Hi Ron,
I've seen your complaint on a few forums. I work at BluePrint and while I am not part of the warranty team, I can't help but asking for more details with what happened. Because each of those engines are run on a dyno for about an hour, and go through a battery of tests before they leave - it includes pressure testing all fluid reservoirs, time on a runout machine to observe cranking compression and proper oiling, then compression and leakdown, comprehensive valvetrain check, and a blacklight test for even the smallest oil leaks. If an engine has a problem on the dyno - and every now and then they do - the entire production line is stopped until the problem is identified. Department managers are held accountable for any issues, it's a big deal when there is a problem. Long story short, it's impossible for an engine that's "knocking" to get past our testing. So that makes me wonder if something went wrong during the initial startup, or if the engine was re-timed improperly, etc. Even then, BluePrint takes care of their customers, but the customers have to go through our troubleshooting procedures - we can't just send out a new engine until we know what went wrong with the original. On a busy day we will dyno and ship 50 or more engines at our plant.
If there's anything more you can share with us, I'd be happy to go poke the warranty guys upstairs, I haven't asked them about this particular engine yet but I am curious to hear more about your issues mainly because it's odd for us to have a customer complaint given that our warranty policy is solid. ?
-Scott