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BDA Cylinder Head Repair after valve and seat damage

BDA Cylinder Head Repair by Vulcan Engineering after valve & Seat damage. www.vulcanengines.com


 


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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 cylinder head. 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 sweet spot. Why the Lovell factor is important: https://www.highpowermedia.com/blog/3346/the-effect-of-valve-size Lovell gas factor calculator: http://www.rbracing-rsr.com/lovellgascalc.html 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 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 on YouTube. 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 their faces. 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.





HEAD REPAIR ( HOW TO WELD CAST IRON )
Prepping and welding the cracked head on the Stover hit and miss engine. Check out 500passwords http://www.youtube.com/user/500passwords





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 gearhead's garage.





Remachining John Deere PowerTech piston
Reducing compression ratio to 1:14.5 and milling valve pockets for tractorpulling Compressie verhouding verlagen naar 1:14.5 en klep uitsparingen frezen.





Overhead Cam at 14K RPM
This video shows an operational cutaway of a BMW S1000RR — a 193HP superbike — bumping against its 14,200RPM redline. A cam and valvetrain at 118 cycles per second is an amazing sight (and sound)





Crankshaft Refurbishing
Many of you have seen this one before. I apologize if bringing it back offends anyone. Domestickilla gave me a crankshaft, and it's a nice one that I want to clean up and use again. You'll be seeing a lot of it and because of this, this video deserves to be here. I fixed what I broke, and this was my experience. In this video Ballos Precision Machine demonstrates magnetic dye penetrant testing, crankshaft polishing and inspecting the balance of a "butchered" 4g63 6-bolt crankshaft.





Durafix Hrvatska - Video
Inovativne elektrode za varenje, lemljenje i popravak aluminija. Novo na tržištu. Razvijeno za potrebe NASA-e i Američke vojske (USARMY). Široka primjena. Uz aluminij pogodno i za bakar, cink, bijele metale i sl. 'nemagnetne materijale'





How to Reseat / Lap Valves (Basic Valve Job)
In this video i'm explaining how to reseat or lap valves in a flathead or overhead valve engine. Also can be called a valve job, but this is not a complete valve job. I also used to much valve grinding compound, it does not require a whole lot. Usually when a engine needs this done is when a engine has low compression that is found to be leaking around the valves, or sometimes a engine will backfire do to the valves not closing completely/properly. Thanks for watching.





try to crank a rusty engine.
NFG wdb108 280se merc. one last time for fun.





How to build a TURBOJET ENGINE
HELLO GEEK WEEK So this is the first in my trilogy of videos about building a turboJET engine from scrap. This video is me building the jet then tomorrow i'll take you through the simple maths and it is simple. enjoy subscribe and see you next video. Music by march to the grave "https://itunes.apple.com/us/album/drugs-squad/id506166537?i=506166702&uo=4 " The scrapyard is C.towell and they are great for off cuts of stainless etc http://www.webuyallscrap.co.uk PLUS more at http://www.colinfurze.com/index.html





Machining 101: How to drill a square hole at home without special tools.
Make your own homemade broaching tool for "drilling" perfectly square holes in steel. In this case we are using it as a tool holder on a milling machine slotting attachment.





Cylinder Head 106 - Casting & Porting Tech
Description. No really guys, what can I type here? I just went on for 18 minutes without shutting up. I apologize for deviating from my normal format, but we're almost there... ...when I port a head, there will be no voiceover, and it will be a 200-series video.





2stroke V8
Evinrude 300XP -91 After a few hours in the workshop.. The expansion chambers are "home made" by hydroforming. The original Exhaust is milled away and the engine block is filled whit plastic. This engine will get electronic fuel injection and will not be used in a boat.. Note: This is a sponsored video for Forge Apollo





Fitting new valve guide seals without removing the cylinder head Suzuki Vitara
This is how you can remove and replace valve guide seals with the head still on the engine. Normally you have to have the head off so you can fit the valve spring compressor on to the head of the valve. I had heard of this method but never tried or seen it done before. The only special tool is a piece of string. Watch the video and see the "Essex Red Neck" at work :-)




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