As I was gapping the Champion #7989 spark plugs I noticed a difference in how far the center wire electrode protruded through the porcelain insulator in several of them.
Here is a photo of 3 plugs which reflect what I'm attempting to describe. Most of the plugs look similar to the one on the right, a couple are closer to the center one, but one (far left) the electrode barely protrudes through. Wouldn't this in effect change the heat range for each of those plugs????
Maybe I'm making too much out of it (hopefully) but it doesn't seem right.
So what do you guys think?

 

Looks like mass production tolerances are to blame for this. As long as they are all gapped the same it should be ok.

 

Almost looks like different heat ranges. Don't think I would be a happy camper with that.

 

Google spark plug heat range and you will see that the ceramic insulator length makes the heat range. Most of the insulator is insde the plug where you can't see it.I don't know how much the exterior portion lenght will effect the plug?

 

Thanks xtoolmaker. I ended up e-mailing a link to this thread to the vendor from whom I purchased these plugs. Hopefully I'll get a reply within a couple of days.
I think what I'm going to do in the meantime (now that I'm 3/4 of the way through this process) is continue on, clean and check the gap on the factory plugs and re-install with antiseize compound. That way they'll remove easily once I get a definitive answer about the center electrode wire.

 

Get some new plugs from a different maker. Why risk possibly having a dumb plug?

 

You haven't had to remove a broken spark plug, have you?

 

What's that supposed to mean? In pieces, no...

 

There's a problem with the plugs breaking off inside the cylinder and I assume that's what he is talking about. Several threads on this , do a search ...

 

That's my point. If he thinks the plugs are shotty, why even bother trying them? Ditch them for another brand and install those instead.

 

I had gotten a response back from the vendor who had made contact with the plug manufacturer. The manufacturer said that as long as the plugs are gapped correctly there shouldn't be any problems even with the electrode wire being short. Thats all fine and dandy, but I'm just really **** about some things and seeing that just bugged the heck out of me. The only other one piece plug is the Brisk brand, but the way I read it, they are one step colder than the stock plug.
I'll just wait it out until Motorcraft comes out with a better plug.

 

Which may never happen seeing as how they now use a different plug. Maybe they will for the aftermarket though.

 

I've got about 2500 miles on my Champions, not a single problem. Car runs great, improved throttle response and great gas mileage. What's not to like?

 

The price. I did see one post where the ceramic fell down closer to the electrode and caused a misfire. Seriously, for the price these plugs carry they should be the best plugs made in the world. I remember when expensive plugs were 6.50 a piece.

I've seen the motorcraft down to 7 a piece now.

 

The big difference - The Champions won't come apart when removed.

 

Upon closer(like real close- my eyes aint that great anymore) inspection, I dont think these plugs are going in my car...some pics of the plugs up close:

picture 1:
1 of 8 plugs is just shy of 2 threads shorter than other 7- would it bottom in the head? do I want to find out?

picture 2:
actually 4 of them are welded a little crooked so electrode is off center

picture 3:
one of the 4 off center has the little platinum pad offset on the ground so far you'd have to gap it diagonally

picture 4:
I didnt notice this until trying to get pics with my camera- hard to get a picture of, but 2 of the plugs got what I'd say is 'just bigger than thread of steel wool' sized metal chips crimped under the top seal- I cant help but wonder if any of these little chips are on the underside??? be sure to blow out your plugs before installing them...

am I nit-picking? yes indeed, but at $103.60 a set, in my opinion I think these are crap(other than being one piece bodies that wont twist off in the head- nice idea, poor execution). I'll need to look at electrode projection, to see if any look like the pic at the start of this thread...

I wrote Champion, will see what they say, but looks to me like 5 of the 8 shouldnt have made it out the door. If they are content with the 'quality' of their products in these pictures, their business is doomed.