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InternalCombustionEnginesHereforthelonghaulCat3406EandC-15Heads-uponthedifferencesInwiththeOldOutwiththeNewAntiqueenginerebuildingLucky113Harley-Davidson110to113enginebuildENGINEAPPEARANCEBEAUTYFORTHEBEASTDOHC1650TWINTURBO.COURTESYRICKMACKIEMERCURYRACING.ANAERAINTERNATIONALQUARTERLYPUBLICATIONJANUARY-MARCH2014 2JAN-MAR2014engineprofessional4FROMTHEPUBLISHER6INDUSTRYNEWSWelcometonewAERAmemberscalendarofeventsnewsandviews10NEWSFROMTHEEDITORByJimRickoffInternalCombustionEnginesarehereforthelonghaul16ENGINEAPPEARANCEByMikeMavrigian36CAT3406EANDC-15BySteveScott44INWITHTHEOLDOUTWITHTHENEWByKimRamont50LUCKY113ByDerekChurchwellHarley-Davidson110to113EngineBuild60SPEEDREADByJohnSatterfield21stCenturyFuelDeliveryScience64TECHSKILLSCONFERENCERECAPBySteveFox66TECHSIDEByDonWeaverRuttsMachineInc.CaterpillarInjectorSeatRepair68HYDROCARBONHEARTBURNByLakeSpeedJr.70AERAAUTOMOTIVEMACHINISTONLINETRAINING72PRODUCTSPOTLIGHTS78TECHBULLETINS86ONTHESAMEPAGEEnginebuildingbookreviewsbyAERATechnicalSpecialistMikeCaruso87MARKETPLACECONTENTSEngineProfessionalmagazineISSN1945-7634ispublishedquarterlybyAutomotiveEngineRebuildersAssociationAERA.Copyright2014AERA.Subscriptionrates70peryearoutsidetheUnitedStates90singlecopy20.Publicationedito-rialandbusinessoffice500CoventryLaneSte180CrystalLakeIL60014.Editorial815-526-7600Advertising507-457-8975Circulation815-526-7600.Sendchangeofaddresstotheabove.TheopinionsbeliefsandviewpointsexpressedbythevariousauthorsinthismagazinearethoseoftheindividualauthorsandnotoftheAutomotiveEngineRebuildersAssociationwhichdisclaimsallresponsibilityforthem.VOLUME7NUMBER1PUBLISHERAERA-EngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014815-526-7600815-526-7601faxChairmanoftheBoardRonMcMorrisMapleRidgeBCCANADAFirstViceChairmanSteveSchoebenBloomingtonMNSecondViceChairmanRexCrumptonTulsaOKTreasurerDwayneDugasNewIberiaLAPresidentPaulHauglieEDITORJimRickoffjimrickoffgmail.comTECHNICALEDITORSDaveHagendaveaera.orgSteveFoxsteveaera.orgMikeCarusomikeaera.orgGaryLewisenginesmsn.comCONTROLLERMelissaRizzimelissaaera.orgGRAPHICDESIGNMariaBeyerstedtmariamcreative.usADVERTISINGSALESJimRickoffjimrickoffgmail.comHalFowlerhalfowlersales.comCIRCULATIONKarenTenderingkarenaera.orgINTERNATIONALLIAISONYolandaCarranzayolandaaera.orgCHIEFTECHNOLOGYARCHITECTRichardRooksrichardaera.org16364450 httpwww.sbi-e-catalog.com2013S.B.InternationalInc.Allrightsreserved.Ocwww.engineprofessional.com3 4JAN-MAR2014engineprofessionalFROMTHEPUBLISHERBYPAULHAUGLIEAERAPRESIDENTTheshowseasonendedinDecemberanditcouldnthavegoneoutwithabiggerbang.Forthefirsttimesince2004thePerformanceRacingIndustryPRItradeshowwasbackinIndianapolis.Yesitwascold.Yestherewassnow.Yestravelwasamess.Butweknewthatwouldntmatterandthatthehardcoreracerswouldbethereinnumbersandtheydidnotdisappoint.Itwasgreattoseeashowwithsuchabuzzofexcitementfromtheexhibitorsandtheattendees.PersonallyIbelievethiswasbyfarthebestPRIShowIhaveattendedinthepast15years.SuretheweatherwasnicerinOrlandobutitwasexcitementthatmadealmostallofusforgetthatitwasDecemberinIndianapolis.Itwasalsotherealizationthattheshowforthehardcoreracerswasbackwheretheheartofracingis.YesJohnKilroyvicepresidentandgeneralmanagerPerformanceRacingIndustryIndianapolisistherightplaceforthisshow.Formanyofthoseattendingitdidntseemtomatterthattheyhadtodrive5or6hourssomeevenlongerorthattheyhadtoendure2layoverstogetthere.PRIwasbackinIndythatswhatmattered.ThePRIshowseemedaperfectendingtogoodyearforthoseintheperformanceandautomotiveaftermarket.InfactthereareseveralshopsanddistributorsItalkedwiththatweremuchbusierinNovemberandDecemberthantheywereanticipatingwhatagoodproblemtohaveItwasgreattoseetheHotRoddersofTomorrowoutinfullforce.MyhatisofftoJimBinghamandwhathehasdonewiththisprogram.Ifyourenotfamiliarwiththeprogramorwhatitsaboutcheckitoutatwww.hotroddersoftomorrow.com.Betteryetgotooneoftheeventstheywillbeatthroughouttheyearandcheerthemon.Simplyputthesearehighschoolstudentsthatareinterestedinenginebuilding.Theyneedourencouragementandourinvolvement.Whatagreatwayforshopstogetafirst-handlookatpotentialemployees.Aswelookforwardto2014therearemoreopportunitiesforusthanbeforewhethertheyjustlandinourlaporwedigforthosehiddengems.ItseasythistimeofyeartosayImgoingtostartofffreshorImgoingtopromisetodothisbetter.Thosearefinebutdontmakethosestatementsifyourenotgoingtomakethempartofyourbusinessplan.Thepointisbealertandawareofthoseopportunitiesandalwaysbereadytomakethemostofwhatyouhave.OverthepastyearIhavetouchedonthatparticulartopicmorethanonceandfeelthatitisonethatweneedtoberemindedofregularly.Nottobeatadeadhorsebutasawaytolookatbreathingnewlifeintoonesbusinessintoourindustry.AtAERAwearecontinuouslylookingforopportunitiestomakethisassociationbetterforitsmembersbetterfortheindustryandimportanttotheenginebuilder.Iwanttoencouragereaderstocontactmewithcommentssuggestionsortopicsforarticles.Yourinputhelpsusputoutabetterproduct.Herestoagreat2014IPriortobecomingpresidentofAERAPaulHauglieworkedforMellingEnginePartsasCanadianSalesManagerandPerformanceProductManagerforMellingSelectPerformance.Feelfreetocontacthimviaemailpaulaera.org.ADecembertoremember CumminsISB5.924valvesCylinderHeadBare.......................................1185CylinderHeadComplete.............................1395CrankshaftSteelforged................................895GasketKitUpper..............................................198GasketKitLower..............................................198ConnectingRod.......................................................79CumminsISC8.324valvesCylinderHeadBare.......................................1980CylinderHeadComplete.............................2385CrankshaftSteelforged...............................995GasketKitUpper..............................................198GasketKitLower..............................................198ConnectingRod.......................................................95ProudmemberofandsupplierofKMSGBuyingGroupCummins8.3L6C6CT6CTACummins5.9L6B6BT6BTA6BTAACummins3.9L4B4BT4BTACompleteHead995eachBareHead680eachCompleteHead465eachBareHead355eachCompleteHead446eachBareHead350eachORDERLINE1-866-210-9251ACCESSINDUSTRIESCO.ORDERLINE1-866-210-9251E-MAILnewcasting1998gmail.comCUTANDSAVETOFILECylinderBlocksCrankshaftsCamshaftsGM6.5truckvan.........................................995eaCummins3.94BTOEM....................................950eaCummins5.96BT.............................................995eaCummins8.36CT...........................................1795eaCaterpillar3306DI..........................................2780eaCummins4BT....................................................575eaCummins6CT8.3..............................................780eaCummins6BT5.9..............................................695eaCaterpillar3306.................................................998eaCummins3.9.....................................................158eaCummins5.9.....................................................138eaCummins8.3.....................................................188eaCYLINDERHEADGM6.5TruckVan..................198eaChevy350Vortec......................228eaChrysler318360........................228eaChrysler3.9................................180eaCaterpillar3306PC8N1187......730eaCaterpillar3306DI8N6796.......730eaCaterpillar3406DINEW..........1580eaCaterpillar3406PCNEW.........1580eaCYLINDERHEADCaterpillar3304PCDI...............580eaJeep4.0331..........................375eaFord4.0EarlyLate...................138eaLONGBLOCKCummins5.9OEM..................5980eaCummins3.94BTOEM...........3980eaCummins8.36CTOEM...........6980eaCONNECTINGRODCummins5.93.96BT4BT...........68eaCummins8.36CT.......................86eaGM6.5NEW.................................55eaOILCOOLERCummins3.9................................98eaCummins5.9..............................108eaCummins8.3..............................138eaGASKETKITCummins3.9UpperKitOEM......88setCummins3.9LowerKitOEM.....88setCummins5.9UpperKitOEM......98setCummins5.9LowerKitOEM.....95setCummins8.3UpperKitOEM....128setCummins8.3LowerKitOEM...108setCALLFORCOMPLETEPRICELIST.NEW AERAwelcomesnewmembersACTIVEAbbieAutoPartsIncBoazALAhmansMotorslipABSWEDENAlaskaEngineServiceAnchorageAKAtecoEngineDynoShopInglesideILBryanEngineRebuildingBryanOHClarksAutomotiveKansasCityMOCoakleyMachineMorgantownINFillmoreMachineLLCNaplesFLFrontierTruckPartsWyomingMIGaltoRacingEnterprisesLakemoorILGrattonCouleeAgriPartsLtdIrmaABCANADAHDFRFrederickMDHempelmanMachineWaddellAZHerbertPerformanceCoRenoNVHurstDieselRepairEEarlPAIndependentMotorRebuildersRoseburgORJasonsRepairPerformanceTelfordPALasVegasSpeedMotorsportsNLasVegasNVLazzaroPerformanceIncOntarioNYLesMobileRepairServiceBurgessvileONCANADAMidwestIndustrialControlsMuscatineIAMJMEnginesEscondidoCAMoodysHotRodShopKansasCityMOMotoresBalderramoSASanJuanC.P.ARGENTINANewmanMachineShopPortsmouthOHOldSchoolPerformanceBasehorKSPowerHouseEnginesLynnINProDiesel2009LavalPQCANADAQualityAutoMachineSanDiegoCAQwinexSpanishLookoutBELIZERectificadoraBuenosAiresCochabambaBOLIVIARevolutionAutoWorksJunctionCityKSSmithEnginesMachineGrandIslandNETameRacingCiudaddeMexDFCPMEXICOValleyPerformanceMachineServiceIoniaMIWildWesEngineBalanceLLCGiddingsTXASSOCIATEBuffaloEngineComponentsBuffaloNYRFEngineMorriceMISCHOOLSColumbiaBasinCollegePascoWAOaktonCommunityCollegeDesPlainesILInmemoryofJohnMenzlerSadlyJohnMenzlerofCompPerformanceGroupPassedawayonOctober42013.Heultimatelysuccumbedinhisbattlewithcancerat67.Johnwasawell-respectedleaderinthemotorsportsindustrywhohadbeenhighlyrecognizedbyhispeers.AmonghisindustryaccoladesMenzlerwasnamedthe2011SEMAPersonoftheYearforhisdistinguishedservicetothetradeassociationandthespecialtyequipmentindustry.HewastheonlyrecipientoftheMotorsportsPartsManufacturersCouncilMPMCIndustryRecognitionAwardpresentedtohimin2000andhewasinductedintotheMPMCHallofFamein2010.MenzleralsoownedaSEMA-membercompanycalledInventiveMarketingMotoFeet.MenzlercaredabouttheindustryandchanneledthatintoactionthatmadeapositivedifferencesaidSEMAPresidentandCEOChrisKersting.Hewasaspiritedfunnyandanenormouslydedicatedguywhowillbedeeplymissed.IDealerExpomovesfromIndianapolistoChicagowithnewdatesinDecemberandAIMExporeturnstoOrlandoinOctoberAdvanstarannouncedthattheDealerExpo2014willnolongerbeheldinIndianapolisinFebruarybutratherattheMcCormickPlaceinChicagoDecember5-72014.TheDealerExpoisuntilnowthelargestbusiness-to-businesspowersportsannualevent.Afterthemotorcycledealerandretaildisasterof2008sglobalrecessiontradeshowsliketheV-TwinExpoinCincinnatiandtheDealerExpoinIndianapolisheldtwoweeksapartfromeachothersearchedfornewanewformulatosupporttheirrespectiveevents.AlthoughmanysuggestionsreportedlyhavebeenmadetotheseshowsorganizersbothregardingattendeescontentandlocationnotmuchhaschangeduntiltheAIMExpoAmericanInternationalMotorcycleExpoannounceditsintentiontorevolutionizethepowersportsindustryasNorthAmericasfirstcombinedconsumertradeandmediaeventcombiningindoorexhibitson300000squarefeetwithoutdooractivitiesinOrlandoatwhatorganizersconsidertheidealtimeandplacefornewproductlaunchesdemorideseducationalprogramsandmore.AIMExpolauncheditsinauguraleventOctober16-202013inOrlandoFloridaandisreturningtoOrlandoOctober15-192014attheOrangeCountyConventionCenter.IIindustrynewscalendarFEBRUARY22-23RACEPERFORMANCEEXPOSt.CharlesILwww.raceperformanceexpo.comMARCH15AERATECHSKILLSCONFERENCEHostedbyLibertyEnginePartsLouisvilleKYMAY16AERATECHSKILLSCONFERENCEHostedbySunnenSt.LouisMOJUNE20AERATECHSKILLSCONFERENCEHostedbyEPWISaltLakeCityUTOCTOBER3AERATECHSKILLSCONFERENCEHostedbyRoushYatesandMahleCharlotteNCNOVEMBER4-6AAPEXSHOWSandsExpoCenterLasVegasNVwww.aapexshow.comNOVEMBER4-7SEMASHOWLasVegasConventionCenterLasVegasNVwww.semashow.comDECEMBER11-13PRISHOWIndianapolisConventionCenterIndianapolisINwww.performanceracing.com6JAN-MAR2014engineprofessional MSTARMTnTARerOEformtandfunVictorReinztheraparallelwithoriginafromplasticsandmMSnctionisthestandardforangeofalequidmetaltTARM.mahle-aftermarket.comwwwT.mahle-aftermarket.comnTARerMAHLEOriginalringsprovideuneandfatigueresistaSAE9qualedancetalengineure100lead-iliconandareith60moreomparableeplacements.gextendsringlifemwearandreducesrminimisringbctorReinzctorReinztrademarkareproperdtheictorReinztrademarkarepropertyofDanaLimitedandusedunderlicensetoMAHLECleviteInc.ictorReinztrademarkarepropertyofDanaLimitedandusedunderlicensetoMAHLECleviteInc. AreyouanengineguyWeareContactusbecausewehavetheanswersforengines.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372.JointodayGotopage90foramembershipapplication.500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600www.aera.orgemailinfoaera.orgtwitter.comaeraepfacebook.comaeraepIindustrynews8JAN-MAR2014engineprofessionalAERAcongratulatesthosewhohavecompletedtheAERAOnlineTrainingProgramAsofJanuary82013269peoplehaveenrolledintheAERAOnlineTrainingProgramforCylinderHeadandEngineMachinistcertificates.Foracompletelistofgraduatesgotowww.aera.orgaera-universitycertificates.CardeaBluepicturedaDieselEngineman2ndClassintheU.S.NavyrecentlycompletedAERAsonlinetrainingcourse.Hehasbeenservingonactivedutyforabouteightyearsandiscur-rentlystationedatatNavalFacilitiesEngineeringCommandPublicWorksDepartmentinNaplesItaly.Thisassociationhashigherlev-elsofmechanicalknowledgeandskillsaidBlue.ThecourseemphasizedwhatIthoughtIknewandwhatIdidntaboutmyjob.IlearnedaboutsafetyandhazardcontrolsmissionprinciplesshopmanagementandmorewhichwaswaymoreindepththanAschool.Hispassionforenginesandracingstartedyearsagoasakidgoingtothedragstripwithhisdad.ThroughasequenceoffortunateeventsIwasalwaysabletostayclosetoawrenchandalwaysgiventheopportunitytodevelopmyskillandpassionnomatterwhatlifethrewatmeBluesaid.IlandedmyfirstspeedshopjobatRogueRacingoutofOrlandoFlorida.LaterIworkedforasmallfamily-ownedsal-vageyardasamechanicandapartsguyatAdvancedAutoParts.StillhungryformoreknowledgeandwantingtofurtherhisskillsheenlistedintheNavy.IrememberspecificallytellingtherecruiterthatIwasnttakinganyjobthatdidntDIRECTLYhavesomethingtodowithbuildingandmaintainingengineshesaid.Hehassincetraveledtheworlddoingwhatheloveswhilecontinuingtoimprovehisskills.IhaveconductedseveraldieselinspectionsonpatrolcraftsreplacedbearingsonopposedpistondieselgeneratorenginesinsubmarinesattendedgovernormaintenanceschoolfuelschoolsoilschoolsACRandcountlessothersBluestated.Inhisoff-timehehashadmanyprojectcarssomemoresuccessfulthanothers.Currentlyhehasan05PontiacGTOthatheisbuildingtodosomecompetitiveracingwithassoonashereturnstotheUnitedStates.Hislongtermgoalistoobtainadegreeinmechanicalorelectricalengineeringandworkinexperimentalandordevel-opmentalengines.Iwouldliketohelpevolveeverythingweknowtodayintheracingindustry.RacingisofcoursemypassionandalwayswillbebutuntilIobtainJohnForcesta-tushejokedIwillcontinuetokeeppushingformoreedu-cationandexperience.IndividualslikeCardeaBlueleadthewayformanyotherdedicatedenginemachinistsinterestedinprovingwhattheyknow.Ifinterestedinaddingtoyourresumeofengineexperi-encecallAERAat815-526-7600ext.202andaskforKarenTenderingore-mailkarenaera.org.Shecanansweryourquestionsandwhenreadyregisteryoutobegintheprogram.Formoreinformationseepage70.IReadthefullstorywrittenfortheNavybyMassCommunicationSpecialist2ndClassEva-MarieRamsaranathttptinyurl.comaeranavy. www.engineprofessional.com9 10JAN-MAR2014engineprofessionalHiTeamBackin2008theAERATechTeamandIwroteafewarticlesforEngineProfessionalregardingalternativefuelsandwhatwascurrentlybeingusedandprojectedtobeusedinthenearfuture.WecoveredEthanolGasoholE85LPGLiquifiedPetroliumGasCNGCompressedNaturalGasHydrogenasusedinfuelcellsaswellasininternalcombusionenginesandElectricity.Therewasatonofgoodinformationinthesearticlesandyoucancheckthearchivesonourwebsitetoreadsomeoftheseveryinformativearticlesatwww.engineprofessional.com.Remembertherewasanenergycrisisgoingonbackin2008andofcoursethegreatrecessionhitattheendof2008.Thefeelingofdoomandgloomwascommonandeverybodyhadanopiniononwhatshouldbethefuelofthefutureandhowitshouldbeused.Wellitssixyearslaterandeconomicsasusualhavetakenover.HerearesomeinterestingfindingsthatwillverifythatourbelovedInternalCombustionEngineICEwillbehereforthelonghaulwellintothe21stcentury.LetsstartbytalkingaboutElectricVehiclesEVsandHybrids.AccordingtoaReutersarticleDoldrumsinU.S.ElectricCarsSalescouldLingerIndefinitelydealersandanalystsdontenvisionahugeleapinsalesofplug-insanytimesoondespitestillhighgasolinepricesaraftofpricecutsandcheapleasedealsonEVs.Betweennowand2020IdontseeEVsgettingtoofarbeyondacoupleofpercentagepointsofmarketsharesaidMatthewStoveranindustryanalystwithGuggenheimCapitalMarkets.ObstaclestoEVsalesincludegettingshoppersjusttotryanelectricorhybridcareasingtheirqualmsaboutsuchthingsashavingenoughchargingstationsandofcoursethepricetag.Thehybridshavealsoencounteredsomebearingfailurescausedbythemanysuddenstart-upsthatoccurwiththistechnology.Couplethiswithnewcarsalesforcesthatoftentakethepathofleastresistancetosell.ManydealersjustdonttakethetimetoselltheadvantagesofEVsorHybridsandtoeducatetheconsumeronthesealternatives.AdvantageICE.Since2010theObamaadministrationisspending5billiondollarstosupportthegoalofgetting1millionplug-inhybridsonU.S.roadsinthenext5years.HowevertheNEWSFROMTHEEDITORBYJIMRICKOFFInternalCombusionEnginesarehereforthelonghaulTECHSKILLSREGIONALCONFERENCEROTTLERTOHOSTNEXTCONFERENCEONSEPT.6INKENTWAanAERAinternationalquarterlypublicationJULYSEPTEMBER2008AlternativeandFlexibleFuelsWhattheymeantoenginebuildersPLUSPRO-SISSABobGreenwoodTechsideOntheSamePageTechnicalBulletinsTheJuly-Sept2008issuefeaturedinformativearticlesonEthanolGasoholE85LPGCNGHydrogenandElectricity.Thisissueisavailableforyourreviewinourarchivesonourwebsiteatwww.engineprofessional.com. www.engineprofessional.com11 12JAN-MAR2014engineprofessionalskepticsincludingFordMotorCompanyHondaMotorCompanyToyotaMotorCompanyandevenseveralbatterymakerscautionagainstthishighlyoptimisticoutlook.Manyexpertssaytheelectriccarsarentforeveryoneinfacttheyarentgoodformostdrivers.ElectriccarsaretooexpensivetaketoolongtorechargeanddontprovideenoughdrivingrangebecausetheyrunoutofjuicetobepracticalformostAmericansForexampletheNissanLeaf8hourstochargecost2200toinstallthechargeronlydrives100milesorlessdependingonairtemperature.EvenAlexMolinarolipresidentofJohnsonControlsInc.PowerSolutionDivisionisntexpectingelectriccarstotakeoff.WhyOnly3ofdriversdrivemanymilesayearinshorttripswhichiswhotheelectriccarsaretargetedat.Gasolinepriceswouldhavetoriseto8or9dollarsagallonforelectriccarstobecosteffectivetothebuyer.Someexpertsthinkthatthesebatterieswillbecomemoreusedinhomeswithhybridcarswhichalsousegasoline.Hondausedtosellelectriccarsandhadtostopduetothelackofsuccessitisthoughtthatthenewmodelsoftheelectriccarswillbenobetteronthemarket.PleaseunderstandtherehasbeenalotofmoneyspentonthesedevelopmentsandsomecompanieswillpressonmostlikelywiththeElectricHybrid.MarkReussGeneralMotorsNorthAmericanPresidentstatesChevyVoltSuccessforGM.ItisthoughttheVoltisheretostayeventhoughtherehavebeensafetyconcernsthereisnointenttoabandontheVolttechnology.InlightofthepastbatteryfireGMismakingasafetyfixtothevehicle.ButweallknowoftheGMbailoutbytheObamaAdministrationandonecanthelpbelievetheVoltwillcarryonfornowbasedpurelyonpoliticalreasons.Hondaseemstobetheleaderinhydrogenfuelcellcars.ThenewestHondafuelcellcaristheFCEXasuccessortotheFCXClarity.Hondatheleaderindevelopmentinfuelcellvehiclesreleaseditsfirstfuelcellcarin2002.Thisisatruehigh-pressurehydrogentankwhichgenerateselectricitythroughitsfuelcellstackandpowersanelectricpowerdriveunit.Howeverdeliveryofhydrogenwillstillbeaproblemcostofvehicleandcurrentdemandallplayagainstthisalternativefuelvehicle.HeyinaperfectworldHydrogendoesmakesense.HoweverwiththeaverageAmericanhouseholdincomebeingsqueezedconstantlybymoretaxesandhealthcarecostsexpensivegreentechnologywillsuffer.Iconsidermyselfarealistratherthananidealist.Itendtolookatthingswithacommonsenseapproach.Thiscountryneedsjobsandoilequatestojobs.Currentlytherearecloseto10millionmenandwomenacrossour50statesinawiderangeofhighlyskilledwell-payingprofessions.InfactoilandnaturalgasindustryexplorationandproductionwagesaremorethandoublethenationalaverageWhywouldthismarketgoawayYourerightitwont.TheUnitedStatesaveragedailyoilproductionisontracktosurgeby1millionbarrelsperdaythisyearthebiggestone-yearjumpinthenationshistoryaccordingtofederaldata.Thecountryhaspumpedanaverageof7.5millionbarrelsofcrudeperdayin2013upfrom6.5millionbarrelsperdayin2012.Thatbreakslastyearsrecordwhenoilproductionjumpedby837000barrelsperdaybetween2011and2012.TheU.S.EnergyAdministrationprojectsthatoilproductionwilljumpbyanother1millionbarrelsperdayin2014largelybuoyedbydrillingactivityinTexasEagleFordShaleandPermianBasinregionsaswellasNorthDakotasBakkenShale.NowcombinethisU.S.productionwiththenewsthatMexicoissettodismantlea75-year-oldbarriertoforeigninvestmentinitsoilfields.AccordingtoaBloombergarticleoncethistakesplacetheboomwouldaugmentasupplysurgefromU.S.andCanadianwellsthatExxonMobilCorp.predictswillvaultNorthAmericanproductionaheadofeveryOPECmemberexceptSaudiArabiawithintwoyears.AninfluxofMexicancrudewouldcontributetoaglutthatisexpectedtolowerthepriceofBrentCrudethebenchmarkformorethanhalftheworldscrude.Nowloweroilpricesshouldequatetolowergasolinepricesandwillprovidedthatwecanrefinetheoilefficiently.AccordingtotheU.S.EnergyAdministrationasofJanuary12013therewere143operablepetroleumrefineriesintheU.S.Thenewestrefinerystartedoperationin2008inDouglasWyoming.Howeverthenewestrefineryinoperationwithacapacitygreaterthan100000barrelsperdaybeganin1977inGaryvilleLouisiana.InMarchof2013theDakotaPrairieRefinerybrokegroundjustoutsideDickensonNorthDakotaandisprojectedtorefine20000barrelsperdayandwillbeoperationalbytheendof2014.InadditiontalkonthestreetforasecondrefineryinNorthDakotaisvalid.Relativelynewdrillingtechnologyhigh-volumehorizontalhydraulicfracturingfrackingnowmakesitpossibletoreachnaturalgasreservesmoreefficiently.FrackingistheuseofsandNEWSFROMTHEEDITORBYJIMRICKOFF EXPERIENCE.EXCELLENCE.APASSIONFORYOURBUSINESS.GlobalOEManufacturerComprehensiveCoverageStockPerformanceNO.1SUPPLIEROFTOTALVALVETRAINSOLUTIONS2014ElginIndustries.Allrightsreserved.www.elginind.comsaleselginind.comContactYourElginDistributorTodayorCall1-800-323-676412-47www.engineprofessional.com13 14JAN-MAR2014engineprofessionalNEWSFROMTHEEDITORBYJIMRICKOFFwaterandchemicalsinjectedathighpressurestoblastopenshalerockandreleasethetrappedgasinside.Horizontaldrillingalsocalleddirectionaldrillingisjustlikeitsoundsafterthewelldrillreachesacertainverticaldepthinthegroundthewellisthendrilledhorizontallymakingthecaptureofoilandnaturalgasveryefficient.BecauseoffrackingU.S.suppliesofNaturalGasisatanall-timehighandweknowthisfuelisanexcellentcleanburningfuelforICEintheformofCompressedNaturalGas.TheBakkeniscurrentlyburningoffmorethan100millioninnaturalgasamonthbecausestorageandpipelinesthattransportithavenotbeenabletokeepup.Oncethepipelinesgetbuiltwewillseeaniceincreaseofthiscleanerburningfuelthatalreadyhasshowngreatpotentialforourinternalcombustionengines.LikeIsaidearlierinthisarticleIamarealistandbelieveinthebasiceconomicsofsupplyanddemand.FossilFuelsarentgoingawayanytimesoon.InfactIthinkIhaveshownyoutheyaregrowingintheNorthAmericanContinentatanalarmingrate.Theeconomicbenefitofjobcreationwiththesefuelsisrealandwontbeoverlooked.WhenIlookatthefactsIbelievethattheinternalcombustionengineishereforthelonghaul.SodoestheU.S.EnergyInformationAdministrationwhichforecaststhatevenin2035morethan99percentofcarsandtruckssoldwillstillhaveICEInternalCombustionEngines.Withadvancedenginetechnologiesthepotentialfuelsavingswillbehuge.SobuildonICEbrothersthefutureisstillyoursIJimRickoffistheEditorofEngineProfessionalmagazineandAERAsmarketingconsultant.Ifyouhaveanyquestionscommentsorconcernscall507-457-8975ore-mailjimrickoffgmail.com.SavetheDateMARCH15LIBERTYENGINEPARTSLouisvilleKYMAY16SUNNENSt.LouisMOJUNE20EPWISaltLakeCityUTOCTOBER3ROUSHYATESANDMAHLECharlotteNCCONFERENCEHOSTINGOPPORTUNITIESIfyouareinterestedinhostingaconferencenextyearpleasecontactJimRickoffat507-457-8975oremailjimrickoffgmail.com. 16JAN-MAR2014engineprofessionalENGINEAPPEARANCEBeautyfortheBeastTEXTANDPHOTOSBYMIKEMAVRIGIANYoustrivetoachieveperfectionandattentiontodetailforeveryperformanceenginebuildthatflowsthroughyourshop.Thegoalistoprovidethecustomerwiththehorsepowertorqueanddurabili-tythatisneededforeachindividualjob.Beyondthefunctionalaspectofthebuildconsidertheaestheticsorappear-anceofthefinishedproduct.Grantedfromanoperatingstandpointappearancetakesafarbackseattoperformance.Inaracingapplicationsomefolksdontcareandothersatleastexpectittolookcleanandpresentable.Forthestreetpeopleitsoftenadifferentstory.Iftheengineispartofarestorationtheengineneedstobecleantidyandfreshlypaintedtoreplicatewhatthefactorydid.Forcus-tomizersandthestreetrodcrowdappearanceifoftenakeyfactor.Asidefromsimplyrattle-cansprayingtheblockandslappingonafewchromegoodieswelldiscussafewviableoptionstomakethebuildstandoutfromthecrowd.InthisarticlewelladdressavarietyofappearancetreatmentsincludingAnodizingPowdercoatingHydrographicsPaintingCeramiccoatingPlatingANODIZINGAnodizingisnotacoatingprocess.Ratheritsanelectrolyticoxidationprocessthattreatsthesurfacewithananodiclayer.Theprocessofanodizingslightlyincreasesthethicknessofthenat-uraloxidelayerthatspresentonthesur-faceofaluminum.Aluminumoxideisgeneratedduringanodizingatnearthesurfacecreatingaluminumhydratewhichprovidestheadditionalsurfacehardness.Sincetheanodizedsurfaceisalsofairlyporousitreadilyacceptsacolordye.Anodizingisonlyapplicabletoalloysandcannotbeusedforferrousmetalssuchasironorsteelsincethesematerialswillrustasaresultoftheoxidationprocess.Anodizingisalsobestappliedtobilletorforgedorsheetaluminum.Coloranodizingdoesnotapplywelltocastingsbecauseoftheirregularitiesorimpuritiesincastpieces.Using360or380diecastalloysasexamplesthehighsiliconcon-tentsilicondoesnotanodizecanresultinblotchinessinthefinishedpiece.Ifyoutrytoanodizeacastaluminumpieceitspossiblethatadullgrayappearancewillresult.Addingcolordyeswillonlymar-ginallyattempttocolorthisdullgraysur-face.Anodizingisbestdoneonaluminumpartsthathavebeenmachinedfrombilletmachinedorformedstock.Ifahighglossisrequiredthesurfacemustfirstbepolished.AnalternativeEventhoughweweredealingwitha64-year-oldFordflatheadblockwewereabletosmoothouttheblockexteriorandapplyurethanebasecoatclearcoattoachieveaglass-likefinish.Notethecreativeyetsimplesparkplugrouting.Thetimingcoverwaspowdercoatedinablackwrinklefinishaswell.Thistypeofattentiontodetailcanmakethedifferencebetweenitlooksfinetowow. www.engineprofessional.com17 offeredbyseveralanodizingsourcesistheapplicationofabrightdipfinishthatsappliedaftertheanodizingprocesswhichreallybooststheglossfactor.NoteIfyouhavecreatedseveralalu-minumpiecesthatareplannedforcoloranodizingitiscriticalthattheexactsamealuminumgradeisusedforallpieces.Variancesinaluminumformulascaneasilyresultincolorvariations.Forinstanceifyoumachineahandfulofpiecesfromscraporunknowngradealuminumoncetheyrecoloranodizedinletssaybluethiscaneasilyresultindifferentshadesofbluefrompiecetopiece.Itsalwaysbesttouseacommonaluminumstockwithallpiecesfabricat-edfromthesamerawstock.POWDERCOATINGPowdercoatingsimplyinvolvesthespray-onapplicationofaspecialthermo-plasticorthermosettingpaintpowderthatisthenoven-heatedresultinginflowandadhesion.Theapplication18JAN-MAR2014engineprofessionalENGINEAPPEARANCEBYMIKEMAVRIGIANABOVEThisturbodragenginebuiltbyBanksfeaturesanover-the-topcustomappearancewitheveryaluminumhoseendandplumbingconnectionanodizedinabrightpink.BELOWForthiscustomsmallblockChevy383strokereveryaluminumcomponentincludingpulleysexhaustblockoffplates-6ANplumbingconnectionsetc.wascustomanodizedinavioletcolorforcontrasttothecustompaintjob. www.engineprofessional.com19PERFORMANCEENGINEBEARINGS TiredofgivingupprotstoonlinecompetitorsOrderafreeENGINEPROtimingsetcatalogfromourwebsite.www.goenginepro.comENGINEPROBRANDENGINEPRODUCTSredotoonlOtimingsetsarENGINEPRgivingecompeailablveaOtimingsetsarpprotsteeENGINEPRderafrrO.tserpargetbettedivorpremotsucptenretnillab-wolyithENGINEPROWyitiswithallENGINEPROparasthewthaToughengineprthrOeeENGINEPRofitserprougetbetturcus.tspardemosllatsnirosecirpetvthaoudonywithallENGINEPReyessionalslikofoughengineprtaloatimingsetceeENGINEPRderafrrOENGINPRBomourwgfrtaloOeeENGINEPRANDENGIPRNDU20JAN-MAR2014engineprofessionalENGINEAPPEARANCEBYMIKEMAVRIGIANinvolvessprayingthepowderwithanelectrostaticchargeappliedtothemetalpiece.Theelectrostaticchargecausesthepowdertoinitiallyclingtothesurfaces.Thecoatedpartisthenoven-heatedtoapproximately320-410degreesFtypi-callyaround395degreesFwhichcausesthepowdertomeltandflowcreatingacontinuousfilmcoating.Oncecuredpowdercoatingprovidesaverydurableprotectivefinishthatishighlyresistanttochippingpeelingorcrackingandweath-erroadconditionexposure.Priortocoatingthesurfacesmustbeabsolutelycleanandfreeofanysurfacecontaminants.Pre-heatingthepartinanovenisoftenusedtoburn-offanysurfaceoilsfingerprintsetc.Thesurfacealsorequiresatoothtopromotecoatingadhesion.Thiscaninvolvelightblastingwithaluminumoxidewalnutshelletc.Silicaglassbeadblastingshouldbeavoid-edsincethiscanimbedparticlesinthesurfacethatmaypreventproperadhe-sion.ThesesmallblockvalvecoversadaptedtoLSheadswerepowdercoatedinacharcoalwrinklefinishthenCNCengravedandcolor-filled.continued LooktoAXEWeareAuthorizedDealersforthefollowinglinesofpartsequipmentJamisonSaenzDigital-680FlowBenchPlainFactThebestvalueforyourdollarJamisonSaenzowbenchesThedigitaldisplayontheD-680providestheoperatorwithaneasytoreadreferenceandspeedsuptesting.TheD-680makestestingsoeasythatabeginnercangetgreatresultsinonlyafewminutes.Bi-directional-owsintakeandexhaustThedigitaldisplaygivesyourealtimevaluesfortemperaturedepressionTestpressurevelocityandCFMFlows1137CFM10h2OFlows796CFM20.4h201.5ofmercury-StandardcarbtestpressureFlows680CFM28h2OMakesureyoucheckthesecapacitiesbeforeyoubuyaowbenchAUDIETECHNOLOGIESDATAAQUISITIONSENSORScomeinstalledinthisbenchwhichmakesitcompatablewithaudieowprosoftwareandyourcomputerSpecications28.5Wide30Deep40Talltoxtureange58Tall240Voltsinglephase45AmpsAutomotiveMachineShopEquipment-NewUsedRebuilt-JamisonEquipment.com-800-841-5405upmewinglinesofpartsequipmentAXELooktoAXEwww.engineprofessional.com21 ENGINEAPPEARANCEBYMIKEMAVRIGIANThermoplasticpowderflowswhenheatedbutcanalsore-flowwhenexposedtohighheatlevelsafterthefact.Forcomponentsthatwillbeexposedtohighheatthermosetpow-derswontre-flowafterinitialcuringandprovideanextremelytoughdurablefinish.Variousheat-levelpowdersareavailableincludinghigh-temperaturepowdersthatcanwithstanduptoaround1100degreesF.Whilepartsthatarecommonlypow-dercoatedincludesuchitemsascontrolarmsvalvecoversbrakecaliperhous-ingsaxlehousingstimingcoversetc.keepinmindthatsincethepartwillbeovencuredtoaround400degreesFweneedtoconsiderthepossibilityofcoreshiftonitemssuchascastengineblocks.Ifablockistobepowdercoatedplantoaccurizetheblockafterthecoatinghasbeenappliedmainborealignmentetc..Howeversinceaheavypowder-coatapplicationmaybetooinsulativepotentiallytrappingmoreheatwithintheblockpowdercoatingablockmay22JAN-MAR2014engineprofessionalCNCengravingofvalvecoversallowsanyenginebuildertoadornhiscustomersengineswithsomethingassimpleasenginedisplacementtohisownshopscustomlogo.IfyoudonthaveaccesstoalocalCNCengraverArtCarltonatInnovatorsWestHutchinsonKSdoesagreatjobandturnaroundtimeisquick. THELEADERINFLYWHEELGRINDINGCALL1-800-527-7604www.regismanufacturing.comREGISMFG.1500CorinthStDallasTX75215800-527-7604214-421-5171Fax800-535-8414214-565-1704FLYWHEELGRINDINGSTONESPartNo.UsageDescriptionSizeK-1053CastIronGeneralPurposeBlackstonewithstraight-sidecup6x212x114212tallK-1054CastIronGeneralPurposeBlackstonewithflarecup6412x212x114212tallK-1049CastIronGeneralPurposeSofterspeckledstonewithflarecup6412x212x114258tallK-1057CastIronGeneralPurposeBlackstonewithflarecup6412x2x1142tallK-1058CastIronGeneralPurposeBlackstonewithflarecup4cup43x218x114218tallR-FATBOYHeavy-dutyBlackstonewithflarecup6x412x234x234tallK-1059CastIronandSteelRubystonewithflarecup6412x212x114212tallK-1052CastIronandSteelRubystonewithflarecup4cup43x112x114112tallK-1055SteelWhitestonewithflarecup6412x2x1142tallK-1056SteelWhitestonewithflarecup4cup43x112x114112tallK-1051SteelSmalldiameter3214x114x34114tallK-57ForVanNorman570Blackstonewithflarecup5334x134x1516K-305ForVanNorman405Blackstonewithflarecup54x2x1Take10offwhenyouorder10ormoreflywheelstonesmaybeassorted.CBNSTONESAspecially-engineeredflywheelgrindingstonecreatedfortheautomobileindustrytocutfasterandlastlonger.LeavesnodirtresidueNotforbilletsteel.CBN-334334cup114arborCBN-55cup114arborCBN-66cup114arborCalltodaytorequestafreeREGIScatalogREGISStonesfitmostpopularflywheelgrindingmachineswww.engineprofessional.com23 notbeawisechoice.Intheearlydaysofpowdercoatingalimitedselectionofcolorswerecommon-lyavailable.Todaywellover2500colorsareofferedincludingvarioussurfacefin-ishesfrommatttosemiglosstoglossaswellasmulti-color-speckledfinishestex-turedfinisheswrinklefinishesandevencoatingsthatmimicchromeplatinginnotonlynickelchromebutothercolorsaswell.Evenneonandtransluscentcol-orsareoffered.Chancesareifyoucanpictureitinyourmindtheresapowdercoatthatwillfillthebill.HYDROGRAPHICSThisprocessisreferredtobyseveralnamesincludingwet-dippingwet-filmprintingwatertransferetc.Theseareallnamesforthesameprocess.Simplyputthisinvolvestheapplicationofaspecialinkwhichisthencoatedwithaclearpro-tectivefinish.Theuseofhydrographicsorwetdippingallowsyoutoaltertheappear-anceofanynon-porousmaterialmetalsglassplasticstovisuallytransformthematerialintoadifferentmaterial.Amind-bogglingarrayofinkgraphicsareavailableincludingthosethatprovidetheappearancecarbonfiberpunchedmetaldiamond-platemetalwoodgraincamou-flagedesignsaswellascreativegraphicsthatdepictflamesskullsbarbedwireetc.Therangeofdesignsarealmostlimit-less.Evenifyouveneverheardofthisprocessyouveseentheresults.FollowingarejustafewexamplesNewcarsthatfeaturewoodgraininteriortrimsactuallyplasticwet-dippedtolooklikewoodShotgunsincamouflagepatternsbarrelsstocksandreceiversarewet-dippedindividuallyandthenreassembledFiberglasshelmetsthatlooklikecarbonfiberCellphonecasesthatlooklikecarbonfiberATVbodiesthatfeaturecamouflagepatternsENGINEAPPEARANCEBYMIKEMAVRIGIAN24JAN-MAR2014engineprofessionalBeforethisintakemanifoldwaswet-dippedwespenthourssmoothingoutthesurfacesinordertomaximizethegraphicsimpact.Shownhereistherawintakepriortoprep.Heresthesameintakeinfinishedform.Iselectedaspecificcarbonfibergraphicfromfourdifferentweavepatterns.RIGHTAnoverheadviewofthefaux-carbonfiberintakemanifold.Evenuponcloseupviewingduringadisplayeveryonethoughtthatthiswasactuallyacarbonfiberintake.INSETThiscloseupisagoodexampleofthequalitythatcanbeachievedbyaskilledwet-dipper.Ablackbasecoatwasappliedfirstsincethisinfluencesthefinishedcolor.Ifwehadlaiddownanorangebasecoatitwouldlooklikeorangecarbonfiber.continued TOLLFREE800.648.7970CheckoutthefullselectionofSilv-O-LiteandKBHighPerformancePistonsatwww.uempistons.comCallusoremailusatsalesuempistons.comforapersonalresponseabouthowUEMpistonscanmakeyourbuildssuccessful.ReinforcedtoplandsCoatedskirtsFloatingwristpinswhereapplicableApplicationspecificaluminumalloysDiamondfinishedskirtsPinholeaccurateto-.0001Morethan485OEreplacementpistons.AsNorthAmericaslargestpistonmanufacturerUEMhasyourpiston.OurprocessesandequipmentfeaturethelatesttechnologyforbothOEreplacementandhigh-performancepistonsforeverytypeofengineyouarebuilding.Wehavebeenmanufacturingaftermarketpistonsforautomotivelighttruckpopularimportandheavydutyapplicationssince1922.390HypereutecticalloyFullymachinedcrownsandvalvereliefsDrilledoildrainbacksFullfloatingwristpinsTriplewoundspirallocksOver190differentoversizepartnumbersReflectivealloyallows2powerincreaseApplicationsavailablewith564thand116thringpacks.VastassortmentofcompressionratiosavailableindishflattopanddomestylesQuenchdometechnologyminimizesdeteriorationZerodeckquenchdesignsLightweightwristpinsavailableinmostapplicationsAllpartnumbersavailableinkitswithringsKBHighPerformancePistonsSilv-O-LiteOEReplacementPistonsBOTHICONSERIESFEATUREOver100applicationsontheshelfOver360differentpartnumberoversizesAvailableinkitswithringsICONFHRForgedHeadReliefPISTONSPremium4032alloySecondlandaccumulatorgroovesToplandminigroovetechnologyDiamondfinishedskirtsTriplewoundspirallocksSpacerringsincludedinshortcompressionheightsthatintersectthewristpinboreICONPREMIUMFORGEDPISTONSPremiumHighductility2618alloyNitrousTurbo-ChargedandSuper-ChargedAppsDualforcedpinoilingonmostapplicationsLateralgasportingonhighercompressionratiosFullymachinedwithdeepvalvepocketsSecondlandaccumulatorgroovesToplandminigroovetechnologyDiamondfinishedskirtsTriplewoundspirallocksSpacerringsincludedinshortcompressionheightsthatintersectthewristpinborewww.engineprofessional.com25 26JAN-MAR2014engineprofessionalENGINEAPPEARANCEBYMIKEMAVRIGIANHowdoestheprocessworkThegraphicpatternisselectedfromarangeofpatterns.Thesearepre-printedinkgraphicsavailableinsheets.Theitemtobetreatedispreparedbycleaningandwiththeapplicationofanappropriatebasecoaturethanepaint.Thecolorofthebasecoatwillinfluencethecolorofthefinalgraphicsincemostinkgraphicsaresomewhattranslucent.Theselectedinkgraphicsheetisplacedontothesurfaceofwaterinaspe-cialtemperature-controlledtank.Theitemtobetreatedisskillfullyloweredthroughthefloatinggraphicsheetsubmergingintothewaterastheinkfilmwrapsaroundandclingstotheitem.Theitemisremovedfromthewatertankrinsedanddriedfollowedbytheapplicationofaprotectiveclearcoat.BasicallytheprocessisverysimilartothatofdippinganEastereggthroughfloatingcolordyes.Thisisaveryover-simplifiedoverviewoftheprocessbutyougettheidea.Oncethecomponenthasbeenpreppedthewet-dipprocessbeginsbylayingtheinkfilmgraphicontothewatersurface.Aftersprayinganactivatortofreetheinkfromitsbindersthedippercarefullyimmersestheitemthroughthegraphicink.Astheitemtravelscompletelythroughthegraphicfilmthefilmclingstothesurfaces.Anyexcessoverhangingfilmthathadnosurfacetoclingisshakenoffwhileunderwater.Oncetheitemisremovedfromthewet-dipwatertankallun-maskedsurfacesarecoatedwiththeinkpatternthelightgreenyouseehereiswheretheinkstuckontolightmaskingtape.Theitemisthenrinseddriedandthenclearcoated.continued www.engineprofessional.com27 28JAN-MAR2014engineprofessionalENGINEAPPEARANCEBYMIKEMAVRIGIANAutomotiveapplicationsaremanyandvaried.Intermsofengineapplicationstheitemsthatmightbeconsideredforwet-dipgraphicscanincludeintakemanifoldstimingcoversoilpansaircleanerhousingsvalvecoversthermo-stathousingsdistributorcapspulleysetc.Whileaskilledwet-dipshopcanuseahigh-temperatureurethaneclearcoattoaccommodateheat-relateditemsthisislikelysuitableforraceenginesthatwillbeexposedtoextremelevelsofheatforextendedperiodsoftime.Howeverforthecustomstreetbuilderorstreetrodfabricatorcustomerwet-dipgraphicsofferaveryviableoptionforappearanceenhance-ment.AsacaseinpointduringarecentPontiacbig-blockbuildinmyshopwehadanaluminumintakemanifoldwet-dippedtoachieveablackcarbonfiberweaveappear-ance.Duringtheenginedynosessionwhereweranabouteightpullsandchangedcarburetorsafewtimesspillinggasintheprocesstheclearcoatandthegraphicwereunharmedandshowednosignsofliftingordiscoloration.GrantedIcantpredictthedurabilityoverthelongtermlifeoftheenginebutconsideringtheheatandfuelspillweencounteredduringasoliddayofdynorunsIwasveryimpressed.OnecautionthatIneedtoimpartinvolvesanyboltholesonthecomponent.Whilethegraphicfilminkisverythintheprotectiveclearcoatcanprovetobeanissueinareaswhereaboltheadorboltwithwasherwillcompresstheclearcoat.Usinganintakemanifoldasanexamplepre-checkthefitofallboltstothemanifoldusingexactlythesameboltsandwashersthatwillbeusedforfinalinstalla-tion.Iftheboltholeentryareasarealreadyspot-facedcarefullycheckforboltheadorwasherfit.Ifthefitisabitonthetightsideincreasethediameterofthespot-facebyQualityControlledExpansionPlugsSince1921BrassStainlessSteel800-433-64141335WFULLERTONAVEADDISONIL60101630953-1000FAX630953-0174EMAILINFOUSTOOLANDMFG.COMU.S.TOOLANDMFG.CO.Evenafterafulldayofdynopullsthehigh-temperatureclearurethaneandunderlyinginkgraphicmaintaineditsnewappearancewhichwasimpressive. about0.030.Iftheholesdontfeaturesport-facerecessescuttheseinagainprovidingperhaps0.030ormoreclear-anceforthediameterofyourboltheadsorwashers.Whenyoudeliverthemanifoldtothewet-dipshoptellthemtomaskthespotfacesurfacespriortoapplyingtheirclearcoat.Ifyoudontpayattentiontothisathickbuildupofclearcoatattheboltholeswillresultintheclearcoatbulgingexpandingastheboltsaretightened.Thiscanpotentiallyleadtoliftingoftheclearcoatdowntheroad.NoteWhileafewbuildersmaybetemptedtotakeadvantageofwet-dippingforanengineblockbeawarethatthisisnotapracticalidea.Firstofalltheblockwouldneedtobesmoothedouteliminatingallcastingsurfaceroughnesswhichisverytimeconsuming.Secondlyconsid-eringtheweightandsizeofablockthewet-dipshopprobablywontbeabletolowerandlifttheblockinoutofthewatertank.Eveniftheyhaveanoverheadcranewhichisdoubtfulproperpositioningoftheinkfilminvolvescarefullyrotatingthepartwhileitpassesthroughthefloat-inginkfilm.Inotherwordswet-dippingablocksimplyisntpractical.AUTOMOTIVEPARTSEXAMPLESFORHYDROGRAPHICSPlasticormetalautomotivedashinsertsPlasticormetaldoorinsertsPlasticormetalconsoleinsertsGaugebezelsShiftknobsShifterarmsAlternatorhousingsBatteryboxesAirinletductingplasticormetalAluminummagnesiumorsteelwheelsCarburetorbodiesbowlsCarburetorlinkagesThermostathousingsIntakemanifoldsValvecoversOilpansTimingcoversAircleanerhousingslidsBoltsscrewswashersyestheycandosmallitemsIntakeairtubesDoormirrorhousingsGrillesgrilleinsertsPlasticormetalbumpersHelmetsPlasticfiberglassormetalfendersBrakemastercylinderlidsMisc.bracketsControlarmsTierodsDriveshaftsDifferentialcoversBellhousingsHeadlightortaillighthousingstrimsSpoilersairdamsDoorhandlesMotorcyclefueltanksMotorcyclefenderswww.engineprofessional.com29THEONLYHEATTABMADEINU.S.A.DONTBEFOOLEDBYCOPIESFROMOFFSHOREIMITATIONSSILVERSEALCENTERMATERIALISCERTIFIEDMADEINTHEU.S.UNDERU.S.STANDARDS.p800-521-2936f800-521-0580silver-seal.comSilverSealProducts19224AllenRd.TrentonMI48183silversealKEEPAMERICAWORKINGPREMIUMHIGH-TEMPHIGH-TEMPLOW-TEMPDIESELMARINEU.S.PATENT5482000250-255F121-124C250-255F121-124C225-230F107-110C187-192F86-89CFRONTBACKPERSONALIZEDHEATTABSAVAILABLEHEATTABADHESIVEEXCLUSIVEFORMULAMADEINTHEU.S.A.HIGH-TEMPHEATTABSPARTHT1MELTINGPOINT250-255F121-124CWecertifythatthematerialsuppliedpursuantorderissuedbyyouandnumberedaslistedaboveconformstoapplicablespecificationsorrequirements.ForCompleteProtectionsilversealBatch100612GeoffreyA.HavensSr.PresidentCertificationofCenterMeltMaterialAMUSTforEngineBuilders-LargeorSmallCourtCasesWonwith100ResultsDONOTRiskYourHardWorkUsingOffShoreImitationsMADEINTHEU.S.A.MADEINTHEU.S.A.MADEINTHEU.S.A.MADEINTHEU.S.A.KEEPAMERICAWORKINGKEEPAMERICAWORKINGKEEPAMERICAWORKINGMADEINTHEU.S.A.MADEINTHEU.S.A.KEEPAMERICAWORKINGTHEU.S.MADEINEREALENIDONTBEFOOLEDBYCOPIESFROMOFFSHOREIMITHEHEONLENTP.S.UUNDERU.S.THEU.S.TIFIEDERIALIETERMPIEFRMFFHREIMIABMADEINU.TTIONSABMADEINU.S.A.HIGH-TEMPHIGH-TEMPPREMIUM121-124C250-255F121-124C250-255FEMARINEDIESELLOW-TEMPHIGH-TEMP121-124C250-255F107-110C225-230F86-89C187-192FFRONTEeeuetratthk.ishatengineteonstarTINGO1-124CatabevidenachaofoftheheatvismpletePWhenanentltoprachesthgihece50-255F1NINythereabouiFeas.rementrAttachOnEachHeadBothSidesofBlock.lnsoterissuedbplescabantolipoaprmsedpunterialsuptabWeceranouyrdsulipftih100612.0HIGHMEL1TEMPARP580tBMI4818ENTORD.CertificationofCenterMeltMaterialBACKUsingOffShoreImitationsorkWurHardDONOTRiskonwith100ResultsWCourtCasesLargeorSmallAMUSTforEngineBuilders-CertificationofCenterMeltMaterialBACKonwith100ResultsCertificationofCenterMeltMaterial19224AllenSilverSealProductssilver800-521-2936fpsilveVERO-EAL.O70TentedisyA.HafreGeo734.479225SI.WWOCALP734.479.47AXF800.521.2936FREEPHONL8.FALLEN.TRENTON192vensSr.MI48183entonRd.19224Allen-seal.comsilver800-521-0580800-521-2936favUsingOffShoreImitationsMI48183800-521-0580continued PAINTIftheenginebuildinvolvestheuseofanaluminumblockaluminumheadsalu-minumintakemanifoldaluminumorzinc-platedoilpanortimingcoveryouprobablywontseetheneedtopaintanything.Ifyouredealingwithcastironandbaresheetsteelblockheadstimingcoveroilpanetc.naturallyyoullneedtoapplysomethingtopre-ventrustandtoprovidetheappearancethatthecustomerrequires.Dependingonthenatureofthebuildyoumightprefertopaintcompo-nentsindividuallypriortofinalassem-blyortopaintthepartialorcompleteassembly.Regardlessofyourapproachthesur-facesmustbecleananddrythatshouldbeobvious.Priortoapplyingthepaintconsiderapplyingathincoatofaquali-tyetchingprimer.Thiswillsealthesur-facestopreventsurfaceoxidationwhichbuysyouabitoftimeifyouarenotabletoapplyfinalpaintthesameday.Anetchingprimeralsobitesinto30JAN-MAR2014engineprofessionalENGINEAPPEARANCEBYMIKEMAVRIGIANINTRODUCINGManyNewExclusiveProductsFor20141-800-533-8010www.goodson.comtwitter.comGoodsonToolsfacebook.comGoodsonToolsAndSuppliesRequestYourFREE2014GoodsonCatalogTodayGetyour144PageGoodsonToolsSuppliesforEngineBuildersCatalogcompletewithpricing.Call1-800-533-8010andaskforCatalogREP1orvisitGOODSON.COMtorequestonebyemail.ScanThisCodeWithYourSmartPhonetoaccessthecatalogrequestformimmediatelySuperScrapersincludingNEW58WideSevereDutyValveRefacingOilHyper-FinishHoningStationUniversalCutterBladeSharpener600PoundAnalogValveSpringTesterMagneticHeadBoltWasherSpringShimRemoversDealingwithvalve-cover-mountedcoilsonanLSengineisalwaysahasslewhenthecustomerprefersacleanerlook.RatherthanrelocatingthecoilsonaparticularbuildwemadeamoldandproducedapairoffiberglasscoilcoversthatattachdirectlytotheOEvalvecovershidingthecoils.ForanaddedtouchweinstalledcarbonfiberstripstothetopsalongwithchromedChevroletbodyemblems. www.engineprofessional.com31PROVENPERFORMANCEWithadvancedfeaturesengineeredspecicallyfortherepairenvironmentFel-ProPermaTorqueMLSheadgasketswithourLaserWeldstopperlayerarethebestsolutionforvirtuallyallMLS-sealedengines.Thesegasketsdecreasecylinderheadliftandareeffectiveupto3600psideliveringastrongerandfarmorereliablesealforahigherqualityenginerepair.100SEALEDLASERWELDSTOPPERTECHNOLOGYMagniedViewthemetalsurfacesprovidingamuchmoredurableadhe-sion.Stayawayfrombargainprimersthatclaimtohavesurfaceetchingcapabilities.TheonlyetchingprimerthatIveusedthatactuallyworksisofferedbySEMthisstuffwillactuallyetchintoglass.Itsexpensivebutworthit.Itsbesttoallowtheetchingprimertocureforabout8hoursormorebeforeapplyingthefinalpaint.Ifyoureallywanttogetcarriedawayintermsofappearanceyoucantakethetimetosmooth-outallsur-faceirregularitiesfromtheblockcastingflashingsdim-pleshighspotsetc.whichwilltakehoursifnotdaysusingadiegrinderwithcuttingbitsandabrasivepads.Ifyouwanttogetreallycarriedawayaftersmoothingoutallsurfaceirregularitiesyoucanaddressremainingimperfec-tionswithanepoxyfiller-primerfollowedbysandingfol-lowedbymoreprimermoresandingetc.untilyouachieveperfection.Aftereachcoatofprimerisappliedandallowedbydrydustthesurfaceswithablackspraypaintthensandagain.Theblackpaintservesasalow-spotrevealerasyousandanylowspotswillremainblackindicatingwhereadditionalfillerisneeded.Thisisalengthyandverytediousprocessandcertainlynotneededfortheaveragebuild.Howeverifyouencounteracustomerwhodemandsthislevelofappearanceandiswillingtopayforyourtimeitsanoption.Naturallytheblockmustbethor-oughlywashedfollowinganyofthesesurface-prepactivi-ties.Grantedyourunanenginebuildshopnotabodyshop.Ifyouencountertherarecustomerwhowantsthisconsiderfarmingtheblockoutforsurfacepreptoalocalandtrustedbodyshop.Applyingthefinalpaintshouldbedoneinstagesapplyingseveralthincoatsasopposedtosprayingoneheavycoat.Thisisneededtobothavoidheavysagsandrunsandalsotopromoteproperpaintsolventreleasetoinsureadequatedrying.ThisoriginalFordflatheadoilpanwasdingedandnasty.Ratherthansimplycleaningtobaremetalandsprayingwetookthetimetoworkoutthedentsaddhigh-densitybodyfillersandapplyhigh-buildprimerandsandrepeatingthisuntilthesurfacewasperfectlysmoothandfreeofwavinessapplyingpaintonlyafterthesurfacewaspreppedtoperfection.Incaseswhereanoriginalcomponentmustbere-usedwhereanewreplacementsimplyisntavailablesavinganoldpartiscertainlyviableevenwhenthecustomerdemandsahighlevelofappearance.continued 32JAN-MAR2014engineprofessionalCERAMICCOATINGSTheuseofhigh-temperatureceramiccoatingshasbeenaroundfordecadesasbothathermalbarriertreatmentforpis-tondomesandcombustionchambersaswellasexhaustmanifoldsandheaders.Fromanappearancestandpointwellfocusonexhaustcomponents.Inadditiontoaceramiccoatingsabilitytolowerunderhoodtemperaturesandtoimproveheatmanagementforheaderorexhaustmanifoldapplicationsthistreatmentpro-videsanexcellentappearance-improverandisavastlysuperiorapproachasopposedtoapplyingaconventionalheatpaint.Tubularheadersandsomeafter-marketcastmanifoldsareavailablealready-coatedfromthemanufacturerusuallyineitherahigh-lusteralu-minumorblackfinish.Forthosehead-ersormanifoldsthatarepresentlybareorpaintedyoucanshiptheitemstoacoatingshopwherethesurfaceswillbepreppedandcoatedinyourchoiceofcolor.DifferentshopsofferdifferentcolorchoicessotakethetimetocheckoutENGINEAPPEARANCEBYMIKEMAVRIGIANSM1000ForOnly21250TheBestSurfacerOnThePlanetPrecisionsurfacingthatyoucanrelyontolastmanygenerations.Bercohas90plusyearsofmanufacturingqualitymachinesthatlastalifetimeJointhethousandsofshopsthathaveexperiencedthequalityofBercobutnowatanaffordableprice.TheownerofthisFordsmallblockwantedamonochromeappearancetheme.Theblockwaspainstakinglysmoothedandpaintedinafinealuminumcolor.MatchedupwithaluminumheadsandheadersfeaturinganaluminumlusterceramicfinishThefinalappearanceofanallaluminumenginewasachieved. www.engineprofessional.com33Onthesurfacemostmoldedrubberslookthesame.ButtheirchemicalpropertiesareinvisiblesowhodoyoutrustYoucantrustFel-Protoalwaysutilizethemostadvancedmolded-rubbermaterialsappliedwithcomputer-controlledprecisioninstate-of-the-artFederal-Mogulmanufacturingfacilities.AnotherexampleofFel-Prosealingsciencestayingaheadtoprovidethebestsealingsolution.UNIQUEFEL-PROONLYCHEMISTRYSEALINGSCIENCE200hourdynamometertestFEL-PROOTHERGASKETOthergasketpartbeganleakingcoolantat140hours.theirofferingsandletthecustomermaketheselection.Choiceswillvaryfromwhiteblackbronzecopperredbluegreenaluminumandmorewithfinishesincludingsatinorgloss.Ceramichigh-heatexhaustcoatingservicesareofferedbyfirmssuchasJetHotCerakotePolydynSwaintechCoatingsandothers.NoteWhileothershopsoffercolorchoicesSwainscoatingsareintendedstrictlyforfunctionandfeatureawhitefrostyappearance.Generallyturn-aroundtimesforheadercoatingsrunanywherefrom1to3weeksdependingonseasonalwork-loads.PLATINGDuetospaceconstraintswelllimitourdiscussionofplat-ing.Chancesaretheonlytimeyoullneedanyengine-relatedparttobechromeplatedisinthoserareinstancesthatinvolvearestorationprojectwherenewreplacementpartssuchasvalvecoversarenotavailable.Chromeplat-inghasbeenaroundforlongerthanIcaretoremember.ItsthebestwaytogobutisbecomingmoreexpensiveandlimitedduetotighteningEPAregulations.PVDphysicalvapordepositionisanalternativefortraditionalchromeplatingthatsmoreenvironmentallyfriendly.Layersofbasematerialpossiblycopperzincandnickelfollowedbychromiumareappliedusingionover-sprayregulatedtemperatureandvacuumwithnohaz-ardouswastebyproducts.PVDisusedonavarietyofmaterialsfromplasticstometalsmostlyindecorativeapplicationswheelsetc..Inmyexperienceitsnotasgoodastraditionalchromeplatingespeciallyfromadura-bilitystandpoint.Dependingonwhereyourelocatedinthecountryyoumayneedtoshipitemsoutforgoodolfashionedchromeplating.Byaddingatastefulamountofaluminumandchromeaonce-boringflatheadwastransformedintoarealshowpiece.continued 34JAN-MAR2014engineprofessionalALUMINUMORSTAINLESSSTEELPOLISHINGIfyoudesireaglossiershinierappearanceonanaluminumorstainlesssteelcompo-nentwithoutplanstoapplyanytypeofcoatingtheoptionsincludehand-polish-ingusingfineabrasivesandpolishingcompoundsandplentyofmuscle-numb-ingelbowgreasepolishingusingabuff-ingwheelandpolishingrougevibratorypolishingorelectropolishing.Vibratorypolishinginvolvesimmers-ingtheiteminaslurryofabrasivestonesthatrubagainstthematerialsurfacesinavibratingmachine.Thelevelofpolishisdictatedbythetypeshapeandsizeofthestonesthesevarywidely.Dependingontheitemathandvibratorypolishingmayormaynotachievetheleveloffinishthatyoureafter.Electropolishingalsoknownaselec-trochemicalpolishingisaprocessthatremovesaminuteamountofmaterialfromametallicworkpieceusedtopolishanddeburrmetalparts.ThisprocessalsoremovesanydiscolorationonthesurfaceENGINEAPPEARANCEBYMIKEMAVRIGIANSpecializinginUsedRebuiltEngineRebuildingEquipmentFARRISEQUIPMENTSALESisoneofthelargestdealersofusedrebuiltenginerebuildingequipmentintheUnitedStates.WehavebeenblessedtoshipourequipmenttonearlyeverystateintheUSAandtoover40othercountriesaroundtheworld.Weinviteyoutovisitourwebsiteforphotosandpricingwww.farrisequipment.comThephotoswillgiveyouanideaofthequalityofourmachinesandalsoshowyouourfacilitiesandpeople.Warrantyprovidedwitheveryrebuiltmachinewesell.ContactSAMFARRISorDONSTONE3001Interstate27LubbockTX79404E-mailsamfarrisequipment.comBuytheRightpieceattheRightpriceFROMTHERIGHTPEOPLECall800-882-1808fortheFARRISTDEALaroundThealternatorbracketpicturedherewasmadefromstainlesssteeloriginallyinasatinfinish.Ahigherdegreeofsheenwasdesiredsothebracketwasenhancedbyusinganelectropolishingprocessthatrequirednohandbuffing. www.engineprofessional.com35PREDICTIVEENGINEERINGEXTREMETESTINGTodaysnewhighoutputturbo-chargedenginescreateunprecedentedheatandstress.ButnewFel-Prohightemperaturealloymaterialsarebeingdesignedtohandlethoseextremesandtomeetthesealingneedsofprofessionaltechniciansbothtodayandtomorrow.HIGHTEMPERATUREALLOYHTAthatwascausedbyheattreatingandoroxidation.Basicallyitsaneasyalternativetoabrasivepolishing.TheworkpieceisimmersedinatemperaturecontrolledbathofelectrolyteandservesastheanodewhenconnectedtoapositiveDCcurrent.Ascurrentpassesfromtheanodewheremetalonthesurfaceisoxidizedanddissolvedintheelectrolytetothecathode.Theprotrudingareasofthemetalsurfacedissolvefasterthantherecessespeaksareknockeddownwhilepreservingthevalleys.similarinthegoalachievedinplateauhoning.Thisisknownasanodicleveling.Theresultabrightlyfinishedsurfacewithoutthetimelabororlessassociatedwithabrasivebuffing.Electropolishingmayormaynotprovidethelevelofpolishthatyoudesire.Ifyouwanttoenhancethefinishintermsofglossvibratoryorelectropolishingwilllikelyprovideacceptableresults.Ifontheotherhandyouwantthehighestlevelofpolishpossibleyoulllikelyneedtodothiswithbuffingpolishingcompoundsandplentyoftime.Youcansavesometimebyfirsthavingtheitemelectropolishedorvibratorypolishedfollowingupwithhandormachinebuffing.GLASSBEADBLASTINGIfasatinsheenisdesiredonanaluminumsurfaceforinstanceonanintakemanifoldandifyoudontplantoapplyanytypeofcoat-ingtreatingthesurfaceviaglassbeadblastingisacommonpracticeinordertoobtainafreshuniformappearance.Howeverifappearanceisthegoalitsimpera-tivethattheglassbeadmediaorwhateverblastmediayouchooseisfresh.Ifthemediahasbeenusedforawhileforcleaningpurposeschancesarehighthatitscontaminatedwithparticlesofoldpaintcarbongreaseorotherdebris.Ifyoublastthesurfacewithdirtymediayoullendupwithamottledappearanceasthecontaminantsareimbed-dedintothesurface.Ifyouplantoblastinordertoobtainacleanfreshappearanceyouneedtoemptytheblastcabi-netcleanthoroughlyandaddafreshloadofmediaintothehopper.IMikeMavrigianhaswrittenthousandsoftechnicalarticlesoverthepast30yearsforavarietyofautomotivepublications.InadditionMikehaswrittenmanybooksforHPBooks.ContacthimatBirchwoodAutomotiveGroupCrestonOH.Call330435-6347ore-mailmikebirchwoodautomotive.com.Websitewww.birchwoodautomotive.com BYSTEVESCOTTTheCat3406EandC-15enginelineshavealonghistoryofupdatesandimprovementssomeofwhichresultedincomponentsthatarenotcompatibleforuseinearlierorlatermodelyears.Understandingthedifferencesin3406EandC-15cylinderblocksheadsandheadgasketscanbeconfusing.Knowingsomeofthedifferencescanbeimportantgiventhemultitudeofexchangeprogramsupdatesandinterchangeability.HEADGASKETSVisuallythereisonlyasubtledifferencebetweenthetwooriginalstyleheadgasketsattheoilreturnportattherearoftheengine.TheearlierenginesusedthePart1539653headgasketwhichhasanintegralsealembeddedintotheheadgasketattheoildrainbackpassageshownontop.ThegasketforthelaterseriesenginesdoesnothavetheintegralsealembeddedattheoilreturnandisdesignedtobeusedwithafreefloatingsealonthelaterstylecylinderblocksasshowninFigure1insert.Caremustbetakenwhencleaningtheblockorspacerplateinthisareasinceabrasivepadsorwheelscanquicklytaperordistortthesurfacesresultinginleaks.Structurallythesetwogasketsareconsiderablydifferent.TheearlierstyleheadgasketisconstructedofasinglelayerofperforatedmetalcoreandtwolayersofgraphitematerialasshowninFigure2.Thisdesignworkswellaslongastheoriginalstyleblockcylinderheadandspacerplateareinverygoodcondition.Laterproductionenginesusedthe2245122headgasketwhichisconstructedoftwolayersofperforatedmetalcoreandthreelayersofgraphitematerialasshowninFigure3.Thisgasketisapproximately13heavierthanthe36JAN-MAR2014engineprofessionalCAT3406EANDC-15BlocksHeadsandHeadGasketsFigure1.Thegasketforthelaterseriesenginesdoesnothavetheintegralsealembeddedattheoilreturnandisdesignedtobeusedwithafreefloatingsealonthelaterstylecylinderblocks.Figure2.EarlyStyleHeadGasketFigure3.LaterStyleHeadGasket www.engineprofessional.com37 earlierseriesgasket.Notethatthislaterseriesgasketdoesnothavetheintegralsealembeddedattheoilreturnandisdesignedtobeusedwithafreefloatingsealonthelaterstylecylinderblocks.Thefreefloatingsealoffersamorepositivesealbetweentheheadandblockascomparedtotheearlierdesignwhichreliedonthecoatedspacerplategaskettosealbetweentheblockandspacerplate.CYLINDERHEADSDifferencesinthecylinderblocksandcylinderheadscanalsohaveaneffectontheheadgaskets.Earliercylinderheadshadaflatsurfacebetweenthecylindersandtypicallyusedtheearlyandlighterthreelayerheadgasket.LatercylinderheadcastingshaveareliefcutorgroovebetweenthecylindersasshowninthecomparisonphotoinFigure4.Thisheaddesignwastypicallyusedinlaterenginesandwiththeheavierfivelayerstyleheadgasket.ThephotosinFigure5showacomparisonofthetwoheaddesignswiththeearlyheadontheleftandthelaterheadontheright.Thevariousexchangeprogramsandcylinderheadsreplacementshaveincreasedtheusageofthesereliefstylecylinderheads.Theyhavebecomefarmorecommoninthemarketplaceandarebeingusedmorefrequentlyintheearlystyleengines.Fieldissuesarosewhentheearlierthreelayerheadgasketswereusedwiththesecurrentdesignreliefcutcylinderheads.Thecombinedconditionsofthecylinderblockspacerplateandcylinderheadcouldallowforthermalpushofthegasketmaterialintothevoidsofthereliefcutspullingthegasketmaterialbackawayfromthefirerings.Dependingontheconditionoftheothercomponentsthiscouldcausetheheadgaskettofailprematurely.Thisfailuremodeisnotthefaultoftheheadgasketitwassimplycausedbytheheadgasketbeingusedwithcomponentsandinconditionsitwasnotdesignedfor.CYLINDERBLOCKSAtthispointonemightaskifthelaterheadgasketwithitsheavierconstructioncouldbeusedinallapplications.Althoughbothgasketdesignshavethesameholepatternsandarewithinthesamethicknessrangei.enocompressionratiochangeusinga5layergasketwithearliercylinderblocksmayresultinleaksorseepagearoundtheoilreturnport.Theearlystyleblockshavealargeoilreturnportattherearthatisapproximately1-383.5cmCAT3406EANDC-15BYSTEVESCOTT38JAN-MAR2014engineprofessionalFigure5.Blockdeckdifferencesprioronleftcurrentonright.Figure4.Originaldesignleftcurrentdesignright.Figure6.aboveEarlyblockfreefloatingsealwillnotwork.Figure7.rightLaterblockomittedseal. www.engineprofessional.com39 40JAN-MAR2014engineprofessionalwide.Thecoatedspacerplategasketsealsbetweentheblockandspacerplatewhiletheintegralembeddedsealintheheadgasketsealsbetweenthespacerplateandhead.Laterstyleblockshaveasmalleroilreturnportthatisapproximately13162cmwide.Thisnarrowportsupportsthefreefloatingsealandsealstheblockdirectlytothecylinderhead.WhencomparingthetwoblockdesignssidebysidethedifferenceismoreapparentseeFigure5onpage38.Theearlycylinderblockscannotsupportthefreefloatingseal.ThephotoinFigure6onpage38showstheearlyblockandlatestylegasketandseal.Ifthefreefloatingsealwereusedwiththisstylecylinderblockthereisnosupportandthefloatingsealfallsintothereturnport.TohelpeliminatesomeoftheconfusionthesedifferentcombinationsmaypresentIPDhasdevelopedaoneheadgasketsolutionthatovercomestheconfusion.Usingitwillalleviateanyissueswiththevariouscombinationsofheadsblocksandheadgaskets.IPDs2245122SPheadgasketoffersanimproved5-layerconstructionandanintegralsealembeddedinthegasketattheoilreturnport.Itcanbeusedwitheitherstylecylinderblock.ThisheadgasketcanalsobeusedwiththefreefloatingsealinthelaterblocksasshowninthephotoshownifFigure7onpage38.Ofcoursewhenusedwiththeearlierblocksthefreefloatingsealcannotbeuseditissimplyomittedfromassembly.Thustheconditionoftheblockandspacerplatemuststillbewithinspecificationssincetheystillrelysolelyonthespacerplategaskettosealbetweentheblockandspacerplate.HopefullythisinformationhasresolvedsomeoftheconfusionandhasexplainedtheIPDsinnovativesolution.Ifyouveanyquestionsdonothesitatetocontactme.ICAT3406EANDC-15BYSTEVESCOTTSteveScottjoinedtheservicedepartmentatIPDin1982workingwithpartsserviceandsalesforavarietyofequipmentdieselandnaturalgasengines.Since2004hehasbeenthedirectorofproductdevelopmentandtechnicalsupportforIPD.Formoreinformationpleasecall713-574-6145oremailsscottipdparts.com.RACEPROVEN.TIMETESTED.3200ArrowheadDr.CarsonCityNV89706TEL800227-8360FAX775883-9497www.dura-bondbearing.comPerformanceEnginesDeserveHIGHPERFORMANCECamBearings.IfyouwanttomatchperformancelevelsandgetthemostoutofyourenginesuseDura-BondRedBoxHighPerformanceCamBearingsHIGHPERFORMANCECAMBEARINGSPrecisionMachined-CenterlessGroundBoredMoreThanDoubletheFatigueStrengthofStandardBearings-WithstandsRacingSpringLoadsMicro-BabbittGrain-ControlledBabbittRollerBurnishedCOATEDHIGHPERFORMANCECAMBEARINGSRetainsEngineOilOntheSurfaceEvenUnderExtremeHeatandPressureSecondaryLubricationIntheEventMomentaryOilStarvationOccursQualityCamshaftBearingsSince1947 www.engineprofessional.com41 42JAN-MAR2014engineprofessional 44JAN-MAR2014engineprofessionalBYKIMRAMONTChancesareifyouarereadingthisarticleandhaveamachineshopwiththebasicmachinesandtoolingyoucancompeteinthisOLDWORLDquitenicely.Illcoversomebasicideasthatarenotrelatedtomachiningthatweusetomakethisven-tureprofitablewithminimumproblems.Youareallusedtocrankshaftspis-tonsvalvetrainmostoldengineshavethesebasicitemsinsomeformorother.Theyarenotreallydifferentthanthehighperformancestrokerengineyoulaboredovertomakeasmallprofitonbecauseeverybodyisdoingitandthecustomercanbuyorgetonedoneanywhere.Withnothingmorethanyourbasicmachinessomepartslocatingandsomesortofspec-ificationsyoucanbebillingdowntimehoursthatarenotnormallybilledasbasiclaborcodeoperations.Theseoldenginescanbeagoodmonthlyincome.Thisarticlepertainslesstothephysi-calrebuildingofanantiqueenginemoretotheinsandoutsofwhatshouldconsistofagooddealofyouryearlyprofit.Everybodyhastheirroutinebutwhenitcomesdowntoitthereissparetimethatcouldbefilledwithbillablehours.MoreprofitWealltendtorunalonganichemarketandunfortunatelygetwrappedupinthedaytodaymachineworkmissingsomeofthebiggerpicture.HereatAutoMachinewenevermadetheconsciousdecisiontoheadintoantiqueenginerebuilding.Itwasmoreofbeinginanareathatcouldsupportthistypeofrebuildingandbecomeprofitable.Itseemslikethedowntrendofbusinessinthelastfewyearshasdrivenmostofustochangeourdailyworkloadfromheadrebuildingflywheelgrindingcrankgrindingetc.thingsthatcarryalaborcodetypepricetomoreofabillablehourtypesituation.OurprofitableworkloadsixtotenyearsagoconsistedmoreofcompactdieselandInwiththeoldoutwiththenewYoudonthavetobeanolderestablishedmachineshoptocashinonantiqueenginerebuilding.Late50s3.4Jaguarwithbandtypetensioner.Early60s3.8Jaguar.Pumpkinpaintisanindicationofmodelandhorsepower. www.engineprofessional.com45 INWITHTHEOLDBYKIMRAMONTsmalltomediumtruckmotors.Economychangedandthatleftahugeholetofill.Wewereusedtobillingjobsonlaborcodesandnotbillablehours.TimetoshiftgearsIwillconfessitisnoteasytobehourdiligent.Youhavetotrackthemcloselytomakesureyouandyourcustomerareget-tingthebestdeal.Letsfaceitsometechsmoveslowerthanothersitsjustafact.Itshardtofeellikeyouaregivingyourcustomerafairshakeespeciallywhenbillingcleaninghoursversusmachininghours.Letsfaceitcleaningpartsistimeconsumingandtheydidnotwanttodoit.RemembercustomercomfortisimportanttotheprojectBecarefulofestimatesonantiqueenginerebuilding.Thebestwaytohandlethisisavoiditifpossible.Whenyougetthecustomercomfortablewithyourshopyoucanprobablygetbeyondthisstep.Wehavefoundifyougooutonalimbandtrytogivethemsomekindofballparkpricescarywordstheywillimprintonthenumber.IsayIthinkwecandothisfor5000.00to6000.00thecustomerwillrememberthe5000.00figureeverytime.Itsimpossibletotellhowmuchtimeyouwillinvestinoneoftheseoldengines.Quickexampleengineswithvalvetrainorwaterjacketcoversgenerallyneednearlyeverybolteitherextractedorsomesortofthreadrepair.1929Chrysler24boltshowmanyhoursHardtofigurecautionhereisbest.Nowthejobisinyourshopanditstimetofigureoutthebillingprocess.Weprefertogetsomesortofdepositcouldbe500.00or1000.00.Justgetsomethingtocoveryourtimetopulltheengineorcomponentapart.Howmanyofushavebeenleftwithanunrebuildableunitbecausewefounddamageorrotbeyondourcontrol.Youcallthecustomerandtell46JAN-MAR2014engineprofessional1931StudebakerPresidentstraight8.EngineisfittedwithRosshighercompressionpistons.CarownersarefromSouthAfricacarcompetedinthe2010PekingtoParisraceandfinished12thinclass. www.engineprofessional.com47himheneedsabettercoreandthereitsits.Hesnotworriedaboutitbecauseitsnogoodandwouldprefertonotpickitupandpayyouforyourtime.GetmoneydownYoudidtheworkyouneedtogetpaid.Iftheunitisrebuildableandassumingitsalengthyrebuildforexample1953235Chevrolettwotothreeweeks1939Delahayebasketcaseonetothreeyearsyouneedtohourtrack.Webillthelongerjobsmonthly.Ifthejobcanbedoneintwotothreemonthsweusuallygetagooddepositandbalanceoncompletion.Youhavetoestablishwhatyouwantperhourforcertainsituationsbacktoclean-ing.Ourlaborrateisbasedon95.00perhourwithaburdenratecostofdoingbusinessof60.00perhour.Youcaneasi-lywrapupadaysworthofhourscleaningthemajorcomponentsoftheenginemuchlesstheincidentalpieces.Ifyoufeelitisnotinthecustomersbestinteresttobill95.00perhourandyouwerecomfort-abledoingitforlessyouneedtobecare-fulnottodropbelowyourburdenrate.Onceagainthecustomervisualconceptofhisbill10hoursat95perhour950.00versus10hoursat75perhour750.00canhaveagoodeffectontheircomfortzone.Youhavealittlespacetoworkonpricingfornon-technicallabor.Mostrestorationshopswouldnotcarebuttheindividualwitha1931PackardStraightEightwouldratherseehismoneygoingtomachiningprocessesthathecantdo.Inotherwordsheiscapableofdoingsomeofthecleaningbutnotreallywillingtodoso.RESEARCHTIMEWehaveavariablehourlaborcodeinouroperatingsystemforresearchtime.Researchtimeisoftenoverlookedandcostlytoprojects.TimespentforfindingspecificationspartsphonecallstoAERAorgettinginputfromothermembersneedstobebilled.Hoursbilledwillincreaseyourprofitsandusuallywillnotupsetthecustomer.Hewouldpreferyoudidthehomeworkandgotthejobdonerightthefirsttime.WhilewearetalkingresearchIneedtomentionsources.AERAisagreatstartforspecsorhelptofindsomeonewhoknowsabouttheengineyouareworkingon.Weusethemalotandviceversa.Specificpartssuppliersofwhatevermodelengineyouareworkingonarealsohelp-fulastheyaresupplyingpiecestoenginebuilderswhomaydomultiplesofaspecif-icapplication.SubcontractingworktocompaniessuchasEffinghamRegrindingHarkinMachineMizpahManufacturingMidwestCylinderHeadandusingtheirinputisalsoagoodsourceforinforma-tion.Useyourresourcesandchargeaccordingly.YOUWANTWHATSometimesjobsonoldenginesarenotascutanddriedastheywouldappear.Strangerequestsseemtocomealongocca-sionally.Onlineforumsalthoughasourceforsomegoodinformationmaycausesomeproblemsforarebuilder.CustomersareprettygoodatgettingintouchwithsomeonewhohasdonethisprojectandfoundashortcutorasecrettomakingtheDontLetYourEnginesFLAT-LINEByUsingAnythingButGenuineMellingOilPumps.MellingwarnsallenginerebuilderstoavoidRiskyOilPumpsfoundinsomeenginekits.TheoilpumpistheHeartoftheengine.DontgambleonaHeartAttack.Withmorethan60yearsofprovenqualityanddurabilityMellingurgesyouandyourcustomerstodemandaNEWHeartGenuineMellingOilPumps2620SaradanDriveJacksonMichigan49204800-635-5464TEL517-787-5304FAXVisitusonlineatwww.melling.comALERT INWITHTHEOLDBYKIMRAMONT48JAN-MAR2014engineprofessionaljobbetter.Everybodyhasanopinionastohowitshouldbe.Ifyouaregettingpushedoutofyourcomfortzoneinarebuildsituationsuchasoddrequestsforupgradessome-bodyputonlineorarequesttodosomethingthatyoufeelwillbedetrimentaltotheoriginaldesignorconceptoftheengineyouhavetobepreparedtomakeadecisiontomoveforwardandbillforthetimeorstandyourgroundbasedonyourmachiningexpertise.Mostcustomersdonotknowanybetter.Youaretheprofessional.Thesemotorshavebeenaroundfordecades.Itshouldnotbeuptotherebuildertoreinventtheunit.Billablehoursshouldnotendupinfailure.WARRANTYVERSUSTIMEWeallworryaboutwarranty.Thereprobablyisnotanyonereadingthismagazinethathasnotbeenstungbyawarrantyissueonalatemodelengine.Mostoftheseoldengineshaveanexcellentchanceofrunningfineandgenerallyneverhaveaproblem.Somepitfallswouldbeleaksnoisyrunshotetc.Weexplaintothecustomerthatalotofthesecarsleakedfromthefactory.Oilsealsarenon-existentinlotsofapplica-tions.Mostcustomersunderstandthatafewdropsofoilisprobablyconsistentwiththeenginemodel.Noisytappetsarealsohardtonaildown.Wetryourbesttogetitquietbutsometimesthesubtlerattledrawsattention.Youwillhavetojudgeifthereisaproblemoritjustsoundslikeanantiqueengine.Warrantyonanantiqueengineishardespeciallyifthecarwasnotrunningupondisassemblyorthecarisbeingtotallygonethru.Alltheusualapplyradiatorrepairoilcoolingorfilteringsystemscarburetorsrebuiltandnotrun-ningrichignitionssystemsatpropertiminggoodbreakinperiod.Unfortunatelyforustheengineprobablywasdonetwoyearsbeforeitwasputinandstarted.Storageofrebuiltengineisimportant.Notagoodideatostoreinabodyshop.Asfaraswarrantytimelineitsuptoyoutofigureoutwhatisacceptableinstoragetime.Forstoredenginesyoutellthecustomertowrenchitoveroccasionally.DotheydoitNooneknows.Wetrytoberelaxedonthewarrantyperiod.Itshardtosay12monthsor12000mileswhenthemotorisinstorageforayearandwheninstalledthecargetsdriven500milesayear.Youhavetohaveconfidenceinyourrebuild.Youneedtobelieveitwillperformcorrectlywheninstalled.Ihopethisnon-technicalinformationhasbeeninforma-tive.Usingbillablehoursandmonthlybillingshouldfillemptyhoursonlaborcodedays.Antiqueenginebuildingisjusttheplacetodothis.IKimRamonthasworkedwithAutoMachineInc.inSt.CharlesILsince1981.Originallyhiredtodocylinderheadworkheeventuallybecamepartnerandnowmanagesfrontendandday-to-dayworkload.Formoreinformationpleasecall630584-1188oremailautomac74aol.com.CONNECTINGRODSWeofferthehighestqualityconnectingrodsforavarietyofapplications.SERVICEPARTSBOLTSOliverservicepartsaremanufacturedtomeetourexactingspecificationsmakingthemidealforreconditioningeffortsandthereplacementofsinglerodsbushingssleevesandbolts.-38716DIAMETERBOLTSUPGRADEOPTIONSAVAILABLESALESOLIVERRACINGPARTS.COM231237-4515WWW.OLIVERRACINGPARTS.COMCRAFTSMANSHIPPRECISIONDURABILITYSTRENGTHAreyouanengineguyWeareContactusbecausewehavetheanswersforengines.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372.JointodayGotopage90foramembershipapplication. www.engineprofessional.com49 50JAN-MAR2014engineprofessionalHaveyoueverfeltlikenothingwasgoingyourwayYouknownomatterhowhardyoutriedorhowmuchyouspentyoujustcouldntgetthestarstolineuplikeyouwanted.WellthatshowalotofHarleyownersfeltafterbuyingtheCVO110modelbikes.Youseetheseweresupposedtobethebestofthebestandthefastestofthefast.SowhatreallyhappenedWellfromastockenginestandpointthe110wasthebiggestofthepowerplantsHarleyoffered.Theyactuallymadeabout20morehorsepowerthantheir96and103counterparts.ThisisallgoodrightSureifyoulikestockbutwholikesstockWedidntandalotofotherHarleyownersdonteither.ThisiswhywehavealwayswantedtodoaperformanceupgradetotheCVO110.YouseemostHarleyownersupgradetheirenginesfrom96and103cubicinchestothepopular107.Youmightrememberthisupgradefromacoupleofyearsago.SowhatsthebigdealyouaskTheyareat107cubicincheswhiletheCVOis110.Tryabout40horsepower.Youseethe107whenupgradedcorrectlywithallthebellsandwhistlesiscapableofmanaging135horsepower.Thiswillleavethe110inthedustwithnowheretoturn.Thatisuntilnow.GetreadytoturntheluckaroundonanyHarley110owneryouknow.WewillstartwithalittlebackgroundinformationforthosenotfamiliarwiththerecenthistoryofHarley-Davidson.Harleyreleasedanewenginein1999theTwinCamafteralongrunwiththeEvolutionenginethatyouseeusedinalotofcustomchopperstoday.Duringtheintroductionperiodofthesenewenginestheyalsostartedofferingaspecialeditionbike.ThesebikesweredubbedCVOswhichstandsforCustomVehicleOperations.TheCVObikesoriginallycamewithcustompaintschemesandspecialaccessoriesthatwerenotavailableontheirstandardmodels.EventuallytheyaddedbiggerpowerplantstotheCVOslineupaswell.WhiletheoriginalTwinCamsweredeliveredwith88cubicinchestheCVOswouldeventuallycomewitha95cubicinchpowerplant.InanefforttokeepupwithcustomrodshopsLUCKY113Harley-Davidson110to113enginebuildBYDEREKCHURCHWELL 2014ElginIndustries.Allrightsreserved.1-800-323-6764www.elginind.comsaleselginind.com1InperformancestockCOVERAGETheressimplynobetterchoicethanELGIN.AftermarketVALVETRAINmanufacturer1AftermarketROCKERARMmanufacturer1OEaftermarketPUSHRODmanufacturer1wwwl--ginind.comsaleseginind.comwww.engineprofessional.com51 HarleymadethelargerdisplacementenginesstandardonmostallHarleyTwinCammodelsaround2007.During2003and2004HarleyofferedacoupleversionsoftheCVOswithalongerstrokedenginetomake103cubicinches.In2007theyintroducedanevenbiggerenginefortheCVOtwincammodelsthe110.Nowthisenginewassupposedtobethecatsmeowtothelowerpoweredearliermodels.Keepinmindthestock88s96sand103stypicallyonlymade6567and69rearwheelhorsepower.WhilemanyHarleyownerswouldconsiderthemselvesfortunatetopickuponeoftheseLimitedEdition110sluckwasnotontheirside.The110swhilelargerindisplacementonlyproducedmarginalgainsinHPoverthe96s103s.Theyquicklyfoundthemselvesbeingoutperformedbytheirsmallercubicinchcounterparts.Tomakemattersworseupgradesforthe110haveprettymuchbeennonexistentevenfromHarleyandmanycustomshops.Thatisuntilnow.WewerefortunateenoughtohaveHighPerformanceLubricantsoutofIllinoisstepuptotheplateandofferustwo2013CVObikes.Ourinstructionsweretodevelopanupgradepackageforthe110withnoholdsbarred.Thisisrightupouralleyasmanyofyoumaybefamiliarwiththeupgradewedidseveralyearsbackbeefingupthe96sto103sor107stobringadditionalcashjobsintoyourshop.WiththisrequestfromHPLwehavefinallygottenthechancetodothesameforthe110.DontyoujustlovethesetypesofcustomersYouknowhereismybikemakeitasfastasyoucanandsendmeabill.Wellwedontseethoseveryoftenbutthankfullywedohavethemsometimeasitallowsforeveryonetogrow.OKenoughabouttheminordetailsletsjumprightinonthe110to113build.Thiskitisactuallyprettysimpletodobutthereareafewcustompartsthatyouwillneedtodosomeresearchon.Thefirstchallengewouldbefindingapiston.Withthelimitedproductionrunsofthesebikesnopistonmanufactureroffersareplacementpiston.Youwillhavetocustomorderaheadoftimeandmostofthebignamedpistonmanufacturerswillbeabletoassistyou.Thestockborefora110is4.00andthestrokeis4.378.Thecylinderwillallowustopunchitoutfora.060overtogetto113cubicinches.Thereisnoneedforcaseboringsothismaintainstheintegrityofthestockcase.Forourparticularbuildwehadaspecialpistonmadewithaslightdomeonittomimicthecombustionchamber.Thestockpistonisaflattopasyoucanseeinthephotoabove.Checkwiththepistonmanufactureryoudealwithastheywillbeabletohookyouupwiththecorrectpistonpinandringpackage.Withthe110sbeingofferedforseveralyearsnowwemightbeabletogetthemtomakeitashelfitem.ThisLucky113willtakethemeaslypowered110of90horsepoweruptoover140horsepower.Thenextorderofbusinesswillbetoworkalittlemagiconthecylinderhead.Forthemostparttheheadisprettyeasy.Westartbyincreasingthevalvesizes.FortheintakewewillorderanintakedirectlyfromourlocalHarleydealer.Theintakeisastockitemontheir120Rengine.The120Rintakevalvewilldroprightin.Thatisafteryoucutinforthebigger2.120valvesize.Nextwewillhavetomakeourownexhaustvalvefromablankastheseatdiameterlimitsusonvalveavailability.Youcouldinstallalargerseatandofcoursewewouldliketogobiggerbutwearetryingtokeepthecostdownwhileproducingmorethanamplehorsepower.Theexhaustvalvewechooseis1.650whichisslightlybiggerthanstockbutitisbigger.Seethevalvesizedifferencesinthephotoabove.Thenextorderofbusinesswillbetheportwork.Againitsbusinessasusualhere.Theonethingyouwanttokeepin52JAN-MAR2014engineprofessionalLUCKY113BYDEREKCHURCHWELLThestockborefora110is4.00andthestrokeis4.378.Thecylinderwillallowustopunchitoutfora.060overtogetto113cubicinches.Forourparticularbuildwehadaspecialpistonmadewithaslightdomeonittomimicthecombustionchamber.Thestockpistonisaflattopasyoucanseeinthephoto.Theexhaustvalvewechooseis1.650whichisslightlybiggerthanstockbutitisbigger.Youcanseethevalvesizedifferencesinthephoto. SPECIALIZINGINREPLACEMENTPARTSFORBENDIXCARRIERCATERPILLARCUMMINSDETROITDIESELHINOISUZUMIDLANDNAVISTARTHERMO-KINGTRANE...yourFriendlyalternativeDieselenginepartsESCOINDUSTRIESINC.TOLLFREE1-800-372-6872FAX951-782-2136SALESESCOUSA.COMWWW.ESCOUSA.COMALLOTHERCOMPANYBRANDPRODUCTANDSERVICENAMESAREUSEDHEREINFORIDENTIFICATIONPURPOSESONLYANDMAYBETHETRADEMARKSSERVICEMARKSORTRADENAMESOFTHEIRRESPECTIVEOWNERS.THEREISNOAFFILIATIONORSPONSORSHIPBETWEENTHESECOMPANIESANDESCOUNLESSEXPRESSLYSTATED.CARRIERBENDIXAREPLASPECIALIZINGINTERPILLARCARRIERBENDIXARTSFORCEMENTREPLASPECIALIZINGINTHERMONMIDLANDISUZUHINODETROITDIESELCUMMINS-KINGRMIDLANDISUZUHINODETROITDIESELCUMMINSTERPILLARTRANE-KINGTHERMOiend...ourTRANE-KINGyalternativeDieselenginepartsyalternative...yourFDieselenginepartsyalternativeTED.XPRETHESECOMPBETWEENSPONSORSHIPTHEREISNOTHEIRRESPECTIVEOWNERS.OFVICEMARKSORTRADEMARKSSERTHEBEREUEDHEREINFRIDENTIFIBRANDPROOTHERCOMPALLANDESCOUNLESSANIESTHESECOMPINRAFFILITHEREISNOTRADENAMESVICEMARKSORANDYTIONPURPOSESONLVICENAMESANDSERBRANDPRODUCTwww.engineprofessional.com53 54JAN-MAR2014engineprofessionalLUCKY113BYDEREKCHURCHWELLmindisthatthereisnomanifoldavailablewithanIDclosetothenewintakevalvesize.Asamatteroffactthereisnotevenoneclosetothestockvalvesizeof2.080.ThebiggestmanifoldwecangetourhandsonatthismomentisaspecialordercustomandithasanIDof1.900.Asweallknowairflowiskeyandyouwillwanttodoeverythingpossibletomakeasmoothtransitionhere.Thisisconsiderablysmallerthanwhatwewouldliketohavebutitwillworkforthebuild.Thenextstepfortheheadsistotakethedeckdown.Thecompressionnumberofthe110hasbeenabigissue.Wewilltotryandget10.5to1bymilling.080offtheheads.Thiswillgetthecombustionchamberdownto92ccs.Wewillthenhookeverythingupwitha700liftspringkitwithtitaniumretainersandaddasetofrollerrockers.Rollerrockersarerecommendedforenginesthatruncamliftsabove.600.Theserockershavearatioof1.625whichisthesameasstock.Therearealsoa1.725ratioavailablethatwillincreasetheliftofwhatevercamyouchoose.OnethingtokeepinmindisthatthereisnomanifoldavailablewithanIDclosetothenewintakevalvesize.Asamatteroffactthereisnotevenoneclosetothestockvalvesizeof2.080.ThebiggestmanifoldwecangetourhandsonatthismomentisaspecialordercustomandithasanIDof1.900.Thisisconsiderablysmallerthanwhatwewouldliketohavebutitwillworkforthebuild.Takealookathowbigthevalveiscomparedtotheportopening.Withthe2007andlatermodelTwinCamhavinganupgradedhydrauliccamchainsetupovertheirearlierspringloadedtensionerwestilloptforthereliabilityofthegeardrivesystem.Theoneontheleftisthestockhydraulictensionerandontherightisthegeardrivesetup.Rollerrockersarerecommendedforenginesthatruncamliftsabove.600.Theserockershavearatioof1.625whichisthesameasstock.Therearealsoa1.725ratioavailablethatwillincreasetheliftofwhatevercamyouchoose.Youcanseethedifferencesbetweenthestockrockerandtherollerrockerinthisphoto. www.engineprofessional.com55 56JAN-MAR2014engineprofessionalInanattempttogainasmuchhorsepoweraspossiblewewillgowitha.678liftcamaccompaniedwithasetofgeardrives.Withthe2007andlatermodelTwinCamhavinganupgradedhydrauliccamchainsetupovertheirearlierspringloadedtensionerwestilloptforthereliabilityofthegeardrivesystem.Seephotosonpreviouspage.Onceagainthisisrecommendedwhengoingabove.600liftwiththecam.WewillnowconnecttheheadsandcylinderswithanMLSheadgasketthatiscurrentlyofferedthroughHarley.ExternallywewilluseaHarleyheavybreatherandthebiggestproductionexhaustsystemwecanfind.Ourexhauststartsoutwitha1-78IDandstepsup.Thebikewillessentiallyremainstockappearingbutletmetellyouthereisahugedifferenceoverstockwhenyoutwistthethrottle.Youwillnoticethisimmediatelyafterplugginginyourtunerofchoice.Whilemappingthisnewmonsteronthedynoitwillnottakemanyrunsontorealizeyouwillhaveyourhandsfull.Thisisabeastofamachineandthefirstbikewedidproduced144horsepowerandthesecondbikealsoproducedover140horsepowertobackupourkit.Takealookatthedynosheetabovetoseethebeforeandafternumbers.Thesearenothingtosneezeat.Whenyoucanofferyourcustomertheopportunitytopickup55horsepoweronaquickoneweekupgradeintheshopyourluckwilldefinitelychangeforthebetter.ILUCKY113BYDEREKCHURCHWELLDerekChurchwellisfromStarRacinginAmericusGeorgia.StarRacingspecializesinpartsforolderdragbikesandlatemodelsportbikes.Theystockalargeandvariedselectionofraceproductsincludingignitionandheadcomponentsvalvessprocketsgasketschainswheelsbrakesnitroussystemscarbspistonsandringsclutchplatesandchassiscomponents.Formoreinformationcall800841-7827orgoonlinewww.StarRacing.com.Whilemappingthisnewmonsteronthedynoitwillnottakemanyrunsontorealizeyouwillhaveyourhandsfull.Thisisabeastofamachineandthefirstbikewedidproduced144horsepowerandthesecondbikealsoproducedover140horsepowertobackupourkit. www.engineprofessional.com57 58JAN-MAR2014engineprofessional www.engineprofessional.com59 60JAN-MAR2014engineprofessionalIwantedtotakesometimetofurtherexplaindamBESTpatentedadvantages.Iamhighlightingtwopatentnumbers6851663B2and6211251.Patent6851663B2isaboutourrevolutionizedventuridesignwheretheventuriisnowabovethedischargeboosterratherthanbelowthedischargeboosterasinallotherdesigns.Figure15showsoldtechnologyboosteraboveventuri.Inthisoldstandarddesigntheaircananddoesgoaroundtheboosterdrawingnoorlessfuel.Changingtheratiobetweenairgoingthroughtheventuriandfuelbeingsuppliedbythebooster.Whenhoodscopepressureisaddedtheproblemevengetsworse.Figures16and17showsimpleexamplesofourVenturiaboveboosterdesign.Inthisdesignalltheairmustgooverthebooster.Keepingairfuelrationlinearallthetimenomaterhowmuchpressureyouputabovetheventuri.Patent6211251isaboutshearingandtumblingthefuelandairandwhenitreachesproperspeedinsidethechannelthenaturalfrequencyoftheairwillfurtherbreakupthedroplets.Thinkaboutasteamofwatergoingoverjustonewaterfallandhowitwillshearthestreamintomanydroplets.Nowput20waterfallsinarowwhitewaterraftingSPEEDREADBYJOHNSATTERFIELDSeeJohnSatterfieldscollectionofvideosavailableatYouTube.comdambest1DoubleyourpleasuredoubleyourfunThesecarbspicturedlefthavepatentedventuriandairfoilbooster21stCenturyFuelDeliveryScienceFigure15isoldtechnologyboosteraboveventuri.Figure16and17showsimpleexamplesofourventuriaboveboosterdesign.Inthisdesignalltheairmustgooverthebooster.Keepingairfuelrationlinearallthetimenomatterhowmuchpressureyouputabovetheventuri. LiftTablewithAGITATIONTouchScreenPLCControlsDualFiltrationSystemOpposingHorizontalTransducersUltraSoniccleanfromTWOdirectionsStainlessSteelConstructionInsulatedTankandLidAutomaticCyclesLOWERLABORCOSTINCREASEPROFITSEMPLOYEEFRIENDLYReducereplacehazardoussolventsOptionsOilSkimerAutoWaterRe-FillUltra3800FLTMainScreenManualOperationScreenULTRA3800FLTCustomUnitsandPLCMulti-StageSystemsAvailableengineprofessionalWWW.AERA.ORGEP61 62JAN-MAR2014engineprofessionalSPEEDREADBYJOHNSATTERFIELDherewecomeThatisaroughideaontheslowspeedaffect.Thehighspeedaffectisalittlemoreaggressive.Whentheforceacrossthechannelishighenoughtocausetheairtoreachitsnaturalfrequencyandvibrateittoowillbreakdownthefueldroplets.Figure2CiswhatIamcurrentlyusingbecauseofitsmanufacture.TheBIGGUNisfigure2Bcascadingrings.Spaceanddepthcanbechangeddependingonfuelandtimeinchannel.IJohnSatterfieldbecameahighlysuccessfulenginebuilderduringhisyearsasadragracer.Hehasmadethescienceofefficientcombustiontechniquesaconsumingpassionwhichhasresultedinhisgainingahighlyregardedreputationinallareasofracing.Formoreinformationgoonlinewww.damBEST.com.InsidealldamBESTMeteringBlocksyouwillfindtheir251Patent. OnecalltotheAERAtechlineandmyproblemwassolved.Tomaintainanedgeintheenginebuildingindustryyouneedresourcesyoucandependon.AERAisaspecializednetworkofprofessionalenginebuildersrebuildersproductionengineremanufacturersandinstallerswiththeexpertiseandconnectionstogetyoutheinformationyouneedwhenyouneedit.WithanAERAmembershipherearejustafewofthebenefitsyoullreceiveIToll-freetechnicalsupportISpecializedenginespecificationsoftwareIEngineProfessionalmagazineIRegionalTechSkillsConferencesIAutomotiveMachiningOnlineTrainingProgramIAvoiceinWashingtonD.C.IAERAcarriesavarietyofhigh-qualityshopsuppliesuniqueitemswhichhavebeenselectedandproducedbasedoninputfrommembersnewandimprovedtemperaturerecorderlabelstagsbagsandmoreISpecialdiscountsfromanumberofpartnercompaniestohelpAERAmembersreducecostsoncreditcardprocessingcomputerhardwareandsuppliesinsuranceshippingutilitieswasteremovalandavarietyofotherservices.IDetailsonallmemberbenefitscanbefoundatwww.aera.orgmember-servicesmember-benefitsEvenifjustoneAERAtechbulletinhelpspreventanenginecomebackyourmembershipiswellworthitsdues.Wereheretohelpyoumakeyourbusinessthebestitcanbe.JointodayCompletethemembershipapplicationonpage90ofthisissueandreturntoAERA.FormoreinformationcallAERAtoll-free888-326-2372orvisitwww.aera.org.AERAEngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600fax888-329-2372815-526-7601www.aera.orgemailinfoaera.orgtwitter.comaeraepfacebook.comaeraepwww.engineprofessional.com63 64JAN-MAR2014engineprofessionalCONFERENCERECAPBYSTEVEFOXAERAfinishedup2013withthreegreatTechSkillsConferenceshostedbycompaniesindifferentregionsofthecountrySeattleKansasCityandDetroitareasmakingsurethatenginebuildersweregivenachancetoattendaconferencenearthem.RottlerMfg.KentWAInSeptemberAERAheadeduptothegreatnorthwestattheRottlerMfg.facility.Rottlercelebrated90yearsofbusinessin2013withatwo-dayconference.DayonewastheRottlerOpenHouseanddaytwowastheAERATechSkillsConference.TheopenhousehadlivemachinedemonstrationstheentiredayalongwiththefollowingpresentationsRottlerCAMSeminarApplyingBasicEngineFailureAnalysisValveSeatandGuidesandLowSulfurDieselFuels.TheopenhouseconcludedintheeveningwithaverynicedinnercruiseontheArgosyforallattendees.Everyonehadagreattimeandthedinnerwasoutstanding.DaytwowastheAERATechSkillsConferenceitwaswellattendedandeveryonewasabletohearsomegreatspeakers.DarrellDayofBatesTechnologiesstartedthedaybytalkingaboutSuperabrasivesHoningandtheireffectsonSurfaceFinishes.Darrellgaveagreatpresentationandthegroupcontributedwithverygoodquestions.LakeSpeedJr.ofDrivenRacingOileducatedeveryoneonFiveThingsEveryEngineBuilderShouldKnowaboutMotorOil.IfyouhavenotheardapresentationbyLakeonengineoilsyouneedtoHedoesagreatjobofexplaininganythingandeverythingyouwanttoknowaboutoilsandwillstayandansweranyquestionsyoumayhave.Lakedidagreatjobandeveryonewalkedawayalittlemoreeducatedonengineoilsafterthepresentation.AfterlunchRodSledgeofKingEngineBearingsspokeaboutBearingLubricationClearancesandTolerances.RonisveryknowledgeableonenginebearingsandImprettysurethateveryonewalkedawayfromhispresentationgainingknowledgeaboutenginebearings.FinishingupthedaywasRandyNealofCWTIndustrieswhoenlightenedeveryonetalkingaboutDynamicBalancingtheKeytoPerformanceandLongevity.Randyhadamachineon-siteandgavelivedemosduringthedaythenfollowedupwithhispresentationonbalancing.PartsWarehouseSupplyKansasCityMOOnOctober9wehadtheopportunitytovisitArrowheadStadiumhomeoftheKansasCityChiefsthankstotheguysatPartsWarehouseSupplyinKansasCityMO.ThefacilitywasgreatanditwasexcitingtohavearegionalconferenceatanotherNFLstadium.ItwasapackeddayofseminarsthatbeganwithRonSledgethetechnicalmanageratKingEngineBearings.Ronhasbeeninvolvedwithperformanceenginebearingsformorethan30yearsincludinghisinvolvementwithmanyNASCARenginebuilders.RonspresentationintriguedtheaudiencetoasksomegreatquestionswhichRonhadtheanswersfor.DuaneBoesofCalliesPerformancewasthenextpresenteroftheday.DuanehasbeenwithCalliesformorethan23yearsandiswellversedinallaspectsof2013endswiththreeinformativeconferencesRegionalconferenceshostedbyRottlerPartsWarehouseSupplySunnenandDartconclude2013scheduleSavetheDateMARCH15LIBERTYENGINEPARTSLouisvilleKYMAY16SUNNENSt.LouisMOJUNE20EPWISaltLakeCityUTOCTOBER3ROUSHYATESANDMAHLECharlotteNCCONFERENCEHOSTINGOPPORTUNITIESIfyouareinterestedinhostingaconferencenextyearpleasecontactJimRickoffat507-457-8975oremailjimrickoffgmail.com. www.engineprofessional.com65performancecrankshaftandconnectingroddesignandusage.Duanegaveagreatpresentationonfailuresofcrankshaftsandthegroupwasabletotakebackinformationtotheirshopsthatwillbeveryuseful.AfterashortbreakBobFoxofDiamondPistonsTrendPerformancetalkedaboutpistondesignandvalvetrain.TheattendeesaskedsomegreatquestionsafterthepresentationandBobwasabletoanswerwithouthesitation.Bobisrecognizedasanindustryinnovatorinpistonandvalvetraindesignandmanufacturing.HeisalsoinstrumentalinthedesignandproductionoftheSpinTronavalvetrainanalysistoolthatisinusetodaybymosttopracingteamsandmostperformancecammanufacturers.FollowinglunchDeanHarveyofCompCamsspokeaboutcamshaftdesignandtheeffectsanenginehasonthecamshaft.Deanspecializesincamshaftandvalvetraindesign.HehasbeenwithCompCamsformorethan32yearsandinadditiontoworkingwithenginebuildersandenginepartsdistributorshealsoworkswithtopProStockandProModteamsincludingNHRAchampionshipteams.WefinishedupthedaywithDaveLoweofChampionRacingOildiscussingthedifferencesinengineoilsandtheusageofoilsindifferentapplications.DaveisthepresidentofChampionBrandswhichproducesmorethan300engineoilsandadditiveproducts.SunnenDartatMacombCommunityCollegeWarrenMIOurlastconferenceof2013wasco-hostedbySunnenProductsandDartatMacombCommunityCollegeinWarrenMIonOctober26.ThedaystartedwithBobDolderofSunnenProductsdiscussingHowtoHoneRacingStreepPerformanceEngines.Bobspresentationwasexcellentineducatingattendeesontheproperfinishandwhathoningmaterialsshouldbeusedtoachievetheproperfinish.Onceagainthegrouphadgoodquestionsafterthepresentationwhichallowedforadditionalinformationtobeprovided.LakeSpeedJr.wasbackagainforadiscussiononTheHistoryOfMotorOil.Lakealwaysdoesagreatjoboneducatingthegrouponthistopic.Afterhispresentationandthetopicsofdiscussionthattookplacefollowinghisseminareveryonewastalkingoilsthroughlunch.AfterlunchattendeesweregiventheopportunitytohearfromDartsveryownRichardMaskin.RichardspresentationEngines101BlocksandHeadsaretheHeartofYourEnginewasnotonlyveryinformativebutalsointroducedDartsnewLSNextBlock.GreatquestionswereaskedandthediscussionwithRichardwasoutstanding.Everyoneinattendanceatallofthe2013TechSkillsConferenceswasabletohearsomegreatspeakerstakesomethingbacktotheirshopsthatcouldeducateemployeesorcustomersvisitthetabletopattendeesandnetworkwithfellowenginebuildersandmachinists.ForthosewhohavenotattendedoneoftheTechSkillsConferencestheyarenotonlyagreatwaytotalktovendorsbutmoreimportantlygiveyoutheopportunitytonetworkthroughouttheday.AERAwouldliketogivespecialthankstoallAERAstaffmembersconferencehoststabletopexhibitorsandattendeeswhomadeallofthe2013AERATechSkillsRegionalConferencesahugesuccess.Youallaretheonesthatmaketheseeventspossible.The2014schedulehasbeenfinalizedseesidebarandwelookforwardtoseeingeveryoneatoneoftheupcomingconferencesLookforthemostrecentconferencescheduleupdatesandinformationontheAERAwebsiteatwww.aera.orgconferences-events.IAERATechnicalSpecialistSteveFoxhasover25yearsexperienceintheenginebuildingindustrywith10ofthoseyearsspentworkinginthemachineshop.SteveisanASE-certifiedMasterMachinistaswellasalongtimememberofthedragracingcircuit.ABOVELakeSpeedofDrivenOilsanswerssomequestionsafterhispresentationatMacombCommunityCollege.LEFTAttendeesatMacombCommunityCollegelistenasRichardMaskinofDartdiscussesenginesandintroducesDartsnewLSNextBlock.ABOVETheregionalconferencehostedbyPartsWarehouseSupplyinKansasCitywasheldatArrowheadStadiumhomeoftheKansasCityChiefs.INSETAttendeeslistentoDeanHarveyofCompCams. 66JAN-MAR2014engineprofessionalTECHSIDEBYDONWEAVERManyofmycustomershavebeenreportingproblemswithCatinjectorseatsonC-15C-16C-18C-323406Estylecylinderheads.Theseatwarpsfromheatandforwhateverreasonespecially5cylinder.Theseatnotbeingconcentricwiththeinjectorboredoesnotallowtheinjectortoseat100ofthewayaround.WhathappenswhentheinjectorseatsealiscompromisedInjectorsealsfailprematurelywhichcancauseShortburstofwhitesmokeatstart-upEngineflutterormissunderheavyload.Sootaccumulatinginfuelsystem.Injectorseatserodeawaymagnifyingtheproblem.VisibleIndicationseeFigure2.Aninjectorthatisbluishincolorabovetheseatingareaisanindicationthatcombustionheatisgettingbytheseat.AsyoucanseeintheFigure1theseatafterbeingmachined.002hasonlycleanedupononeside.Thisimperfectionwouldhavepreventedtheinjectorfromseatingontheuncutsideandcausetheinjectortiptooverheatduetopoorheattransfer.ExcessiveheatcouldcausethetiptostickallowingcombustiontoaccesstheO-ringallowingittooverheatandleak.Endresultisanenginemisfireasaresultofcombustionenteringintothefuel.Inthecut-awayviewoftheCatinjectorseatshowninFigure3youwillnoticetheinjectorONLYcontactsontheupperareaoftheseat.WhenIperformthisrepairImachinethewholeseatingareauntilareacleansupentirely.Machiningtheseatswhiletheheadisinstalledtotheblockaccommodatesforanydistortionthatoccurswhiletorqueingthecylinderheadandcomponents.NOTETheinjectordoesnottouchtheinjectortube.Caterpillaroffersnorepairforthisconditionandrecommendsreplacingthehead.Italsohasbeenreportedthatremanufacturedheadshaveoftenbeenfoundtohavetheinjectorseatsbadlyerodeduponpurchasingthehead.Replacingthiscylinderheadcancostupwardsof8500.00whichisnotincludingthetruckdowntime.RuttsMachineShopcanmachinetheinjectorseatswiththeheadinstalledontheblockforafractionofthecostofreplacingtheheadwithminimaldowntime.NOTEThetoolingisnotforsaleIAERAMemberDonWeaverisfromRuttsMachineInc.anemployee-ownedandoperatedprecisionenginerebuildandmachineshoplocatedinElizabethtownPennsylvania.TheyhavenumerouscustomerslocatedthroughoutPennsylvaniainallborderingstatesandaroundtheworld.Formoreinformationcall717368-8532cellor717367-3011shop.Websitewww.ruttsmachine.com.CaterpillarInjectorSeatRepairFigure1.Badseat.Figure2.600milesafternewinjectorandabadseat.Figure3.Cut-awayviewofinjectorbore www.memorialmachine.comForover40yearsithasbeenourgoaltoprovidethehighestqualityenginecomponentrepairavailable.OurTulsaplantat43000sq.ft.isoneofthelargestmostmodernintheindustry.PlusourOklahomaCityplantwith23000sq.ft.givesustheabilitytolimitcriticaldowntime.IEngineBlocksWehavethelargestandmostmodernengineblockrebuilddepartmentsintheindustry.Wehave8CNCboringmachinesandhavethecapacityofmachining3600CaterpillarandATWaukeshaengineblocks.MemorialMachinealsohasaroboticmetalsprayingsystemtoreclaimdamagedmainboresandworntopdecks.ICylinderHeadsOurcylinderheadrepairservicemakesuseofthelateststate-of-the-artmachinesavailablespecificallydesignedtoproducethefinestqualityofwork.Allheadsarebuiltwiththehighestqualitypartsavailablematchedtoexactspecificationsforbothlandfillandnaturalgasapplications.AllheadsarebuiltwithNewPartsnotrefurbishedorreuseandsalvageguidelines.IConnectingRodsandAccessoriesWehavethemostuptodateconnectingroddepartmentintheindustry.Wehavedevelopedprocessestorebuildnearlyalltypesofhighspeedconnectingrodsincludingmanywithserratedcaps.CompleteReconditioningServiceavailableforwaterpumpsoilpumpsrockerarmassembliesfuelvalvesandmanyotheraccessoriesforhighspeedengines.WespecializeinthefollowingenginesWaukesha704270441179817AT-25AT-27WhiteSuperior6G-8258G-82512G-82516G-825Caterpillar379398399Caterpillar3508351235163520Caterpillar36063608361236166303S.40thW.Ave.TulsaOK74132Toll-free800-437-7986Phone918-446-1828Fax918-446-1504SpecializinginRebuildingNaturalGasandLandfillGasEngineComponentswww.engineprofessional.com67 68JAN-MAR2014engineprofessionalBYLAKESPEEDJR.Letsfaceitthingschange.Notonlyhasthepriceofgasolinedieselandmotoroilschangedinthelastdecadeorsothechemicalmakeupoftheseproductshaveallchanged.ThereductioninSulfurindieselfuelgasolineandmotoroilhashadmeasurableeffectsonfuelinjectorsandothervitalengineparts.AddtothatrestrictionsonadditiveslikeZincDialkylDithioPhosphateanditseemslikethewholeworldoffuelsandlubricantshasturnedupsidedownattimes.Beforeyouletallthischangegiveyouacaseofheartburnrememberthatknowledgeispowersohereisasummaryofthechangesingasolinedieselandmotoroils.Youcanusethisknowledgetosteerclearofpotentialpitfallsaswenavigatethenewchemicallandscape.SULFURREDUCTIONAllcrudeoilscontainsulfur.YoumayhaveheardofthetermSweetorSourcrude.Thisisinreferencetotheamountofsulfurinthecrudeoil.Asaresultproductsofrefiningcrudeoillikedieselfuelgasolineandconventionalmotoroilscontainsulfur.Todaysemissionsregulationslimittheamountofsulfurinalloftheseproducts.Whilethisisabenefitforemissionsitdoeshavesomeconsequences.PrimarilySulfurisanaturallubricantsoreductionsinsulfurreducethenaturallubricityofrefinedproductslikedieselfueletc...ThishasbeenevidencedinDieselenginessincetheadventofUltraLowSulfurDieselfuel.ProblemswithinjectorwearhavebeenattributedtothelackoflubricityinUltraLowSulfurDieselfuel.Thesulfurreductionhasalsoimpactedbothgasolineandmotoroil.Thelowerlevelofsulfurinmodernmotoroilsdoesreducethenaturallubricityoftheoil.Sincethemid1990smoreandmoremotoroilsarebeingblendedfromlowersulfurGroupIIandGroupIIIbaseoilsasopposedtothetraditionalhighersulfurGroupIbaseoils.CouplethatwiththereductioninZincDialkylDithioPhosphateanditiseasytoseewhyprematurecamshaftandlifterwearhasskyrocketedsincethemid1990s.TheeffectofreducingSulfuringasolineisnotrelatedtolubricitybutitisrelatedtowear.Corrosivewear.YouseesulfurisnotjustalubricantSulfurhasanaffinityformetalsurfaceswhichcanpreventotherchemicalsfromreactingwiththosemetalsurfaces.CouplethereductioninsulfuralongwiththeadventofEthanolingasolineandcarburetorssuddenlywereatrisk.Againthetimingissimilar.Inthemid1990sEthanolbeginstobeaddedtogasoIinejustasthesulfurlevelsarereduced.Bythemid2000sthecriticalpointhadbeenreached-toomuchethanolinthefuelcomparedtothelevelofsulfurandgasolinedetergentadditives.Theresultcorrosionincarburetors.TheEthanoliscorrosivetowardstheAluminumSteelandZincalloysusedincarbsfuelpumpsandfueltanksandnowthefuelhaslesssulfurtoprotectthosecomponentsfromtheEthanol.Theresulthasbeenwidespreadproblemswithcorrosionincarburetors.CouplethatwithlowerlevelsofgasoIinedetergentsinpumpfuelanditiseasytoseewhycarburetedenginesfromBigBlockChevysto2Strokeleafblowershavebeenstrugglinginthepastdecade.Thereductioninsulfurisnottheonlyissueaffectingfuelandlubricants.Thedrivetoreduceemissionsresultedinotherchemicalchangesbesidesreducingsulfur.OnechangewealreadymentionedistheadditionofEthanoltogasoline.TheadditionofEthanolisdirectlyrelatedtoemissionsandtheadventofEthanolblendedgasolinehasbeeneffectiveinregardstoemissionsreduction.HowevertheadditiontoEthanolingasolinehashadothersideeffectsprimarilycorrosion.EthanolishygroscopicwhichisafancywayofsayingthatEthanolabsorbswater.ThechemicalcocktailofEthanolandwaterisverycorrosivetoaluminumsteelandzinc.Thepresenceofwaterinthefuelalsospeedsuptheoxidationofthefuel-againafancywayofsayingthebreakdownofthefuel.Whenthefueloxidizesitcanleadgummydepositsthateffecttheperformanceofbothfuelinjectionsystemsandcarburetors.Becausemoisturecontaminationisrelatedtostoragetimeandconditionsdailydriversrarelyseeanyoftheseissues.Howevervehiclesthatseelongtermstorageandinfrequentusetendtofallvictimtotheseissues.Marineapplicationsaretheworstcasescenariobecausetheyfeaturebothhighmoistureenvironmentsandlongperiodsofstorage.Anotherareaofchemicalchangeismotoroil.Inordertoprovidebettercatalyticconverterefficiencytheamountandtypeofadditivesusedinmotoroilshavechanged.ThemostrecentAPISNandILSACGF-5oilstandardscallfortheuseofanewtypeofZincDialkylDithioPhosphatethatprovidesbettercatalyticconverterprotection.AtthisyoumaybeaskingarentalltheZincZincDialkylDithio-PhosphateadditivesthesameThesimpleanswerisno.SeveraldifferentcompoundswithintheZincDialkylDithioPhosphatefamilyexistandsomearebetteratprotectingcatalyticconverterperformancethanothers.ThesenewadditivesarecalledPhosphorusRetentionZDDPsandtheyhavereplacedtheolderstyleZDDPinAPISNandILSACGF-5motoroilformulas.WhilethisisgoodnewsformodernenginesandstockValvetrainsenginetestinghasshownthesenewZDDPsarenotasgoodfortheolderstyleflattappetvalvetrains.Againknowledgeispower.Nowthatyouareawareoftheseissuesyoucaneasilytakestepstoavoidtheseproblems.DieselengineownershaveavarietyoffueladditivestochoosefromthatrestorelostlubricitytoUltraLowSulfurdiesel.Ownersofstreetrodsandlawnmowersalikecanseekoutnon-ethanolgasolineorchoosetotreatethanolblendedgasolinewithacorrosionanddepositinhibitoradditive.ThesefueladditiveproductsimpartlubricitycorrosionprotectionanddepositcontroltoreadilyavailablefuelsandmotoroilswithboostedlevelsofZincDialkylDithioPhosphateprovidetheincreasedanti-wearprotectionolderenginesandhighperformanceenginesneed.IHydrocarbonHeartburnLakeSpeedJr.fromDrivenRacingOilisthesonofLakeSpeedSr.whoracedinNASCARfrom1980to1998.Formoreinformationcallat704239-4401ore-maillspeeddrivenracingoil.com.Findmoretechnicaldataatwww.drivenracingoil.com. IsYourCarburetedHotRodReallySafeRunningEthanolBlendedPumpGasONLYIFYOUREUSINGCARBDEFENDERTheProblemEthanolCorrosionInCarburetedHotRodsTheSolutionDrivenCarbDefenderFuelAdditiveSimplypour-inabottleofCarbDefenderwitheachfill-upespeciallybeforeextendedstorageperiods.CarbDefenderisproudlymadeintheUSAandsoldinconvenient6-packcartons70041.Donttakeourwordaboutthisgrowingproblem.ScanthisQRcodetoreadarecentFoxNews.comarticle.1.866.611.1820DRIVENRACINGOIL.COMEthanolCorrosionCanQuicklyDestroyYourCarburetorEthanolKillsCarbswww.engineprofessional.com69 70JAN-MAR2014engineprofessionalAbouttheProgramEachprogramisanonlineself-pacedcoursewithuptooneyeartocomplete.GaryLewisbookAutomotiveMachiningEngineRepairwillbeincludedwiththe150registrationfee.Everythingatechnicianwillneediscontainedintheprogramwithvideoclipsandsupplementalreadingsatkeylocationswithintheprogram.Thebookwillbeusedasasyllabuswhennotonline.Eachchapterwillbefollowedbyamultiplechoicetest.TherewillbeafinalexamforeachcertificationCylinderHeadandorEngineMachinist.AERAoffersacomprehensiveonlinetrainingprogramnotjustatestleadingtodiploma-qualitycertificatesinCylinderHeadsandEngineMachinist.Technicianswhosuccessfullyearneithercertificatewillholdproofthattheyhaveaprofessionalunderstandingofautomotivemachiningfundamentalsmeasuringtoolsshopsafetyfastenersenginetheoryenginediagnosisenginedisassemblycomponentcleaninginspectioncrackdetectionandrepaircomponentreconditioningandcylinderheadandblockresurfacing.Theinformationinthisprogramispresentedfromtheviewofenginemachineshopoperations.Basicproceduresareselectedfromthosewithwideindustryacceptanceandrepresentwell-balancedandcompetentstateoftheartpractice.GaryLewisInstructorandAuthorFormoreinformationcallAERAat815-526-7600ext.202oremailkarenaera.org.CylinderHeadandMachinistCertificateProgram www.engineprofessional.com71AERAONLINETRAININGREGISTRATIONFORMNAMECOMPANYNAMEAERAIDNUMBERCOMPANYADDRESSCITYSTATEZIPPHONEE-MAILADDRESSREQUIREDSIGNEDBYFEES150perpersonINCLUDESGaryLewisbookI2-4PEOPLEfromthesameshop.................................................................125perpersonI5-9PEOPLEfromthesameshop.................................................................100perpersonI10PEOPLEfromthesameshop..................................................................75perpersonEachpersonregisteredwillreceiveaGaryLewisbook.PleaselistadditionalnamesbelowTOTALAMOUNTENCLOSEDICHECKPLEASEMAKEPAYABLETOAERA.CREDITCARDIVISAIMASTERCARDIDISCOVERIAMERICANEXPRESSCARDNUMBEREXPIRATIONMMYY3-DIGITCSSCARDHOLDERNAMECARDHOLDERSIGNATUREIfpayingbycreditcardpleasefaxcompletedregistrationformtoAERAtoll-freefax888-329-2372OrmailyourcompletedformwithpaymenttoAERA500CoventryLaneSuite180CrystalLakeIL60014.CallAERAtoll-freeifyouhaveanyquestions888-326-2372ordirectat815-526-7600. FluorescentMagneticCrackInspectionKitsThisNEWCrackInspectionKitfeaturesGreenFluorescentMagneticPowderthatglowsbrightlyunderblacklightbutalsoworksundernormallightingconditionsThekitincludes115VHeavyDutyElectronicCrackDetector1PoundFluorescentMagneticPowderPowderAtomizerAssemblyACBlacklightFluorescenceEnhancingGlassesOrderNo.FCD-KITJobber699.991-800-533-8010www.goodson.comtwitter.comGoodsonToolsfacebook.comGoodsonToolsAndSuppliesEasytoreadreferencespeedsuptestingFactoryinstalledDepressionControl-AudieFlowsoftwareincludedBi-directionalowsintakeandexhaustJamisonSaenzDigital-1000SupterStalkerThedigitalprecisionofaJamisonSaenzowbenchaddedtoyourshopspellsQualityControlandPrideforyourbusiness.Flows1673cfm10h2OFlows1171cfm20.4h20Flows1000cfm28h2OAudieTechnologiesDataAquistionAutomotiveMachineShopEquipment-NewUsedRebuilt-JamisonEquipment.com-800-841-5405H70ASeriesIntroducingTHECUTTINGEDGEhosinifhguosrdaeeHnoeHgat2SenhoitcetorhPsarrCweocLitamotuAeferplotronCecorFdaoLcitaomtuAogrpysaelotronCenercShcouTCNCdedenttaunelho-ot-elhodetaomtuAEDGECUTTHEelcyccitamotueannouiaetalphsinirfsvgnitsancehewgamaydltsotcnveersppleyetromgednahisinfecafurstceiontaeropdetaomtuaorfginmmarogsginvasorbal07ot05iontaeropottlermfomr.cebookfacgottlermfomr.coutubey.comgottlermfr1-800-452-053412538727050A98032USAWteneetKtrouth200thS8029SEDGETINGCUTTHEyrasvgermf1-800-452-0534A98032USA72JAN-MAR2014engineprofessional ORDERLINE1-866-210-9251ALSOAVAILABLECUMMINS8.36CTCALL1-866-210-9251TOPLACEYOURORDERGasketKitUpper..............128setGasketKitLower..............108setCylinderBlock...................1795eaOilPump.............................138eaOilCooler............................138eaConnectingRod.....................86eaCrankshaft..........................780eaWaterPump..........................98eaCamshaft............................188eaCummins8.36CTCylinderHeadComplete995eaCummins8.36CTCylinderHeadBare680ea2.5LFORDSP25-236PistonwPinFord2.5LDOHCL42009-12FusionEscapeAvailableinStd020030040SizesUsewithHastingsRings2C5162SafetyAutoPartsCorp.18245ValleyBlvd.CityofIndustryCA91744www.safetyautoparts.compistonswww.engineprofessional.com73 Oldfavoritesandnewcoverageallareincludedinthe2014MAHLEClevitePerformanceEngineBearingCatalog.Over160pagesofcoverageandspecificationsincludingcoveragefor15differentenginemanufacturesfromAcuratoVolkswagenmakethisourbiggestbookever.DieselcoverageincludesCumminsBseries466IHC466JohnDeereandGMDURAMAX.AlsoincludedarethespecialracebearingsforNASCARapplicationsandNHRAProstockengines.TogetyourcopycontactyourCleviteEngineBearingdistributorandaskthemtoincludecatalogEB40-14onyournextorder.Seehundredsofqualityusedandrebuiltenginerebuildingmachinesandtoolsonourwebsitewww.farrisequipment.comCall800-882-1808fortheFARRISTDEALaroundE-mailsamfarrisequipment.comALLOTHERCOMPANYBRANDPRODUCTANDSERVICENAMESAREUSEDHEREINFORIDENTIFICATIONPURPOSESONLYANDMAYBETHETRADEMARKSSERVICEMARKSORTRADENAMESOFTHEIRRESPECTIVEOWNERS.THEREISNOAFFILIATIONORSPONSORSHIPBETWEENTHESECOMPANIESANDESCOUNLESSEXPRESSLYSTATED.ESCOINDUSTRIESINC.TOLLFREE1-800-372-6872FAX951-782-2136SALESESCOUSA.COMWWW.ESCOUSA.COMTRACTO-PARTSCENTERINC.TOLLFREE1-877-371-5235FAX951-328-5239SALESTRACPRO.COMWWW.TRACPRO.COMALLOTHERCOMPANYBRANDPRODUCTANDSERVICENAMESAREUSEDHEREINFORIDENTIFICATIONPURPOSESONLYANDMAYBETHETRADEMARKSSERVICEMARKSORTRADENAMESOFTHEIRRESPECTIVEOWNERS.THEREISNOAFFILIATIONORSPONSORSHIPBETWEENTHESECOMPANIESANDTRACPROUNLESSEXPRESSLYSTATED.74JAN-MAR2014engineprofessional REGISCATALOGCalltodaytorequestyourFREERegisCatalogfilledwithhundredsoftoolsandsuppliesforenginebuildersandrebuilders.Formoreinformationcall800-527-7604orvisitthewebsitewww.regismanufacturing.com.LargestDistributorInUSSpecializingInAgandIndustrialEnginePartsQualityControlledExpansionPlugsSince1921800-433-6414U.S.TOOLANDMFG.CO.630953-1000FAX630953-0174EMAILINFOUSTOOLANDMFG.COMBRASSSTAINLESSSTEELwww.engineprofessional.com75OVER9000LINEITEMSWeprideourselvesathavingthemostcompleteinventoryofcylinderheadcomponentsfromvalvestospringsguidestoseatspistonstopushrodscrankshaftstofullcylinderheadsifitbelongsinanenginewehaveit.Sinceweonlysellwholesalewehavedistributorsandsuppliersacrossthenationthatcansupplytheend-userwiththepartstheyneed.AskyourlocalmachineshoporpartsupplieraboutourPremiumPEPProductsHighPerformanceOEMHeavyDutyDomesticImportMarine MELLING.COM517.787.8172WatchourTECHTIPWebVideosPAR.M.Dura-Bond2014CatalogDura-BondBearingCompanyintroducesitsnew2014enginepartscatalog.Thiscataloghasmanynewappli-cationscompletewithphotoscompetitorsinter-changeconversionreferencechartsandapowdermetalvalveseattechnicalinformationandinstallationinstructionmanual.Formoreinformationpleasecall775883-8998orvisitwww.dura-bondbearing.com.76JAN-MAR2014engineprofessional HighPerformanceLiftersHyliftJohnsonmanufacturesallthehighperformanceliftersthatyouneedinclud-ing817R900R2011R951R969R976R23062314and2317.A.015precisionholeisburnedwithanE.D.M.intothecenterofthebottomofthelifterallowingaconstantoilsupplytothecamlobes.Thisallowstheuseofhighervalvespringpressuresmoreaggressiveprofilesandincreasedlobelife.Harley-Davidsonrollerapplicationsarealsoavailableincludingthehighper-formanceallsteelEVO.A-2303www.toplineauto.com800-441-1400UniqueboregageforfastpreciseholemeasurementNeedsnoelectricityorcompressedairSunnensPGBoreGagestakeanintuitiveapproachtoholegagingwithamechanicaldesignandspeedometer-typescaleforquickvisualconfirmationofIDinsidediameterbyabusymachineoperator.Thegagecombineslab-preciseaccuracy0.0000250.0006mmwithashop-hardeneddesignthatscompactportableandmountableonmachiningstations.PGgagescanbeusedtoexaminetheentireborefordiametertaperbarrelbellmouthout-of-roundandlobing.VariousmodelsareavailableforgagingIDsfrom0.090to4.310.MetricmodelscoverIDsfrom2.0-109.47mm.Formoreinformationvisitsunnen.comorcontactyourSunnenrepresentativeat1-800-325-3670.Q-powerCrankshaftswww.Q-power.com1-888-333-3210Callforadistributornearyou.QualityalwayscomesthroughAllisChalmersCaseIHCaterpillarCumminsDavidBrownDetroitDieselFordJohnDeereKomatsuNavistarPerkinsISO9000CERTIFIEDwww.engineprofessional.com77VibratechTVDHeavyDutyHarmonicDampersVibratechTVDoffersviscousdampersrangingfrom5to36fordieselandgasenginesusedinthetruckingindustryoffhighwayconstructionvehiclesagriculturesta-tionarypowerapplica-tionsoffshoredrillingminingmasstransitandmilitaryapplications.Heavydutyharmonicdampersshouldbereplacedevery500Kto750Kmilesorateverymajoroverhaulorin-framerebuild.Awornoutdamperleadstouncontrolledharmonicvibrationswhichadverselyaffectsengineperformanceandlongevity.Reducingtorsionalharmonicvibrationsequalsincreasedenginepowerincreasedenginetorqueincreasedfueleconomyandincreasedenginelongevity.Protectyourbot-tomlinebyinstallingaVibratechTVDdamper.www.vibratechtvd.comph.716.592.1000MadeintheUSA 78JAN-MAR2014engineprofessionalTB2631CrankshaftInstallationon2001-2004GM6.6LDuramaxDieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationonthecrankshaftinstallationfor2001-2004GM6.6LDuramaxdieselengines.Theunusualconcerninthisprocedureiscorrectplacementofthreethrustwashersatthenumberfivebearinglocation.Figure1.MainBearingIdentificationTopBlockLowerCapFollowtheprocedureslistedbelowtoinstallthecrankshaftbearingsandcrankshaftfortheDuramaxdieselengine.1.Installtheuppercrankshaftbearingsintothecylinderblock.Thebearinghalvestobeinsertedintothecrankshaftmainbearingsaddlehaveawidegrooveandoilholeinthecenterofthebearing1asshowninFigure1.2.Installthelowercrankshaftbearingsintothecrankshaftbearingcaps.ThebearinghalvestobeinsertedintothecrankshaftmainbearingcapsdoNOThaveanoilholeorgrooveinthebearing2asshowninFigure1.Figure2.ThrustBearingWasherLocations3.Installtheupperthrustbearingstothecylinderblock.Therearetwothrustbearingwashers1and3inthecylinderblockandonelowerthrustbearingwasherintheNo.5crankshaftbearingcaplocation2asshowninFigure2.Lubricatethecrankshaftbearingsurfaceswithcleanengineoil.Installcarefullylaythecrankshaftintothecylinderblock.InstalltheNumber5crankshaftbearingcapwiththelowerthrustbearing2.Figure3.NewMainBoltTorqueSequence4.Installtheremainingfourcrankshaftbearingcapsnumbers1-4.5.NOTICETheseenginesNEWboltshaveapre-appliedmolybdenumdisulfidecoatingforthreadlubrication.Donotremovethecoatingoruseanyadditionallubricant.Improperlylubricatedthreadswilladverselyaffectthebolttorqueandclampload.Improperbolttorqueandclamploadcanleadtoenginedamage.6.InstalltheNEWcrankshaftbearingcapbolts.7.TightenthecrankshaftbearingcapboltsinthepropersequenceasshowninFigure4.1ststepinsequencetightento98Nm72ft.lbs..2ndstepinsequencetightento132Nm97ft.lbs..3rdstepinsequencetightenanadditional30usingJ36660-A.Figure4.SideBoltTorqueSequence8.CleanthecrankshaftbearingsidecapboltsandapplyGMPN97720043CanadianPN88901148totheboltflange.9.Installthetenbolts.Tightenthecrankshaftbearingcapsideboltsto78Nm58ft.lbs..tech www.engineprofessional.com79TB2632BalanceShaftInstallationFor1998-2003Isuzu2.2LY22SEEnginesTheAERATechnicalCommitteeoffersthefollowinginformationdetailingthebalanceshaftinstallationfor1998-2003Isuzu2.2LY22SEengines.Consideringandimplementingthisinformationduringassemblywillallowforoptimumsystemoperationafterenginestartup.ADJUSTMENTPROCEDUREFigure1.CrankshaftAlignment1.Turncrankshaftinenginerotationaldirectiontoalignmentmark21stcylinderTDCasshowninFigure1.2.InthiscrankshaftpositiontheflattenedsidearrowsinFigure2ofbothbalancershaftsmustfacedownwardandmustbeonahorizontalline.Figure2.BalanceShaftTimedPosition3.ScrewmeasuringdeviceJ-430383inFigure3withlongknurledbolt1into1stbalancershaftintakesideandtighterhard-tightmeasuringarm5mustpointin9oclockdirectionshowninthisillustration.Installdialgaugeholderwithdialgauge4oncylinderblock.Figure3.SpecialToolsInstalled4.Placepre-tensionedprobe6inFigure4ofgaugeonmeasuringarmofmeasuringdeviceJ-43038.Theprobemustbesetpreciselybetweenthenotchmarkssquaretotheplanesurface7.Figure4.DialIndicatorProbeLocation5.Determinetheleftandrightstopsbyturningtheknurledbolt2inFigure3.Setthedialofthegaugetozero.Usetheknurledbolt2inFigure3tomovethesecondbalancershaftexhaustsidebackandforth.Again-simultaneouslyreadoffthetoothbacklashfromthegauge.Thepermissibletoothbacklashis.0008to.0024.020-.060mm.6.Thetoothbacklashmustbemeasuredinfourdifferentpositions-turnthecrankshaftfurtheratthefasteningboltofthetimingbeltdrivegearby45intheenginerotationaldirectionuntilthemeasuringarm2inFigure3isat6oclock.7.Thenloosentheknurledbolt3inFigure5fixthemeasuringarmat9oclockagainandrepeatthemeasurement. Figure5.KnurledKnobandMeasuringArm8.Ifthevaluedeterminedinoneofthefourmeasurementlocationsliesoutsidethetolerance.0008to.0024.020-.060mmthetoothbacklashmustbereadjusted.9.Removebalanceunitfromcylinderblockcrankshaftbearingcapsandremovewithbalancerpiece.Thebalancerpiecehasanumbercodeforeasyassignment.Thetoothbacklashcanbeadjustedbyusingabalancerpiecewithadifferentthickness.NOTEThenextlargerorsmallerbalanceraltersthetoothbacklashby.0008.020mm.ExampleofselectionofbalancerpieceTheinstalledbalancerpiecewiththecode70gaveatoothbacklashof.0031.080mm.Ifabalancerpiecewiththecode67isnowinstalledthetoothbacklashwillbeapproximately.0024.060mm.CAUTIONOnlyonebalancerpiecemaybeinstalled.REASSEMBLY1.Turncrankshaftinenginerotationaldirectiontoalignmentmark2inFigure11stcylinderTDC.2.TurnbalancershaftsuntiltheflattenedsidesarrowsinFigure2ofbothbalancershaftsfacedownwardandareonahorizontalline.Figure6.BalancerAdjustmentPiece23.Installselectedbalancerpiece2inFigure6withbalancershaftunittocylinderblockcrankshaftbearingcap-tightenallfixingboltstothespecifiedtorque.Torque15FTLBS20Nm.4.Afterinstallingthebalancershaftunitrecheckthetoothbacklashandreadjustifnecessary.NOTEIfthebalancershaftunithastobereplacedusethethickestbalancerpiecewiththecode85fortheinitialassemblythisguaranteestoothbacklashinallconditions.Thereareelevenbalancershimsavailableasshowninthechartbelow.5.InstalloilstrainertooilpumpwithnewsealringandinsertfixingboltswithlockingagentsuchasLoctite242or271tothespecifiedtorque.Torque6FTLBS8Nm6.Installoilpansupport.Torque14FTLBS20NmAdjustsurfacesofthecylinderblockandtheoilpansupport.7.Installoilpanandtorquemountingboltsto1ststep5.8FTLBS8Nm.2ndstepRotateboltsanadditional30.AvailableBalanceShaftAssemblyShimsCodeMarkingThicknessofShim55.021-.022.535-.565mm58.022-.023.565-.595mm61.023-.024.595-.625mm64.025-.026.625-.655mm67.026-.027.655-.685mm70.027-.028.685-.715mm73.028-.029.715-.745mm76.029-.030.745-.775mm79.030-.032.775-.805mm82.032-.033.805-.835mm85.033-.034.835-.865mm80JAN-MAR2014engineprofessionaltechAERATechnicalBulletinsalsoavailableonlineAERAmailsEngineProfessionalmagazinequarterly.ThetechnicalbulletinsinEnglishandSpanishcanbefoundonourwebsiteatwww.engineprofessional.com.Ifyouhaveanyquestionsorifyouneedtechnicalsupportsendane-mailtoinfoaera.orgorcalltoll-free888326-2372.www.engineprofessional.com TB2633ConnectingRodandTorqueCautionOn1999-2012CaterpillarC15EnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingaconnectingrodandtorquecautionon1999-2012CaterpillarC15engines.AsdescribedintheearlierpublicationTB-2608therearecurrentlythreedesignsofconnectingrodsusedforC15dieselengines.Alongwiththattherearetwodifferentbolttorquevaluesuseddependingonwhichconfigurationtheconnectingrodincorporates.IfthecorrecttorquevalueisNOTusedenginedamagemayresult.Fortheconnectingrodsusedinthisenginetheconnectingrodcapswilleitherhaveatwoboltoptionorafourboltoption.Itisimportanttousethecorrecttorquevaluesforthecorrectboltconfigurationusedforthisengine.RefertothefollowingtableandillustrationwhentorqueingconnectingrodsfortheC15engines.ConnectingRodCapTorqueValueandProcedureTwoBoltTypeConnectingRodCapTORQUEVALUEPROCEDURE59-61FTLBS90FourBoltTypeConnectingRodCapSeeFigure1belowfortorquesequenceTORQUEVALUEPROCEDURE1.Lubricateboltthreadsandseatingfaceofcapswithcleanengineoil2.Torquethebolt1andthebolt3to47-53FTLBS3.Torquethebolt2andthebolt447-53FTLBS4.Rotatethebolt2andthebolt4foranadditional55-655.Torqueagainbolt1andthebolt3to47-53FTLBS6.Rotatethebolt1andthebolt3foranadditional55-65.Figure1.FourBoltConnectingRodCapTorqueSequencewww.engineprofessional.com81SAVINGCYLINDERSFORNEARLY70YEARSLetusstraightenyourlogisticsout.IfyouneedalogisticspartnerwhocansteeryourshippingbusinessintherightdirectionyouneedFreightquote.com.Weofferavastarrayofproductsandservicesspecificallydesignedtogiveyouanoptimalshippingexperience.Dontgetlostinamazeoflogistics.VisitFreightquote.comorcallusat800.323.5441today. 82JAN-MAR2014engineprofessionaltechTB2634CrankshaftBearingSelectionfor2011-2014Chrysler3.6LPentastarEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingthecrankshaftbearingselectionprocessfor2011-2014Chrysler3.6LPentastarenginesusedinJeepGrandCherokees.Thisinformationshouldbeconsideredanytimecrankshaftbearingarebeingreplaced.Theupperandlowermainbearingsareselectfittoachieveproperbearingoilclearances.FivedifferentpossiblecrankshaftmainbearingjournaldiametergrademarkingsLocation1inFigure1.arestampedintothefrontcrankshaftcounterweight.Thesemarksarereadfromlefttorightcorrespondingwithjournalnumber1234.Figure1.CrankshaftGradeMarkingsCrankshaftmainbearingjournaldiametergrademarkingscorrespondtospecificjournaldiameters.Thechartbelowidentifiesthefivecrankshaftgrademarkingsandtheirassociatedjournaldiameters.CrankshaftMarkingAssociatedJournalDiameter12.8341-2.834371.9870-71.9905MM22.8343-2.834471.9906-71.9941MM32.8344-2.834571.9942-71.9977MM42.8346-2.834771.9978-72.0013MM52.8347-2.834872.0014-72.0050MMEngineblockmainbearingjournaldiametergrademarkings2arestampedintotheleftsideoftheengineblock.Thesemarksarereadfromlefttorightcorrespondingwithjournalnumber1234asillustratedinFigure2.Figure2.Engineblockmainbearingboregrademarkingscorrespondtospecificjournaldiameters.Thechartbelowidentifiesthefiveengineblockmainboregrademarkingsandtheirassociatedjournaldiameters.CylinderBlockMarkingsMainHousingBoreSize13.0317-3.031877.0055-77.0090MM23.0316-3.031777.0019-77.0054MM33.0314-3.031676.9983-77.0018MM43.0313-3.031476.9947-76.9982MM53.0311-3.031376.9910-76.9946MMForupperandlowermainbearingselectionobtainthegradeidentificationmarksfromthecrankshaftandengineblock.Mainbearingsareavailableinfivesizes.Upperandlowersizescanbemixedonajournalinordertoachievethedesiredoilclearance.0009-.0020.023-.050MM.Thechartbelowidentifiesthefivesizesavailableandhowtheyshouldbeselectedbasedoncrankshaftandengineblockgrademarkings.EngineBlockCrankshaftMarkingMarking123451111222233321222233334322233334444233334444553334444555UPPERLOWERmainbearingstoachieve0.024-0.050mm0.0009-0.0020in.oilclearanceAsshowninFigure3theuppermainbearingshells2andlowermainbearingshells1aremarkedwiththebearingsize3onthebearingliningsurface.Theupperandlowerbearingsareavailableinfivedifferentsizesandcanbemixedonajournalinordertoachievetheproperoilclearance. www.engineprofessional.com83Figure3.MainBearingIdentificationUpperandlowermainbearingshellsareavailableinfivesizes.Thechartbelowidentifiesthefivebearingsizestoaidintheproperbearingselection.BearingMarkingBearingShellThickness1.0982-.09842.4951-2.4987MM2.0981-.09822.4915-2.4951MM3.0979-.09812.4843-2.4879MM4.0978-.09792.4843-2.4879MM5.0977-.09782.4807-2.4843MMNOTECrankshaftthrustwashersarenotselectableandareonlyavailableinasinglethickness.BearingoilclearancecanalsobedeterminedbyusingPlastigageorequivalent.AreyouanengineguyWeareContactusbecausewehavetheanswersforengines.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372.JointodayGotopage90foramembershipapplication.FindenginespecsfastandeasyPRO-SISSAENGINESPECIFICATIONSOFTWAREGIVESYOUACCESSTONEARLY7000ENGINESPECIFICATIONSWITHJUSTACLICKOFYOURMOUSEPLUSYOUCANADDYOUROWNCUSTOMENGINEINFORMATIONTOTHEPRO-SISSADATABASE.SOBYTHETIMEITTAKESYOUTOFINDTHEMANUALWITHPRO-SISSAYOUVEALREADYFOUNDYOURSPECSANDAREBACKTOWORK...THATSAMONEY-MAKINGDIFFERENCEWWW.AERA.ORGPRO-SISTOLL-FREE888-326-2372815-526-7600500COVENTRYLANESTE180CRYSTALLAKEIL60014twitter.comaeraepfacebook.comaeraep 84JAN-MAR2014engineprofessionaltechTB2635SuzukiMetricThreadedFastenerInformationTheAERATechnicalCommitteeoffersthefollowinginformationconcerningmetricthreadedfastenersforSuzukiengines.Thisinformationshouldbeconsideredanytimethereisboltreplacementorcleaningofthreadsisoccurring.MostofthefastenersusedforSuzukienginesareJIS-definedandISO-definedmetricfasteners.Whenreplacinganyfastenersitismostimportantthatreplacementfastenersareofthecorrectdiameterthreadpitchandstrength.ThesmallertheboltdiameteristheharderitissovisualizedifferencesbetweentheJISandISOthreads.NOTECombiningmaleandfemalefastenerswithdifferentthreadpitcheswilldamagebothfastenersifawrenchisusedtotightenthem.Itisimportanttonotethatevenwhenthenominaldiameter1ofthethreadsisthesameJIS-definedandISOdefinedfastenersmaybedifferentinthreadpitch2orwidthacrossflats3.RefertoFigure1forgraphicview.Figure1.FastenerDetailFastenersComparisonTablebelowforthesedifferences.Beforeinstallingafastenercheckitforcorrectthreadpitchandthenscrewitinoronthematingfastenerbyhand.Ifthefasteneristootighttoturnbyhanditsthreadpitchmaybedifferentfromthatofthematingfastener.Table1.JIS-TO-ISOMainFastenersComparisonTableFastenerStrengthIdentificationMostcommonlyusedstrengthclassesofmetricfastenersare4T6.87Tand8.8.Strengthclassisindicatedbyanumberorradiallinesembossedontheheadofeachbolt.Somemetricnutshaveapunchednumber6or8ontheirendsurfaces.Figure2showsdifferentstrengthmarkingsatoptheboldhead.Figure2.Number1NutStrengthIdentificationWhenreplacingmetricfastenersbesuretouseboltsandnutsofthesamestrengthclassasorhigherclassthantheoriginalboltsandnuts.Itisalsoimportanttoselectreplacementfastenersofthecorrectdiameterandthreadpitch.CorrectreplacementboltsandnutsareavailableasSUZUKIspareparts.MetricboltsandnutsStrengthclassnumbersormarksThelargerthenumberthegreaterthestrength.StandardTighteningTorquesEachfastenershouldbetightenedtothetorquespecifiedineachsectionofserviceinformation.Ifnotorquedescriptionorspecificationisprovidedintherelevantsectionrefertothefollowingtighteningtorquechartfortheapplicabletorqueforeachfastener.Whenandifafastenerofgreaterstrengththantheoriginaloneisusedusethetorquespecifiedfortheoriginalfastener.SeeTighteningTorqueChartpicturedright.NOTEForflangedboltsflangednutsandself-lockingnutsofthe4Tand7Tstrengthclassesadd10totheapplicabletighteningtorquesgiveninthefollowingchart.Thefollowingchartisapplicableonlywherethefastenedpartsaremadeofsteelorlightalloy. www.engineprofessional.com85Self-lockingnutTB2636AlternativeCamBoreRepairFor1995-2000MercedesBenz3.2LEnginesTheAERATechnicalCommitteeoffersthefollowingalternativecamshaftboredetailtoallowcylinderheadre-useon1995-2000MercedesBenz3.2Lengines.Thisrepairoptioncanbeutilizedwhentheoriginalcamboresarewornbeyondoriginalspecifications.ToallowforcontinueduseofthisDOHCcylinderheadMercedesBenzoffersrepaircamshaftswith.50MMoversizediameters.NOTEIfbearingseizingorseverescoringispresentthecamshaftbearingborescanbewidenedby.50mmandacamshaftwithoversizedbearingjournalsinstalled.Usethechartbelowtodetermineoriginalandrepairdimensionsforthecamshaftsandcamshaftbores.CAMSHAFTOriginal.50MMRepair29.947-29.963mm30.434mm-30.450mm1.1790-1.17961.1982-1.1988HEADBOREOriginal.50MMRepair30.000-30.021mm30.500mm-30.525mm1.1811-1.18391.2008-1.2218Thesurfacefinishofthemachinedcamshaftbearingboresshouldbemaintainedatapeak-tovalleyheightof.001-.004mmandthemaximumoutofroundnessshouldnotexceed.012mm.Thepermissiblemisalignmentofthefrontandrearboresshouldnotexceed.040mm.Boreclearancedesiredshouldbe.035mmradial.06-.21mmaxial.CAUTIONWhenperformingrepairscamshaftswithanoversizeof.50mmmustbeusedforreconditionedengineswith.50mmcamshaftbearingbores.Thecamshaftbolttorqueshouldbe15.5FTLBS21NM. 86JAN-MAR2014engineprofessionalONTHESAMEPAGEBYMIKECARUSODavidVizardsHowToSuperTuneAndModifyHolleyCarburetorsByDavidVizardSubjectAnothernewcarburetorbookwrittenbywell-knownauthorDavidVizardonHowToSuperTuneAndModifyHolleyCarburetors.ItdoessayAllNewEditiononthecoversoletssee.WOWitisnewandthebookiscrammedwiththecorrectinformationandmorethanjustcarbstoo.Readingthechapterheadingsbelowininformationgivesyoujustaverysmallideaofwhatiscoveredinthisbook.Youwillbesurprisedbywhatyouwilllearnhereasthereisplentytolearnfromwithinthepagesofthisbook.InformationChapters1acarbstruefunction2operatingprinciples3calibrationrequirements4simplemixturemeasurements5mileagecalibration6carburetorselection7boosterscience8idletransition9full-power10acceleratorpumpcircuitcalibration11ramairandheatmanagement12fuelsystems13calibratingforvariousfuels14improvingairflow15intakeportmatchingplusasourceguidesoyoucanfindanythingyouseeinthebook.SuggestionKnowingthelatestinformationoncarbsetupstobeusedonnaturalaspiratedenginesaboutboostersidlefeedrestrictionsairbleedspowervalverestrictionchannelsneedleandseatscarbspacersfuelsignitiontimingandsparkplugs.Howyoucanextractallthatyourcombinationhastooffer.Thenyouneedtobuythisbookormaybeyoujustliketolearnandknowwhy.Dynotestingofvariespartsalsoincludedinthebook.Printedin2013bySADesignSA216www.cartechbooks.com.ISBNID978-1-934709-65-8ChampionshipEngineAssemblyByReher-MorrisionRacingEnginesSubjectThisupdatedbookandaudioCDsetisbasedontheBigBlockChevroletracingengineandcontainsmoreinformationthanbothoftheoldlowerandupperassemblybooks.ItisthebestbookontheBBCracingenginethatIhaveseentodate.Thisisaclassroom-stylebookwithquestionsattheendofeachchaptertomakesurethatyouunderstandwhatyoujustread.AlongthewaytheyhaveinsertedRuleandBSwhichseparatestruthfromnon-truth.InformationThebookcoverstheprinciplesofraceengineoperation.Theupperenginesectioncoversbuildinghorsepowercamshaftsvalvetrainselectingheadsandvalvescarburetorsintakemanifoldsandheadersspecialmachineworkracingignitionsandhowtoassembleyourengine.Thelowerassemblysectioncoversselectingblockscrankshaftsconnectingrodsmeasurementsandspecialmachineworkpistonsringspinsbearingsmeasuringdisplacementandcompressionratiodegreeingthecamshaftwetanddryoilsystemsandhowtoassembleyourshortblock.Thishighlytechnicalinformationisprovidedforracingengineswhicharebeingusedoff-highwayonly.AudioCD1featuresPortingByTheNumbersinterviewwithDarinMorganandAudioCD2featuresBottomEndPerformanceinterviewwithBradMorgan.SuggestionRememberthetechnicalinformationprovidedinthisbookcanbeappliedtootherenginessotheyareusefulevenifyourenotbuildingaBBCengine.ThisbookandCDsetwillbetreasuredbyyouorbuythemforsomeonespecialasagiftthattheywillnotsoonforget.WheretoBuyrehermorrison.comengine-bookorcall855-467-4880.ModernEngineBlueprintingTechniquesByMikeMavrigianSubjectThetitleprettymuchsayswhatyoucanexpectinsidethisbook.Readingthechapterheadingsbelowininformationgivesyoujustaverysmallideaofwhatiscoveredinthisbook.Dontbesurprisedbywhatyouwilllearnhereasthereisplentytolearnfromwithinthepagesofthisbook.MikestatesThisbookisdictatedtoallprofessionalperformanceenginebuildersforwhomGOODENOUGHisnevergoodenough.InformationChapters1flawdetection2engineblocks3blockmachining4oilingsystems5engineMath6crankshaft7connectingrods8pistons9pistonrings10camshafts11cylinderheads12valvesspringsretainersandlocks13rockerarms14pushrods15intakemanifolds16balancing17timingsystems18engineperformancecoatingsandtreatmentsplusasourceguidesoyoucanfindanythingyouseeinthebook.SuggestionMikehastackledthehugetopicofengineblueprintingandcondensingitintoonebook.NotaneasytaskforanyonetodobuthehasmadeitEASYforallofUStoreadlookatthepicturesdiagramslearningfromthiswellwrittenbook.Hecoverstheoldtriedandtrueinformationprovenovertheyearsandthenhepresentsuswithupdatedcurrentinformation.Includingwhathehaslearnedalongthewayuptoprintingtimein2013.DontpassthisbookupPrintedin2013bySADesignSA251www.cartechbooks.com.ISBNID978-161325-047-1 PEGGYGREENCall507-457-0755or866-457-8975peggybigrivergmail.comRepresentinganumberofqualitylinestobringyouthebestvalueforallyourshopsupplyneeds.HOMEOFREGISNORTH35517SkyviewDriveWinonaMN55987HOMEOFREGISNORTHCallwww.engineprofessional.com87ENGINEREBUILDINGEQUIPMENTSUPPLIESServingtheEngineRebuildingIndustryforover25Yearswww.rtsalesinc.com1625NorthMilfordRdHighlandMI48357Phone248-887-0422Fax248-887-0150MARKETPLACEGrayMarineParts.comWeofferavastarrayoforiginalGrayMarineenginesenginepartsaccessoriesandsomuchmore.Ifyouhavebeensearchinghighandlowforahard-to-ndpartthensearchnomoreCallusandwellnditforyouCall630-485-5007salesgraymarineparts.com 88JAN-MAR2014engineprofessionalMARKETPLACEAttentionAERAMembersAdvertiseyourbusinesscardwithEngineProfessionalmagazineandcapitalizeonthefastestgrowinghardcoreenginepublicationintheaftermarketMarketplaceBusinessCardAdOrderFormNameCompanyAERAIDAddressCityStateZIPPhoneFaxE-mailRate____________xofinsertions______Total__________________NOTEPleasemailpaymenttoKarenatAERAseeaddressbelow.E-mailelectronicartworkJPGorPDFtomariamcreative.usIVisaIMasterCardIDiscoverIAmericanExpressIfyoudonothaveanelectronicfilemailbusinesscardalongwithpayment.IIIIIIIIIIIIIIIIExpirationDateMMYY________________3-digitCSC________PrintCardholderNameCardholderSignatureFaxtoll-free1-888-329-2372OrmailwithyourpaymenttoEngineProfessionalMagazineAERA500CoventryLaneSuite180CrystalLakeIL60014U.S.A.QuestionsPleasecontactKarenatAERAtoll-free888-326-2372or815-526-7600karenaera.org.HalFowler404-427-0171halfowlersales.comorJimRickoff507-457-8975jimrickoffgmail.comE-mailartworktomariamcreative.usBusinessCardAd3.5x21xRate2004xRate170Alladsrunfullcoloratnoextracharge.ToadvertiseinthissectionyoumustbeanAERAmember.Fordetailsonhowtojoinvisitwww.aera.org.Fourtimesayearover15000copiesofEngineProfessionalaresenttoanauditedlistofengineprofessionals.MARKETPLACEisforAERAmembersonly.ItwillbefeaturedineveryissueofEngineProfessionalmagazine. OnecalltotheAERAtechlineandmyproblemwassolved.Tomaintainanedgeintheenginebuildingindustryyouneedresourcesyoucandependon.AERAisaspecializednetworkofprofessionalenginebuildersrebuildersproductionengineremanufacturersandinstallerswiththeexpertiseandconnectionstogetyoutheinformationyouneedwhenyouneedit.WithanAERAmembershipherearejustafewofthebenefitsyoullreceiveIToll-freetechnicalsupportISpecializedenginespecificationsoftwareIEngineProfessionalmagazineIRegionalTechSkillsConferencesIAutomotiveMachiningOnlineTrainingProgramIAvoiceinWashingtonD.C.IAERAcarriesavarietyofhigh-qualityshopsuppliesuniqueitemswhichhavebeenselectedandproducedbasedoninputfrommembersnewandimprovedtemperaturerecorderlabelstagsbagsandmoreISpecialdiscountsfromanumberofpartnercompaniestohelpAERAmembersreducecostsoncreditcardprocessingcomputerhardwareandsuppliesinsuranceshippingutilitieswasteremovalandavarietyofotherservices.IDetailsonallmemberbenefitscanbefoundatwww.aera.orgmember-servicesmember-benefitsEvenifjustoneAERAtechbulletinhelpspreventanenginecomebackyourmembershipiswellworthitsdues.Wereheretohelpyoumakeyourbusinessthebestitcanbe.JointodayCompletethemembershipapplicationonthenextpageandreturntoAERA.FormoreinformationcallAERAtoll-free888-326-2372orvisitwww.aera.org.www.engineprofessional.com89AERAEngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600fax888-329-2372815-526-7601www.aera.orgemailinfoaera.orgtwitter.comaeraepfacebook.comaeraep 90JAN-MAR2014engineprofessionalAPPLICATIONFORU.S.ACTIVEMEMBERSHIPELIGIBLITYREQUIREMENTSApplicantshouldbeaproprietorshippartnershiporcorporationthathasadequateautomotiveshopequipmentandperformseitherenginemachiningenginemodificationengineassemblyorengineinstallationandwhoseprincipalbusinessservestheautomotivetrucktractormarinedieselandotherclassesofretailindustrialandcommercialaccountsandnotprimarilysellusedpartswhichtermdoesnotincluderemanufacturedpartsintheirmainplaceofbusiness.1.Pleaseremitasheetofcompanyletterheadcompanybusinesscardorcompanyinvoicewithapplication.2.Ifyourbusinessmeetstheabovecriteriapleasecompletetheformbelow.Pleaseprintlegiblyortype.COMPANYINFORMATIONCompanyNameDatebusinessstartedContactPersononenameonlyBusinessAddressCityStateZipPhoneFaxEmailWebsiteHowmanypersonnelinyourshopincludepart-timepersonnelPleasechecktheappropriatecategoriesforlistingintheAERAMembershipDirectoryIACCustompassengercarandlighttruckenginerebuildingIADDieselheavy-dutyandindustrialenginerebuildingIAFForeignmotorcycleandsmallenginerebuildingIAHHigh-performanceenginerebuildingIALDrivelinerebuildingIAMMarineenginerebuildingIAPProductionenginerebuilding100permonthIAYCylinderheadrebuildingspecialistIAIEngineinstallationIOtherPAYMENTMUSTACCOMPANYAPPLICATIONIENTIREAMOUNTENCLOSEDMONTHLYPAYMENTPLANSAVAILABLEContactAERAfordetails.CREDITCARDIVISAIMasterCardIAmericanExpressIDiscoverICHECKPleasemakecheckpayabletoAERACardholderNamepleaseprintCardNumberExpirationSecurityCodeCardholderSignatureIattestthatmyfirmmeetstheaboverequirementsandgiveAERApermissiontoverifytheinformation.SignatureTitleRECOMMENDEDFORMEMBERSHIPBYSendapplicationandpaymenttoAERA500CoventryLaneSuite180CrystalLakeIL60014.Orfaxyourcompletedapplicationwithpaymentto888-329-2372toll-freeor815-526-7601.Youmayalsoapplyonlineatwww.aera.org.IfyouarealreadyanAERAmemberpleasegivethisapplicationtoafriend.CallAERAtoll-free888-326-2372ordirect815-526-7600withanyquestions.AERAMEMBERSHIPDUESSelecttheappropriatepersonnelcategoryforyourshop.NumberofshoppersonnelI1-3........................................37030.83monthI4-8........................................45337.75monthI9-24......................................58548.75monthI25ormore............................69157.58month 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THECUTTINGEDGEBlockFrameBoringSurfacingLineBoringandGeneralCNCMachiningRottlerF100MachiningCentersHeavyDutyDesign.CuttingEdgeSoftware.OEMEngineRemanufturingcaOEMEngineRemanufturinglLatheengineeringneedssincemetthemovhaancdvsaertltRosandOEMrderebuilrecisionmainprerManuftltRoOEMEngineRemanuf23.e19engineeringneedssincstdemandingemetthemoeddesignsandequipmentancerturcaemanufsandOEMrorengineoolsfchinetecisionmaaellobaturingisaglcaerManufturingcaOEMEngineRemanufeddesignsandequipments.erorenginederaturingts.oundparrchiningoflmaefblarytRothewithlLaaticerVdditionofatheaelwithvetherloanotchineseMasPurpoesMulti-akerttltRolLaaticerts.egarchiningoflrthewithdditionofaelwithchinesesMulti-thelLacontactrottlermfg.com.facebook.comrottlermfgwww.youtube.comrottlermfgwwwottlerTHECUTcontactrottlermfg.comrottlermfg.facebook.comrottlermfg.youtube.comrottlermfgmfg.comottlerTINGEDGETHECUT1-800-452-0534125387270502UentW8029South200thStreet92JAN-MAR2014engineprofessional