told me. The turbo was heatted up so much that it began to have play. The turbo any how was not leaking any oil and could not have produced the white smoke. The engine had problems of itself.
I started then to remember when I first saw my car at KDR with the smoke everywhere. There were 2 containers of Prestone coolant in front of my car with coolant all over the floor in front of it. Think about it, white smoke poring out = coolant problem (it smellled like coolant all the way back to Jersey.)
I spoke to Malloy Mazda about the problem and they had no problem replacing the engine ( it was under my warranty and agreement with KDR). Now all I'm waiting for is for Oct 2nd for Dave to come back from vacation and swap out my engine for another new rebuild. I'm assuming, my coolant seals are toast.
What do you guys think of this fuck up?:mad:

Here is a couple pics of your T-88
 

You still remember me the guy with the Red T-78. I took these pics last week when I came to pick up my car at KDR and happen to see your car there. I can see that Dave have pulled out your engine. I see your turbo laying down and I take a couple of pics of it. I also see a dyno sheet in your car it was something like 347rwhp and 500+ft. lb of torque. I think it is something wrong with the dyno number. So is Dave going to pay for your engine or what. Sorry to hear that, it sucks bad. So this time you better do it right. I remember that you have a stock engine and all you did was the power fc, the T-88 and some fuel stuff right. So you mean to tell me that because the engine blew up and how come your turbo blew up also, how is this possible. But all I know is $$$$.

http://www.z32.org/unsorted/Dsc00314.jpg
http://www.z32.org/unsorted/Dsc00315.jpg

the mullet strikes again

One thing you guys seem to forget or don't follow; if you want reliable big power then you need to use the best components. Use new rotors and rotor housing or ones with known low mileage, have the side housings relapped and spec, very carefully spec the e-shaft and stat gears bearings, upgrade by modification the oil system, and have the complete rotating assemble dynamically balance. Use all new rotor seals on every
rebuild.

This is not as important if you are only going to run up to about
14PSI with street or stock porting, but when going above this it
definetly is the way to go.

I would never again use a Mazda or other rebuild just to save money. I got bit by Hayes doing that!

Just my conservative experienced POV.

ROFL .. sux carl.

my engine is currently getting rebuilt and street ported. only parts being reused are rotors and eshaft :D

My engine is being rebuilt by Larry Scott and $4300 of new parts from MazdaComp. The only re-used piece is the rear rotor. It's getting an aggresive street port also. I am still not sure about turbo's, mine have cracks etc and I don't want to risk them hurting my new engine so will either run new twins or a T04S or T78.

I remember a while back when Mr. Gordon Monsen had his car tuned on the dyno at KDR and the engine blew up, Dave took care of it without charging him. Gordon, can you tell us your experience again to help this guy out?

When I was at KDR a few weeks ago I remember seing a red fd with a single turbo that was being worked on. I asked Dave about it and he said it was being rebuilt. He said the owner wanted a single turbo kit installed on a 80k mile motor. Despite Dave's advice to rebuild the motor first, the single turbo kit was installed anyway. When Dave went to tune it on the dyno the motor popped at 10 psi. Now I don't know if this is the same person and car, but if it is, you cannot blame Dave for that kind of stupidity. You can't just slap a big turbo on a old motor and expect it to hold up. Dave has always been honest with me and always provided me with the best service.

Yeah I would be concerned about how many miles you had on your motor. You mentioned you have a ton of mods. But how many miles did you have on the motor??? Not saying that it should be anyones fault, but give us that peice of information, so that we can have the whole story.

I agree with Ihor. Dave has been nothing but honest, reliable, and upfront with me at all times. I have a KDR/Malloy rebuilt ported motor. One point I'd like to make is that the Malloy rebuilds are all basically new w/new rotors and new rotor housings. When I was looking for a new motor in April Dave told me they were all new and when he pulled mine apart to port it, the rotors and housings were new as expected.

We definitely need more details. In the past when Dave has made mistakes he has always corrected them free of charge. Something doesn't seem right here...

My car had 70k on it. I was running the single turbo set up before I came to KD. To tell you the truth, my car ran sweet. Perfect idle, no detonation, and massive acceleration. I came to dave for reliability mods and some additional tuning. He swapped out all my HKS and Greddy piggy back fuel computer stuff, for the Apexi PFC. (Dave recommended it over the Haltech)
Now back on the subject, my car shouldn't have blew up. I paid for it anyway. The turbo was also sent to Majestic Turbo, because Dave said that the turbo was causing the smoking. Dave was wrong. The new rebuilt turbo is back on the new engine, and it's smoking still. I remember Dave wiping up all the splattered coolant on my I/C piping. I thought it was from way before, I was wrong.
Thanks Dave. You sent me home with an engine that you knew had coolant leaks and other problems. I could have messed up a whole list of other components too on the ride back to Jersey.
Another thing was that Kevin from Majestic turbo said that the turbo was practically new, there were no leaks. Because Dave told me to send the turbo to Majestic Turbo to get the oil seals replaced, I wasted $554 including shipping. Thanks again Dave.

pfc over haltech? heh probably cuz hes backed up and doesnt have the time to do a decent haltech install =]

That's not funny. I paid Dave $1500 for the PFC, not including the installation. I spoke to Ari today at E-town, even he says that it shouldn't have happened.
Anyway I don't even want any trouble with Dave. The Mazda dealer said they will support me with my warranty. I hope Dave does the same for the labor. I think I spent enough money on a stock rebuild.

Gordon: I went with your suggestion, to go with KDR. I wasn't ready to be so disappointed. Carl...

Wassup Carl!
 

So it looks like you paying for the whole deal. So is your turbo still working. Your car is still at Dave right.

Hey Alex. What's up? Dave gave me my car back right before he went on vacation. He should be back on Oct 2nd. Mazda's going to ship a new engine to KD on the 1st, so it get's there when Dave gets back. I'll also be there on the 2nd to drop off my car for the engine swap.
I have to tow my car there, and guess who's taking care of that bill too? Yours truly.
This type of shit, makes me want to sell my car. The Rx7's will surely be a dying breed if this type of occurrences keep happening.:eek:

Well I will be there Oct.23 to get my car dyno and tune hopefully his dyno is up and running. So you say that you are going to put another engine in there is it stock and are you still using that T-88 that Dave saids is no longer good.

I already had the turbo sent to Majestic Turbo for the rebuild. It has been put on my car. I started her up and she's still smoking. The engines a gonner.

Sorry about your $ loss.

Dave didn't do the single install, right? Who did?

I installed the turbo kit. All the small stuff is easy to do. Why would you pay for anything you can do. The only thing I wouldn't do was pull out the block, build and port. Maybe I would later, I gotta pick up one of those cherry pickers.:eek:

Personally, I'm not going single until I can pull the block, rebuild it and have some port matching done. Only thing changing that would be blowing it completely now.

Now I know quite a few of you have tied on a single with the stock block. And some of you have actually not blown that stock block yet...

I still think Gordon has done alot of trailblazing for some of us long time lurkers. And he in turn has built on the vast store of information from other people. Not sure if its a common theme or common sense, but I know (esp. from CP's experinces) I am going for the rebuild before the single.

Happy at 368RWHP for the time being...

Back on the subject, my car is back at KDR. Dave has told me that the 850 primaries were causing the plugs to foul out, and that was the cause for the stalling out all the time.
The smoke problem was still a mystery, and was the oil eating problem. There are many ways to deal with the problem. One way is to waste alot of time breaking down the block and finding the faulty rings and seals. And the other way is to use the warranty from Mazda and replace the faulty block. Obviously we went with swapping out the block.
Dave is going to warranty the work and take car of the new labor and parts charges. And Malloy Mazda's going to ship another new block at no charge.
I had a good discussion with Dave before I left the car. We agreed the care wouldn't leave until it was running at 110%.
Hopefully the car will finally come out right.
I'll keep you posted. Carl...:eek:

Hmmm - this gripe-thread seems to be turning into a real soap-opera.....:)

Looking forward to learning how the car turns out.

Those who want to read Dave's post in this regard can find it at:

https://www.rx7club.com/vforums/show...2&pagenumber=1

I am the thread originator. All that replied to the thread contributed in converting a comment post into a childish soap opera. Even Dave from the infamous KDRotary has joined in as one of the star contributors.:eek: