Spool Barra Engine
Building an Indestructible Barra

Building an Indestructible Barra: Key Internal Upgrades – A Must-Read for Ford XR6 Turbo Owners

If you’ve got a Ford XR6 Turbo, chances are you’ve dreamed of turning that mighty Barra into an absolute weapon. Whether you’re chasing big power for the drags, roll racing, or just want a rock-solid street beast, the key to making your Barra bulletproof lies in the internals. In this guide, we’ll break down the must-have upgrades to build an indestructible Barra that can handle serious boost and keep sending it without grenading itself.

1. Forged Pistons – Because Cast Just Won’t Cut It

The stock cast pistons in the Barra are good for mild power gains, but start cranking up the boost, and they’ll cry enough quicker than you’d like. Upgrading to forged pistons is a no-brainer – they’re stronger, take heat better, and can handle serious cylinder pressures without cracking under load.

  • CP Bullet - lower cost but extremely capable up 1,000 engine HP with standard pins, upgrade to 9310 for 1,300-1,500hp
  • Spool Heavy Duty CP Pistons - high horsepower applications 1,300 engine HP plus. HD forging, 9310 pins standard
  • Ross Fully Optioned - Crown Coating, Skirt Coating, H13 Pins rated to 1,800 HP plus and extreamly good value

2. H-Beam or I-Beam Conrods – Keeping Your Bottom End Together

Factory Barra rods are notorious for turning into spaghetti when pushed beyond their limits. If you’re aiming north of 400kW at the wheels, it’s time to step up to a proper set of rods.

  • H-Beam rods – Perfect for street and moderate power builds (~820hp range).
  • I-Beam (Drag Pro) rods – Built for absolute abuse, suited for mega power and high boost applications.

Both options from Spool Imports are made with 4340 billet steel and come with ARP 2000 or L19 bolts to keep them locked in under load.

3. Head Studs – The Secret to a Reliable High-Boost Barra

Running boost without upgrading your head studs? Bad idea, mate. Stock bolts can stretch, leading to blown head gaskets and loss of compression. ARP head studs are the go-to upgrade for keeping your Barra’s top end locked down tight.

4. Head Gasket – Keeping the Seal Strong

The factory OEM head gasket is already a solid choice, however, there are a couple of performance options to consider:

5. Main Studs & Girdle – Bottom End Insurance

If you’re chasing serious power, upgrading your main studs and adding a girdle will help keep the bottom end of your Barra together under extreme conditions. A main girdle ties everything in tight, reducing flex and preventing dreaded crank walk.

6. Billet Oil Pump Gears – Stop the Common Barra Failure Point

One of the biggest weak points of the Barra is its oil pump gears. The factory sintered gears have a nasty habit of shattering under high RPM and boost, leading to instant catastrophic engine failure.

7. Upgraded Valve Springs – Keep It Singing to Redline

Stock valve springs can struggle with boost and high RPM, leading to valve float and power loss. A set of performance valve springs is crucial, especially if you’re running high lift cams.

8. Camshafts – More Lift, More Power

The factory camshafts are surprisingly capable for low to medium builds, but if you're chasing extra power and top-end performance, Kelford has a solid range of upgrade options.

Final Thoughts – Send It with Confidence

Building a tough Barra isn’t about throwing money at every part you can find – it’s about upgrading the right components to handle the power you want to make. With forged internals, billet oil pump gears, heavy-duty valve springs, and upgraded fasteners, your Barra will be ready to take on big boost, big RPM, and big skids without missing a beat.

At Spool Imports, we stock the best gear to build a bulletproof Barra. Check out our range of forged pistons, conrods, and billet upgrades and turn your XR6 Turbo into an unstoppable machine. Got questions? Hit us up – we love talking Barra builds!

Stay boosted!