I noticed some excessive wear in my TCI pilot extender. However, I didn't find any correlate wear on the actual billet pilot of the converter. A couple things I was thinking about...is my crank flexing? Or maybe the metal of this TCI piece is suboptimal compared to the billet converter leading to the breakdown?

It's not aweful wear and I'm contemplating re-using the piece. CircleD said they could weld on an extender or they also have a replacement part for $40.

 

That doesn't look like rubbing wear, it looks like galvanic corrosion, particularly the pitted areas.

 

There is evidence of rubbing.

 

Stock cranks are used in 1600hp builds without issue...I doubt that 75mm was flexing it. Regardless, the converter doesn't rotate relative to the crankshaft, so how could it rub?

 

Maybe if there was play and the bushing was floating but that wouldn't cause it to look like that.

 

Looks like that thing was moving around in there. Why not use one that bolts to the flexplate with longer bolts?

 

The extender isn't fixated to the crank or converter, so it need not rotate with them. Also, the flexplate flexes in and out and there really shouldn't be any angular deflection but I'm wondering if there is a very small component. There has to be an explanation for the findings.

 

Possibly converter not centered in bushing, know its a long shot but would explain it...

 

Stock cranks do flex around 1000rwhp

Has your oil pressure been steady? Signs of crank flex is a loss of oil pressure typically 5 or 10 psi lower then normal when warm

 

George, I haven't seen any noticeable drop in oil pressure (55 psi cold idle, 45 warm) but that's on the stock cluster which who knows if it's reliable.