09/03/2026
Brief update: 2 steps forward, innumerable steps backward;
The last couple of weeks have not been good, at least not from a productivity standpoint.
First and foremost, Yeti is down. I dropped it off with Kevin a few weeks ago for him to install a wideband O2 system so I could start fine-tuning the carb. Kevin got the system installed, took the truck for a brief test drive, and the truck responded by promptly overheating to 240°. He limped it back to the shop, checked coolant once it was safe to do so, only to find the radiator basically empty. As there were no external leaks and nothing coming out the exhaust, that left only one option--when he pulled the dipstick, he found the crankcase full of milkshake.
Just before the 2nd dyno session, I'd pulled the intake to swap out the solid roller lifters for the Johnson hydraulic rollers. As the intake gaskets were still in decent condition, I simply siliconed them and reinstalled the intake as I've done countless times before. There initially appeared to be no problem as the engine exhibited no issues while on the dyno.
Looking back at that moment, it dawned on me that I couldn't remember re-torquing the intake bolts, so I had Kevin R&R the intake. The gaskets didn't look all that great and the intake bolts had indeed loosened up, so I/we assumed we'd found the issue. Everything was buttoned back up, and the initial fire-up appeared promising as the engine ran fine (after a double oil change btw), and a brief test drive had coolant temps at 170°-180°, so the truck was parked and left for the following day to wrap up the final small loose ends.
Yeti had other ideas.
When Kevin re-checked the oil, it was over full, and the coolant level had dropped. This time there was no milkshake, but there was roughly a quart of water that made it's egress from the oil pan before the oil came out.
The only possibility I can think of is that there may be a porosity issue with the block--there was a tiny "blemish" in the #6 cylinder after Mike had finished boring & honing the block, but it was initially deemed to be cosmetic. Apparently it wasn't.
(Look at the 12:00 position of the bore about half way down in the attached pic)
Kevin is booked up for the next couple of weeks, but once he has time the next step is going to be pulling the plugs and pressurizing the cooling system while listening with a stethoscope in the #6 hole to see if anything can be heard. Assuming this is indeed the issue, the 572 will have to come back out and be completely disassembled so I can have the #6 hole sleeved.
I'm not even going to bother with trying to chemically seal it for 2 reasons:
1) The leak is winding up in the crankcase, and the last thing I want in the oil is sodium silicate--remember that whole "cash for clunkers" fiasco from a while back?--that's precisely what big brudder used to intentionally destroy the engines so they could not be salvaged/reused.
2) I'm not going to trust a chemical sealant to hold up under direct cylinder pressure.
As I have big expenses (taxes and homeowners insurance) coming up, I definitely do not have the extra funds to cover this at this time, so it's a matter of whenever Kevin can find the time to dedicate to it and I can find spare funds to dedicate to it.
That fiasco aside, I'm still in hurry up and wait mode on several other projects due to delays with outside resources. This is actually a significant issue as I can not complete these projects until I have parts back, and as such I can not get them listed for sale so I can recover those investments.
As of now, it looks like "death by a thousand paper cuts" is on the itinerary for me.
Something's gott'a give...🙁