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Volvo Diesel Engine head porting : grinder time !

gasket port matching the head for better flow music : Ronald Jenkeens "fifteen fifty"


 


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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!!!





DIO MONSTER RACING PISTON PROBLEMS
54MM piston is too tall and will hit crankshaft. The skirts must be shaved to supply clearance for full piston/crank rotation.





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.





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.





CNC Cylinder Head porting and CNC Engine Blocks on the SAME Machine!
CENTROID ENGINE SHOP CNC Machining Center. 3 Machine tool in 1. CNC port cylinder heads and Blueprint and CNC machine engine blocks AND produce all kinds of CNC parts using the same machine.





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.





Volvo bus diesel engine TD70 1968 turbo B57
A short movie from when I started my Volvo bus engine with my welder :)





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





Block Preparation Part 1
Preparation for powder coating and Glyptal application. Audio track is an original performance by Rojo Del Chocolate. My block is being powder coated rather than painted. It's just something I do. The GSX had it on the last block so it's getting it again. Since the tools are so similar and the mess is the same, I'm going ahead and preparing it for the Glyptal application as well. These 2 coatings will require being baked separately. The powder coating is baked on at a hotter temperature than the Glyptal, so it's going first. The surface preparation instructions for Glyptal is as follows: Surface to be painted should be dry and free from dirt, wax, grease, rust and oil. Remove all grease and oil by washing surface with mineral spirits. Wipe or scrape off all loose dirt, rust or scale. The last sentence is what's covered in this video. The 2nd sentence happens next (although it's already degreased), and I'll get it back from powder coat with it in the state described in sentence #1 completed. If following these instructions to the letter of the law. Second and third opinions in... the main journal is fine. You'll notice that I didn't coat the main caps, or "suitcase handles". I'm not going to. You bang around on these installing and removing them, and I don't want to risk chipping them once they're coated. They're below the windage area, and there will also be an un-coated main bearing girdle down there. This video covered 25 hours of actual work. Yes, I kept changing into the same filthy clothes every shoot because I wanted it to look consistent. You have to take your time doing this kind of work, and be VERY VERY CAREFUL! If for some reason you're crazy enough to attempt what I do in this video, you do so at your own risk. This is an elective treatment that I've never done, but I am by no means the first person to do it. I'm learning about it just like the rest of you.





How to port and polish high performance v8 heads,tips,tricks and trade secrets exposed
*******CHECK OUT PART 2 ***** http://www.youtube.com/watch?v=sZDlZxqRVJw COMBUSTION CHAMBERS http://www.youtube.com/watch?v=D63jgJs95gY DEGREE CAMSHAFTS http://www.youtube.com/watch?v=azLX1pi2oVE I look at porting and polishing high performance heads,I been building engines for 30 years, most of that time in research and development,I explain in real simple terms air flows and velocities,these 308ci General Motors Holden heads have been transformed over 70 hours,I show you all the do's and dont's,keep a lookout for the rest of the rebuild vids, as we head into final assembly,especially dialing in camshaft's,compression ratio's and everything else that makes internal combustion engines cranky,Aussie Heads and Race Engines-One Man One Shop





Porting an aluminum intake manifold, basics of porting and polishing.mpg
Porting and Polishing Basics. Porting on an aluminum intake. A few principles and techniques for porting. The therory and approach discussed can be applied to porting most intakes and porting and polishing in general. Abrasives, carbide burrs, surface finish, porting tools and tips. Equipment from CC Specialty Tools (ccspecialtytool.com)





How to port and polish a turbo exhaust housing
I'll fill this in later. The "book" I typed in this field before didn't save. Come back later if you want to read more about the theories behind porting and polishing.





Combo 5-axis CNC Cylinder Head & Block Machining center: The CENTROID A560 Port/Block
CNC port cylinder heads, blueprint and CNC machine engine blocks and make all kinds of parts with one machine the CENTROID A560. See the machine in action porting cylinder heads and machining blocks.





Classic Car Porting Heads for Power
This segment is from automotive author Jim Richardson's video, "How To Port Cylinder Heads for More Power." Here Jim describes how to do port matching. www.classiccargarage.tv





"How To" Port polish an intake manifold
In this video I show you how to port polish an intake manifold. Remember to wear your safety gear and take your time. The intake itself took roughly 2 hours to polish. Removal of the head is recommended before any grinding or polishing to ensure none of the filings make it into the cylinder bore and cause damage to the cylinder walls.





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