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The surface between the cap and rod are bigger than the steel rod and serrated (cap will be cut off by EDM.)

Hi all, We found the mistake. The deformation was measured from the fixed piston pin so included the stretching of the beam. Measured across the big end diameter, the deformation was 0.7 thou. Thanks for the links Tmoose. From reading them I can see that I'll need to do some testing of these...

HarleyE30, Have you subtracted the force needed to accelerate the piston towards the crank? Some of the combustion force is accelerating the piston so will not go into the pin. cheers, derek

Thanks Mike and Jack, It sounds like 1 thou would be ok. I'm still hoping that someone who works in this area will pitch in. cheers, Derek

Thanks, My gut feeling was around 1 thou as the recommended big end bearing clearance is 1.8-2.5 thou. My FEA gave 10 times this which was a shock so I've either done it wrong or I need to beef up the cap a bit [smile]

Sorry I wasn't clear-- elastic deformation at TDC due to the tensile load in the rod.

Hi all, Does anyone know what would be acceptable conrod cap deformation. The big end details are 57mm ID, 30mm wide, 7500 rpm, max force on the cap 35kN. Thanks! Derek