Boss 429 Cylinder Head Straightening
John Edwards discusses how he uses a thermal cleaning oven to straighten
excessively warped aluminum cylinder heads at his Costa Mesa R&D Automotive
Chevrolet Thermal Engine Cleaning Process
This video demonstrates the Sunnen Thermal Cleaning system that was used to
clean a small block (SBC) Chevrolet engine block by John Edwards @ Costa
Mesa R&D Automotive Machine (949) 631-6376. Your comments appreciated!
Cylinder Head 204 - Porting & Polishing
This is a first-generation 1992 1.6L Hyundai Elantra
small-combustion-chamber head. Thats what it is. It's a J1 engine's
In Cylinder Head 106 I talked about the mainstream porting theories as they
are discussed. We looked at a cylinder head that I have thousands of
dollars of professional work performed on, and a bone-stock
second-generation head that I didn't port.
In this video I just might do something you haven't seen done before. For
some, that may be uncomfortable. The port and polish job I perform here is
what I think will work best for my current build. This is not an extreme
killer port job. What will be different here is where port textures are
concerned, I will be following the advice of a reputable source that will
remain un-named. You're free to port yours differently than I do in this
video, and I give you that out, around the 20 minute marker.
The Hyundai is far from being an ultimate-performance build. It's a $400
box of scraps with nothing but time invested. It's perfect for this video.
My finished product WILL be an improvement over what I had. I don't yet
have access to a flow bench. I still have an achievement to un-lock. As
far as you should be concerned with the techniques I employ... without flow
numbers there is no evidence of what this will do, but we will gather lots
of info from dynp sessions and drag strip time slips. If I could test it on
a flow bench, I would.
There are MANY, and when I say many, I mean thousands of flame war
mongering pirates floating around on rough seas with a hair trigger cannon
finger itching to fire if you port a head any differently than what the
herd mentality says to do while porting a cylinder head. I cover the herd
mentality because it has merit. It's been tested. Tried and true. But I
don't follow it to the letter of the law. I'm definitely not here to
de-bunk it. I would port a cylinder head differently for each build based
on how that engine was used. There's an extremely valid reason why
relating to air speed. It's not the texture of a port that maximizes the
effect of fuel atomization, but the velocity of the air running through an
x or y sized valve. The driving factor in this is the piston speed. I'm
not going to give you the technical information, but will refer you to
information about the Lovell factor. There's a better description of this
in the links below, and even a calculator to help you find your engine's
Why the Lovell factor is important:
Lovell gas factor calculator:
Only people who have flow testing equipment know for sure what really works
and have the capability to produce a perfectly-matched port job for the
ultimate performance build. Those guys know the definition of ultimate,
and THEY are floating below the water Aegis-class submarines ready to blow
your comment up if you don't know what you're talking about. They don't
care if you're an armchair mechanic or a herd of pirates. I will say,
they're zoomed in pretty close on me right now, and I'm expecting to take a
few hits. My work will be tested based on Dyno and drag strip performance,
and the results will be posted here. Fortunately, those kinds of videos
are a WHOLE LOT EASIER TO MAKE!!!
Cylinder Head 205 - Degree DOHC Camshafts
This video is all about establishing your valve timing baseline, and
adjusting your camshafts to the manufacturer's spec. It's only ONE of
several steps that should be performed when you're assembling your engine
on an engine stand. Establishing these conditions with accuracy while your
engine installed in the car is a near-impossibility, and the reason why...
is demonstrated in this video. There are several challenges to overcome
when performing these procedures on a 4gxx series Mitsubishi engine, and
they're all defeated here.
The cylinder head used in this video is a J1 spec '92 Hyundai Elantra
small-combustion chamber head which has had several valve jobs and has been
resurfaced multiple times by budget engine remanufacturers who didn't care
about quality control, as well as performance shops who do. It has had no
less than .040" removed from the head gasket surface, the valves are
recessed because of all the valve jobs performed, and at some point when it
was cut, it wasn't level. Removing material from the deck surface will
change the installed camshaft centerline, and that will change your
engine's valve timing events even if all other parts remain the same.
I would claim this is a multi-part video except that I've got the videos
broken up by topic already, and this one is all about setting your cams to
the manufacturer's specification. It is not the end of testing that will
be performed with these tools. The basics concerning the process and tool
fabrication are covered here. Further discussion on this topic concerning
the effects of advancing or retarding camshafts from spec, and for checking
your valve clearance will be in the videos that follow. I had to end this
video after the manufacturer's spec was achieved to make it easier to
digest, and because it would have created a video greater than one hour in
length despite the break-neck speeds that things happen here on
Where your cams are set determine how the swept volume of the combustion
chamber gets used. The information on the manufacturer's spec sheet is
their recommendation for baseline settings that will help you get the most
out of those camshafts. Whether or not your engine can operate with those
specifications without additional hardware or without causing a
catastrophic failure will be expanded upon in Cylinder Head 206. The next
video should be used as a companion to this video because establishing the
manufacturer's baseline is not the end of the assembly or testing process.
It's only half the battle. Should you be lucky enough to find your
combination of parts allow your camshafts to fit and requires no additional
adjustment after assembly, the steps in this video and in Cylinder Head 206
should still be performed if you are doing the assembly yourself. Failure
to inspect these variables may lead to a tuning nightmare once the engine
is back in the car, hard starts, or worse... bent valves and damaged wrist
Making these tools and performing these steps will give you the peace of
mind to know with certainty that your engine is operating safely at its
Cylinder Head 105 - Valve Job Basics
Valves not sealing? Valves not bent? This is how you fix that problem.
In this video I outline the basic valve job procedure. Cleaning the
valves, cleaning the seats, cleaning the combustion chamber and lapping the
valves in to make a better seal.
Here I cover the process start-to-finish. It's the same exact process for
pretty much all non-rotary combustion engines. It takes patience and
perseverance to do this job, but anyone can do it. Reference your service
manual for measurements and service limits. Everything else that's not in
your service manual is in this video.
I apologize for not having broken busted crap to work with in this video.
It's more beneficial to all of you when bad fortune falls on me because it
gets well documented, and many people watching these videos are looking for
answers. If you have bent valves, you will discover it quickly once you
chuck one up in the drill. You'll see the face of the valve wobble around
while it spins. You'll see evidence of this damage on the valve seat. If
it's bad, you may see damage on the valve guides in the form of cracks or
missing pieces where the valve guides protrude through the head ports.
Give all that stuff a good visual inspection. ...and if you doubt yourself,
never hesitate to get a second opinion or consult a machine shop. They
will have access to expensive tools that you wont find in your average
Cylinder Head 201 - Radius Cut Valve Job
This video covers the complete valve job process that your machinist might
perform. If the 100 series videos didn't help you identify and correct a
problem with your cylinder head, then this is the next step. This video is
brought to you with permission from my machinist in full 1080HD, and covers
cleaning up the head inside and out, preparation and setting up a radius
cutter, cutting all 16 valve seats, valve grinding, and spans 3.5 hours of
actual work in under 30 minutes. There's nothing like this anywhere else
THANK YOU BALLOS PRECISION MACHINE. Thank you for the professional
explanation and execution of a job excellently-done, and un-precedented
access to your facilities.
A valve job is done by re-grinding or replacing valves, and then having new
seats cut to match the faces of the valves you're using. There are several
different machines that might be utilized to achieve this result, but the
process is the same no matter how it's done. There are seat cutters that
utilize cutting stones. There are valve seat cutters with 3 separate
angles installed 120° out-of-phase, and there are single cutters with all
3 angles (radius cutter) that cut with one blade in one pass. The machine
demonstrated here is a Sunnen VGS-20 Radius Cutter. This machine (now out
of production) produces a gradual curved seat that's superior to the shape
of a traditional 3-angle seat. While a radius cutter does contain the 30,
45 and 60 degree angles, it does so without leaving any sharp edges between
My valve selection includes Supertech 1mm oversized nitride-coated
stainless steel undercut and back-cut intake valves, and 1mm oversized
Inconel back-cut Exhaust valves.
Inconel is a high-temperature alloy utilized in marine and forced-induction
performance engines that can handle more abuse than steel can without
melting. The other characteristics of the valves which are discussed
typically yield bigger gains in airflow than simply using a bigger hole and
a bigger valve.
Why I did this to a perfectly-good cylinder head:
I changed cams. Because the valves were previously recessed during another
valve job 9 years ago, my valve installed height was increased and this
raised the operating positions of my rocker arms. My new camshaft
selection dictates using the stock valve install height. The only
solutions to this valve install height problem are to either replace the
valve seats, or install oversized valves. I opted for the latter.
Ultrasonic Cleaner - Engine Head (Severe Clean Ultrasonics)
This video shows an engine head being cleaned in a Severe Clean Model SC-11
ultrasonic cleaning system. The cleaning process to about 20 minutes
altogether, and cleaned oil and carbon both internally and externally.
These ultrasonic cleaning systems work great in machine shops that deal
with any type of internal engine part.
454 Chevrolet in Thermal Cleaning Oven
Take a look at how a BBC Chevy marine engine is cleaned in the Sunnen TCS
cleaning system. Watch as a rusty old hulk is brought back to serviceable
Pontiac Performance Tips from Butler Performance V8TV
http://www.v8tvshow.com - 314-783-8325 - Certain engine builders specialize
in specific brands, and for Pontiac power, Butler Performance is in the
forefront. We visited Butler to get the lowdown on the latest in hi-po
parts for Pontiac V8s and to spec out a motor for project "Splitter."
Here, David Butler takes us through the shop and brings us up to speed on
the latest in Pontiac performance.
LS3 Piston Pin Clip Removal
This is how you remove the piston pin clip from the LS series piston. Now
you know! www.engine-machining.com (949) 631-6376
Crankshaft Oil Hole Chamfering
Watch as John @ Costa Mesa R&D Automotive Machine chamfers the oil holes on
a Fiat stroker crankshaft. www.engine-machining.com (949) 631-6376