Bulletproof Diesel head crack repair kit? - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 18 (permalink) Old 07-17-2016, 11:09 PM Thread Starter
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Bulletproof Diesel head crack repair kit?

Anyone use this to repair a crack in the injector bore? I have a crack above the cup on #5.

It's about half the price of a head, but I don't have the ability to lift the cab to do a proper head job. This kit looks promising.

Anyone have experience with it?

BPD Cylinder Head Repair Tool, Ford 6.0L



BTW, here is my diagnosis:


2005 F350 6.0/5r110
1998 Jeep TJ 5.9/46RE/Stak D300
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post #2 of 18 (permalink) Old 07-18-2016, 04:22 AM
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Re: Bulletproof Diesel head crack repair kit?

Never used it. Don't know anyone who has. If you have the money, you can do a head job with the cab on....just takes a little patience and finesse.

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post #3 of 18 (permalink) Old 07-19-2016, 01:37 AM
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Re: Bulletproof Diesel head crack repair kit?

There is a new product out there, 6.0L Ford Powerstroke Cylinder Head Repair Kit - Save $5,000! , it replaces the cup with a longer one and you have to change the base of the injector.

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post #4 of 18 (permalink) Old 07-19-2016, 03:26 AM Thread Starter
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Re: Bulletproof Diesel head crack repair kit?

Quote:
Originally Posted by codykthekilla View Post
There is a new product out there, 6.0L Ford Powerstroke Cylinder Head Repair Kit - Save $5,000! , it replaces the cup with a longer one and you have to change the base of the injector.
Thanks for the recommendation. Was hoping I could find someone who has put some miles on Bulletproof's fix before.

This morning I called and talked to Tim at Accurate Diesel, and decided to go with their kit. I'm not too excited to have a different lower injector body, but only because it offends my OCD. :)

I'm only 90% sure it's the head, it still may be the cup. I can't quite get in there with my eyes, only with a mirror. So after spending the $650 on the BP tool, I still may need to buy/rent a cup puller and do the cup. With the Accurate Diesel kit, it replaces the cup with a longer one that spans that crack. Seems like a permanent fix also, where the BP is likely a permanent fix, but cracks may grow.

With the ability to rent a cup puller from Accurate, it's also $200 cheaper to go with them.

2005 F350 6.0/5r110
1998 Jeep TJ 5.9/46RE/Stak D300
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post #5 of 18 (permalink) Old 07-19-2016, 04:04 PM
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Re: Bulletproof Diesel head crack repair kit?

Let us know how it goes.

2002 F-250 CCSB PSD 4X4, 38R, S&B CAI, Bully Dog GT, 4" Exhaust, 05 head lights and grill, 08 power fold mirrors, tailgate, bumper, tail lights, 2014 chrome steps.
1979 Bronco 4X4, 460, c6, 205
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post #6 of 18 (permalink) Old 07-20-2016, 01:52 AM Thread Starter
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Re: Bulletproof Diesel head crack repair kit?

I will do. It looks straightforward, but I also haven't done cups before.


The dirty injector is the one that came out of #5. Any idea what is causing the discoloration/burning on the lower body? I suspect the lower o-ring is also bad (it's flat and hard) and letting diesel down into the cup? Any ideas?


2005 F350 6.0/5r110
1998 Jeep TJ 5.9/46RE/Stak D300
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post #7 of 18 (permalink) Old 07-20-2016, 02:06 AM
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Re: Bulletproof Diesel head crack repair kit?

it looks rusty?
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post #8 of 18 (permalink) Old 07-20-2016, 03:39 AM Thread Starter
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Re: Bulletproof Diesel head crack repair kit?

Maybe coolant was pushing down there after the fuel pressure fell off when engine turned off?

2005 F350 6.0/5r110
1998 Jeep TJ 5.9/46RE/Stak D300
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post #9 of 18 (permalink) Old 07-20-2016, 09:18 AM
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Re: Bulletproof Diesel head crack repair kit?

One of mine was the same color, but all gooey. It was gelled up fuel from a bad o-ring. Maybe yours is just at an earlier stage of this?

2004 Excursion 6.0
New HPOP/HPO system o-rings; Updated standpipes and dummy plugs
EGR delete; Rebuilt oil cooler; CCV collection mod
VR Black Diamond head gaskets and ARP studs
Oil and coolant bypass filters; Shell EC-1 coolant
Rebuilt turbo; 250 amp alt; 6000 watts of brain scrambling
One giant 240 pound English Mastiff riding shotgun!
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post #10 of 18 (permalink) Old 07-22-2016, 02:33 AM Thread Starter
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Re: Bulletproof Diesel head crack repair kit?

Today I pulled the cup, and installed the longer cup and lower injector body from Accurate Diesel. This seems to be a great fix.











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2005 F350 6.0/5r110
1998 Jeep TJ 5.9/46RE/Stak D300
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