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Fire Ringed heads, H11 studs= problems
I am the shop foreman at a local Ford store and i have a customer with an 07 450 and he originally came in with the banks setup (4" turbo back, intercooler and piping, intake elbow, cold air intake, otto mind with power pda) and he had blown head gaskets. not so uncommon. he decides to order fire ringed heads, h-11 studs (apparently their tensile strength is higher than the APR's), sct livewire, and egr delete. so we install everything except the livewire (he uses a custom tune for turning on the fan clutch sooner) and everything seems fine. the setup seems foolproof and, in theory, this should be the sweet setup. so he comes in last week with a coolant consumption isssue, turns out he's got blown head gaskets. here's the weird part. one of the o-rings is broken and the custom gaskets aren't cut correctly around the o-ring leaving too much gap between the ring and cooant passages. the other weird part is that the rings themselves have left grooves in the block. i know that it is not a result of being clamped down too tight as the h11 studs require only 175 ft/lb and they show a good even crush all the way around. i am confident of my tech's abilities as none of my diesel tech's have ever had a set of head gaskets come back after doing them and we do at least one set a week.
here's my question, does anyone have fire ring experience and have they ever seen scarring to the mating surface of the block because of them? also, do different companies do their fire ring setup differently (diameter of the rings) as this would make a difference.
i won't tell the name of the company as i don't want to make this a he said/she said battle
any help is appreciated