Donnelly Engineering

09/09/2026

Lockie’s tidy 80 Series came in for one of our Drive In, Drive Out 1HD-T Performance Packages — and that’s exactly what he got! 🔥

Upon strip-down and inspection, unfortunately we found a few underlying issues.

First, the harmonic balancer had come loose and damaged the crankshaft keyways. With the engine having already had another rebuild during its life, we also found the block was already at maximum oversize and required re-sleeving.

We then discovered that following the previous engine failure, the previous engine builder had fitted an unmatched set of connecting rods, with the rods varying by around 50 grams across the set. This certainly wouldn’t have helped engine harmonics or overall engine reliability.

So, we got stuck in and carried out the following:

🔧 Machine & Engine Work
• Acid dip chemical cleaning + sandblasting
• Crack testing & pressure testing of cylinder head
• Full cylinder head reconditioning
• Re-sleeving all 6 cylinders
• Boring & torque plate honing
• Final cleaning of all components
• Measuring all clearances
• Assemble long engine + fit all bolt-ons
• Refit engine to vehicle
• Fit front-mount intercooler
• Road test vehicle
• Vehicle taken to Elite Diesel Performance for bed-in process and run-in tune 🔥

Components Supplied:
• Genuine crankshaft replacement
• ACL Race bearings
• ARP head studs
• Spool H-beam connecting rods + ARP rod bolts
• Genuine thermostat
• Genuine gasket set
• Genuine timing kit
• Genuine water pump
• stainless steel welch plug kit
• genuine harmonic balancer + bolt, washer & keys
• Genuine late-model pistons
• ADS Injection reco injectors
• ADS Injection 200 hp injection pump
• UFI 18G turbo + fitting kit
• PDI front-mount intercooler

And the result? 😮‍💨🔥

This 80 Series is now making 183 hp & 539 Nm, running 21:1 AFR and 19 psi of boost, while pushing those big 35” tyres.

There’s still plenty more fuel and boost left in it for down the track — but for now, once Lockie gets some miles on the new donk, we’ll see what this thing is really capable of! 🔥

Another 1HD-T brought back to life and built properly. 💪

Donnelly Engineering — Automotive, General & Marine.

25/08/2026

Spray welding seal positions on Muir gear ⚙️ Marine Solutions Australia

15/08/2026

🚤 Donnelly Engineering — Your One-Stop Shop for Everything Automotive, General & Marine!

Did you know we manufacture prop shafts in-house? 🔧

This one came to us with a cracked shaft, so we manufactured a brand-new 2205 stainless steel prop shaft, custom-made to suit the existing coupling and propeller.

If you’re experiencing bad vibrations or need:
🔹 Cutlass bearings
🔹 Shaft seals
🔹 Prop shaft repairs or manufacturing
🔹 General shaft work

Give the team at Donnelly Engineering a call today! 📞 5531 4499

Quality workmanship, manufactured in-house. 🇦🇺

26/06/2026

Very well said PowerHouse Engines

23/06/2026

📢 we are hiring 📢

🛠️ Are you a first or second or a trade qualified fitter & turner? There’s an opportunity to join our team!!

What we are looking for:
✅ team player with a positive work attitude and attention to detail
✅ passionate about your career
✅ have a car licence
✅ ready to learn

If this sounds like you, let’s chat!

Please email us a resume and a short description of yourself to:
[email protected]

07/06/2026

02/06/2026

Another 1HZ-T package palleted up and heading back to the legends at .mechanical 🔥
This build includes:
• Genuine replacement 1HZ cylinder head
• Fully re-sleeved cylinder block (previously at maximum oversize)
• Torque plate honed block
• Cylinder block surfaced using a CBN cutter
• Polished crankshaft
• ACL Race bearings
• Spool H-beam connecting rods
• Turbo-spec pistons
• ADS 11mm boost-compensated pump & injectors
• Genuine seals throughout
Built to handle the boost and ready for many more kilometres. 💪

10/05/2026

When a brand-new engine isn’t an option, sometimes the only choice is bringing the old girl back from the dead 😬😝⚓️
This 4-cylinder 3.0L 181ci MerCruiser came in with severe rust damage and water sitting where it definitely shouldn’t have been… after a cylinder bore failure let water flood the cylinders 💧❌

Instead of replacing the whole engine, we brought it back to life with:
🔧 Re-sleeved cylinder block
🔧 Brand new cylinder head
🔧 New gaskets, bearings & seals
🔧 Fresh piston rings
🔧 Full rebuild and clean-up

The transformation speaks for itself 👌🔥
From rusty and seized… to fresh, clean, and ready to hit the water again 🌊

Proof that sometimes a proper rebuild is all an engine needs 💪⚙️

MarineEngine WorkshopLife EngineRestoration BeforeAndAfter MechanicalRepair BoatMaintenance RebuiltNotReplaced MarineWorkshop EngineBuild OnTheTools

10/05/2026

Cummins 5.9 short block assembly 🔥
You did not in fact have to divorce your wife , become a alcoholic or shave your eyebrows for this package 😝

06/05/2026

🔥 JESSES ONE OF A KIND TD42 ENGINE BUILD 🔥
Built in-house at Donnelly Engineering — this is what happens when there are absolutely no limits.
Starting with a brand-new genuine block and engineered to perfection, this TD42 is packed with the best of everything:
💥 Billet crankshaft & billet main caps
💥 Forged rods with ARP rod bolts & head studs
💥 Mahle pistons & ACL race bearings
💥 Genuine cylinder head with HD valve springs & titanium retainers
💥 ADS boost compensated performance pump + reconditioned injectors
💥 Ross Racing balancer
💥 HPD upgraded crankcase PCV
💥 Stainless freeze plugs, genuine gaskets & seals
💥 Genuine timing cover assembly
✔️ Torque plate honed
✔️ Fully balanced rotating assembly
✔️ Built for strength, reliability, and serious power
No shortcuts. No compromises. Just elite engineering from start to finish.
💪 If you’re chasing the ultimate TD42 setup — this is it.
4x4Australia PatrolBuild HighPerformanceDiesel NoLimits