Subaru Flywheel lightening and Balancing
Watch John Edwards @ Costa Mesa R&D Automotive Machine as he lightens and
balances a brand new Subaru flywheel on the Sunnen DCB 750 balancer.
Crankshaft Balancing Counter Weight Reduction
This big block Chevy engine is getting a trim job on the crankshaft counter
weights because we are installing some .400" longer connecting rods with
some very light forgerd pistons. We had to remove a total of 400 grams to
get the crankshaft to balance correctly. Costa Mesa R&D Automotive Machine
Shop (949) 631-6376 Don't forget to 'Click' and SUBSCRIBE and tell your
friends about this channel.
H D Cylinder Boring
Watch John Edwards @ Costa Mesa R&D Automotive Machine as he bores a
Harley-Davidson bylinder for larger pistons. (949) 631-6376 Don't forget to
'Clicl' and SUBSCRIBE.
BMW Connecting Rod Modifications
John Edwards discusses how he machines BMW connecting rods to reduce weight
for increased RPM for naturally aspirated and forced induction engines.
Atomic Performance Products - XR6T High Performance Conrods
Atomic billet steel conrods were designed from scratch with one principle
in mind; use aerospace quality materials and sophisticated manufacturing
processes to produce an extremely strong, light and durable connecting rod
for the popular inline 6 cylinder Ford SOHC/DOHC engines, at an affordable
The Design and Evaluation Process
The Atomic engineering team set out to address these parameters by
designing what many performance engine builders are now calling the finest
conrod on the market for the Ford DOHC 6 cylinder engine.
Extensive CAD/CAM computer modelling was employed and produced a H-Beam
design, which has an extremely high stiffness-to-mass ratio. The next step
was to pick the correct materials, heat treatment and surface treatment
processes to ensure durability under rigorous performance applications.
Next came FEA modelling (Finite element analysis) to simulate stresses on
the conrods. This also entailed weighing every piston, gudgeon pin and ring
set on the market and loading this information, plus stroke, rotating and
reciprocating conrod values into our computer modelling software to
calculate the stresses.
The greatest load exerted on a conrod in an engine producing 600 comes not
from the force of normal combustion but from the tensile force exerted by
the piston at top dead centre (TDC). At 5250 RPM the piston exerts a
tensile load on the conrod of 1908 gs (-1693 kgs) at split overlap TDC
reversal. If you increase maximum engine speed by only 1000 RPM to 6250
RPM, the TDC tensile load rises by 50.4% to 2870 gs. At 7500 RPM the
tensile loading increases to 4132 gs, clearly demonstrating the Atomics
design strength of 8000 gs means it has plenty in reserve.
Excessive loads at TDC are brought about by a high reciprocating mass
and/or by increasing engine RPM, so it is essential to design reciprocating
engine components with the lowest mass possible to minimize premature lower
bearing shell bearing failure. This is particularly relevant to our
customers who are turning their engines to 7500RPM+.
For more information, visit
Blueprint 103 - Connecting Rods
Connecting rods are the crux of the engine. They're responsible for
carrying the force of the explosions that occur in the combustion chamber
and using it to turn the crankshaft. Oil clearance specifications of the
"big end" and "small end" are crucial to maintaining consistent oil
In this video we take 3 measurements:
Rod Journal (also called Crank Pin) Diameters
"Big End" Bore diameter
Using the Journal diameters and the "Big End" Bores, you can calculate your
oil clearances of each bearing. The process is illustrated here. Anyone
rebuilding an engine who doesn't know its history should check all of these
clearances whether or not they're re-using the rods. If the crank,
bearings or connecting rods are going to be replaced, it's imperative that
you measure the new parts as well to ensure they're in spec.
Balancing a Jaguar E Type crank at Classic Jaguar in Austin, Texas
Fiat X1/9 Pistons & Connecting Rods
This video will show some of the modifications that are made by John
Edwards @ Costa Mesa R&D Automotive Machine on a 1500cc Fiat X1/9 (Punto
Marea) connecting rods and new forged JE pistons. www.engine-machining.com
Connecting Rod Weight Reduction
Here's another weight reduction method used by John @ Costa Mesa R&D
Automotive Machine. Check it out!