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ChallengesinLowVolumeHighAccuracyBoreHoningDieselEnginesOpportunityforallFamilyBusinessPlanningWhyitscriticaltoyourbusinessandyourfamilyCustomBuildfortheStreetRodMarketCreativeideastocatertothecustomcrowdTECHNOLOGICALPOWERHOUSEALL-NEWCORVETTELT1V-82014CORVETTELT1V-8GENERALMOTORSCO.ANAERAINTERNATIONALQUARTERLYPUBLICATIONAPRIL-JUNE2013 2APRIL-JUNE2013engineprofessional4FROMTHEPUBLISHER6INDUSTRYNEWSWelcometonewAERAmemberscalendarofeventsnewsandviews10NEWSFROMTHEEDITORByJimRickoff14ALL-NEW2014CORVETTELT1V-8ByDaveHagen24CUSTOMBUILDFORTHESTREETRODMARKETByMikeMavrigianCreativeideastocatertothecustomcrowd48DIAMONDSAREABLOCKSBESTFRIENDFORHONINGByRayKemble56CHALLENGESINLOWVOLUMEHIGHACCURACYBOREHONINGBySanjaiKeshaven62WHYISFAMILYBUSINESSPLANNINGCRITICALTOYOURBUSINESSANDYOURFAMILYByIrvingKatz68DIESELENGINESOPPORTUNITYFORALLByDwayneDugas74TECHSIDEByLakeSpeedJr.OW-16in201676PRO-SISCORNERBySteveFoxEnteringCustomSpecs80AERAAUTOMOTIVEMACHINISTONLINETRAININGCylinderHeadandEngineMachinistCertificateProgram82TECHBULLETINS87MARKETPLACECONTENTSEngineProfessionalmagazineISSN1945-7634ispublishedquarterlybyAutomotiveEngineRebuildersAssociationAERA.Copyright2013AERA.Subscriptionrates70peryearoutsidetheUnitedStates90singlecopy20.Publicationedito-rialandbusinessoffice500CoventryLaneSte180CrystalLakeIL60014.Editorial815-526-7600Advertising507-457-8975Circulation815-526-7600.Sendchangeofaddresstotheabove.TheopinionsbeliefsandviewpointsexpressedbythevariousauthorsinthismagazinearethoseoftheindividualauthorsandnotoftheAutomotiveEngineRebuildersAssociationwhichdisclaimsallresponsibilityforthem.VOLUME6NUMBER2PUBLISHERAERA-EngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014815-526-7600815-526-7601faxChairmanoftheBoardDwayneDugasNewIberiaLAFirstViceChairmanRonMcMorrisMapleRidgeBCCANADASecondViceChairmanSteveSchoebenBloomingtonMNTreasurerDavidBianchiSeattleWAPresidentPaulHauglieEDITORJimRickoffjimrickoffgmail.comTECHNICALEDITORSDaveHagendaveaera.orgSteveFoxsteveaera.orgMikeCarusomikeaera.orgGaryLewisenginesmsn.comMikeEighmymikeeighmygmail.comCONTROLLERMelissaRizzimelissaaera.orgGRAPHICDESIGNMariaBeyerstedtmariamcreative.usADVERTISINGSALESJimRickoffjimrickoffgmail.comHalFowlerhalfowlersales.comPRODUCTIONJanJuhljanaera.orgCIRCULATIONKarenTenderingkarenaera.orgINTERNATIONALLIAISONYolandaCarranzayolandaaera.orgCHIEFTECHNOLOGYARCHITECTRichardRooksrichardaera.org24486874 engineprofessionalWWW.AERA.ORGEP3 4APRIL-JUNE2013engineprofessionalFROMTHEPUBLISHERBYPAULHAUGLIEAERAPRESIDENTAnoverlookedtoolinyourbusinessisthewarehousesupplyingyourparts.WhyGenerallythiswarehousehasclosedirecttieswithallofthefactoriesandcanprovideyouwithcurrentup-to-dateinformation.Additionallythesewarehousescanalsoprovidethesettingforhostingtechnicalpresentations.Thesecanprovideaninformalsettingforattendeestolearnaboutnewproductsorexistingitemsandgivetheflexibilitytoaskreal-worldquestions.Rememberthegoodwarehousesarepartsguysgurusandhavetheinventorytokeepyourjobsgoing.Eveniftheydonthavethatuncommonpieceinstocktheycanusuallytrackitdownforyou.YesthisisallaconvenienceandyesyoudopayforitbuthaveyouevertakenthetimetofigureouthowmuchitactuallycostyouthelasttimeyoutriedfindingandorderingaspecificpartyourselfImeanreallyfiguringoutthecost.Thetimespentonthephoneorcomputerthetimewaitingfortheshipmentthetimethejobtooktofinishthecostofthepartthecostoftheshipmentetc.Thesearecoststhatmanytimesbusinessesoverlookbecausethatsjusthowtheydoit.Wellimaginejustmakingonephonecallorplacingyourordersonlineimaginehowmuchyouwouldactuallysave.SpeakingofcostshowmanyofushavetrulycalculatedtheworkouremployeesdoMeaningdoyoureallyknowhowmuchyoumadeonthatsetof4.6LheadsImwillingtobetmostofusdontactuallyknowsomeofthecostsoutsideofthehourlywagewehaveintoeachjobwesendoutthedoor.Sureyouhaveapricewhensomeonecallsonthephoneandwantstoknowthepriceforarebuiltheadorenginewecanfirethatrightoff.ButhowdidyoucomeupwiththatpriceIsthatwhattheothershopdownthestreetoracrosstownchargesWheredidtheycomeupwiththatpriceThinkofitthiswaybyknowingwhatyourtruecostsareoratleasthavingarealcloseideayouwillbebettersuitedtostayinginbusinessandbecomingmoreprofitable.TrueyoumaynotalwaysbethecheapestbutifyouretakingthetimetoidentifyactualcoststhenIbelievethequalityofyourworkwillspeakforitself.RememberifyoucontinuouslylosemoneyoneachjobthatcomesinhowlongwillyoubeinbusinessMakingaprofitismorethanmatchingthepricefromyourcompetitordownthestreetsoyoucangetajobinthedoor.Itsaccountingforallthefactorsthatgointodoingthatonejobcosttorunthemachinecostforsuppliescostfortheoperatorandcostforthetimeittakestocompletetheoperation.Toooftenshopsarewillingtotaketheeasyrouteandjustslapthecurrentstreetpriceonajobthenhopeandpraytheyllhaveenoughmoneyattheendofthemonth.EventhoughcertainpoliticiansandleaderswouldhaveyoubelieveitPROFITisnotadirtyword.Neverbeafraidtochargewhatyoubelieveyourworkisworth.KeeponwrenchinIPriortobecomingpresidentofAERAPaulHauglieworkedforMellingEnginePartsasCanadianSalesManagerandPerformanceProductManagerforMellingSelectPerformance.ShopSuccessGettingaheadandgoodbusiness 52.964-264133333215-9070705290707070-529.7.7.64226401364.064-64..064-36810083825681008382862215GM6.5truckvan.........................................995eaCummins3.94BTOEM....................................950eaCummins5.96BT.............................................995eaCummins8.36CT...........................................1795eaCaterpillar3306DI..........................................2780eaCummins4BT....................................................575eaCummins6CT8.3..............................................780eaCummins6BT5.9..............................................695eaCaterpillar3306.................................................998eaCummins3.9.....................................................158eaCummins5.9.....................................................138eaCummins8.3.....................................................188eaGM6.5TruckVan..................198eaChevy350Vortec......................228eaChrysler318360........................228eaChrysler3.9................................180eaCaterpillar3306PC8N1187......730eaCaterpillar3306DI8N6796.......730eaCaterpillar3406DINEW..........1580eaCaterpillar3406PCNEW.........1580eaCaterpillar3304PCDI...............580eaJeep4.0331..........................375eaFord4.0EarlyLate...................138eaCummins5.9OEM..................5980eaCummins3.94BTOEM...........3980eaCummins8.36CTOEM...........6980eaCummins5.93.96BT4BT...........68eaCummins8.36CT.......................86eaGM6.5NEW.................................55eaCummins3.9................................98eaCummins5.9..............................108eaCummins8.3..............................138eaCummins3.9UpperKitOEM......88setCummins3.9LowerKitOEM.....88setCummins5.9UpperKitOEM......98setCummins5.9LowerKitOEM.....95setCummins8.3UpperKitOEM....128setCummins8.3LowerKitOEM...108set5 6APRIL-JUNE2013engineprofessionalAERAwelcomesnewmembersACTIVEActionMachineShopSandSpringsOKAdvancedMachiningProcessesQueensvillageNYAdvantageEuropeanAutoPartsHudsonvilleMIBDMetalFactoryLLCMountainViewCABaillieDieselNixaMODZMachineMarysvilleCADavesDieselRepairAchesonABCANADAEngineGuruJenisonMIFarnamsGenuinePartsMitchellSDHPMachineWilliamsportINHartlineMachineShopDoddCityTXHickmansPerformanceLaurinburgNCKeeEquipmentOrangevillePAMachineShopToolInc.NorthBergenNJMaquinasOpeinSLLasPalmasSPAINPro-StarEnginesBristolCTSandstoneNapaMachineSandstoneMNRectificaSaoJoseBeloHorizonteBRAZILTallerElCilindrodeFlorenciaFlorenciaCOLOMBIATalleresLuisMSimonoSantoDomingoDOMINICANREPUBLICVGMotorsportsLLCEddyvilleIAWaglerCompetitionProductsOdonINWaynesRepairWentworthSDASSOCIATEC.A.T.PowerEnginePartsEastvaleCACorpManufAutomotrizSACelayaGtoMEXICODartMachineryLtdTroyMILevelSevenGroupLLCClevelandOHNationalPowerSupplyYakimaWASCHOOLAlexandriaTechCollegeAlexandriaMNMEMBERGETTERBobDavisSunnenProductsEliasSantanaHatoReyMotorRebuildersElginIndustriesreceivesPlatinumSupplierAwardfromGMCustomerCareandAftersalesElginIndustriesaleadingU.S.-basedmanufacturerofengineandchassiscomponentsrecentlyreceivedthePlatinumSupplierStatusawardforOutstandingOn-TimeShippingPerformancefromGeneralMotorsCustomerCareandAftersales.ThisawardrecognizesElginforconsistentlyperformingaboveexpectationsandcontinuousexcellenceinsupplyingpartstoGeneralMotors.Elginsultra-modernfullyintegratedmanufacturingcomplexhasearnedabroadrangeofqualityawardsandcertificationsfromleadingcustomersintheautomotivecommercialvehiclemarkets.GMsPlatinumAwardrecognizesourdedicationtosupplyingthehighestqualityenginepartsinatimelymannersaidBillSkokpresidentElginIndustries.Thisisahighlyrespectedawardanditrecognizesourcommitmenttothecategory.ForadditionalinformationcontactyourElgindistributorvisitwww.elginind.comorcall800-323-6764.IAERAcongratulatesthosewhohavecompletedtheAERAOnlineTrainingProgramAsofMarch192013139peoplehaveenrolledintheAERAOnlineTrainingProgramforCylinderHeadandEngineMachinistcertificates.Foracompletelistofgraduatesgotowww.aera.orgaera-universitycertificates.Theseindividualsleadthewayformanyotherdedicatedenginemachinistsinterestedinprovingwhattheyknow.IfinterestedinaddingtoyourresumeofengineexperiencecallAERAat815-526-7600ext.202andaskforKarenTenderingore-mailkarenaera.org.Shecanansweryourquestionsandwhenreadyregisteryoutobegintheprogram.Formoreinformationseepage80.IInMemoryofLowellPruetzLowellKirkPruetzpassedawayonFebruary252013athisOrlandParkILhome.In1976hejoinedtwoverygoodfriendsandbetweenthethreeofthemtheyopenedanEnginePartsWarehouseintheshadowsofComiskeyParkinChicago.HardPartsWarehousestillexistsatthatlocationtoday.ThereweretwoimportantthingsinLowellslifehisbusinessandgolfespeciallywithhisbrothers.EvenLowellslossofsightlaterinlifecouldntkeephimfromhisfavoritepassion.Heteamedwithaformergolfprowhotaughthimhowtoadapthisgameasablindgolferandhehitthegolfcourseanddrivingrangeseveraltimesaweek.HeissurvivedbyhissiblingsEdJoycePruetzJoAnnHermSteinkeMonroeNancyPruetzNancyPruetzandPeggyMichaelFarnsworthandlong-timedevotedfriendandcompanionKathyandlastbutnotleasthisfaithfulservicedogZen.IIindustrynewscalendarAPRIL13AERATECHSKILLSCONFERENCEHostedbyDeAnzaCollegeAutoTechCupertinoCAMAY16AERATECHSKILLSCONFERENCEHostedbyMAHLEandDrivenRacingOilatRichardChildressRacingWelcomeNCJUNE8AERATECHSKILLSCONFERENCEHostedbyLibertyEnginePartsIncPittsburghPAwww.liberty-engine-parts.comJUNE22AERATECHSKILLSCONFERENCEHostedbyNationalPerformanceWarehouseCompaniesatCMASpeedWarehouseLosAngelesCAJULY10-12PAACEAUTOMECHANIKAMEXICOMexicoCityMEXICOwww.paaceautomechanika.comNOVEMBER5-7AAPEXSHOWSandsExpoCenterLasVegasNVwww.aapexshow.comNOVEMBER5-8SEMASHOWLasVegasConventionCenterLasVegasNVwww.semashow.comDECEMBER12-14PRISHOWIndianapolisConventionCenterIndianapolisINwww.performanceracing.com engineprofessionalWWW.AERA.ORGEP7 RottlerCelebrates90thAnniversaryRottlerManufacturingLLCofKentWAiscelebratingits90thAnniversaryin2013.Rottleristheonlyfull-linemanufacturerofmachinetoolstotheperformanceracingenginerebuildingOEMmanufacturinglocomotivemarineandnaturalgasindustries.Rottlerproducessmallmediumandlargemulti-purposeCNCmachiningcentersseatguideequipmentvalverefacers5-axisportingmachinessurfacinghoningandboringmachines.Rottlers90thyearinbusinesscomesontheheelofarecordsalesyear.Rottlerwillbecelebratingthe90thAnniversaryattheir6thAnnualOpenHouseonThursdayandFridaySeptember26thand27th2013.Formoreinformationgotowww.rottlermfg.comevents.Rottlerwasfoundedin1923byClarenceT.RottlerandtodaycontinuestoberunbytheRottlerfamily.ForRottlersfullhistorygotowww.rottlermfg.comhistory.IEnginePartsGroupInc.developsPerformanceScholarshipatUNOHAnationalenginepartsmanufactureranddistributorbelievesithasfoundawaytoaddressconcernsofmachineshopownerswhoworryabouttheavailabilityofgoodyoungtalenttohirefortheirshops.InanefforttoprimethetalentpumpEnginePartsGroupInc.andtheUniversityofNorthwesternOhiohaveannouncedthecreationoftheEngineProPerformanceScholarshipFundatUNOH.Theinitialfundingiscomingfromthedonationofa500horsepowersmallblockChevroletprojectracingenginethatwasprofessionallybuiltusingEnginePropartsbytheCopeBrothersAutomotiveMachineShopinTacomaWashington.UNOHsCollegeofAppliedTechnologywillberafflingofftheenginethisspringwithhopesofraisingmorethan15000tokickoffthescholarshipprogram.InadditionEPGIhascommittedtodonatingadditionalmoneyonanongoingbasistosustaintheprogram.UpondonatingtheengineEPGIpresidentDonWebersaidThefutureofourcompanyandthatofenginebuildersacrossthecountryisonlyasstrongastheinterestofyoungpeoplewhowanttocomeintoourindustry.Webersaystheindustryneedstodoallthatitcantoensurethatthenextgenerationsareencouragedtochooseenginetechnologyasacareer.TheUniversityofNorthwesternOhioistheperfectplacetoestablishthescholarshipfundsaysWeber.Theuniversityfeaturesthelargestfacilityinthecountrydedicatedtolearningthescienceofhighperformancevehicles.Withinitsseven-acreperformancemotorsportscomplexstudentsaretrainedonallbrandsofperformancecarsusingstate-of-the-industrymachinesandequipment.SteveFarmerUNOHsVicePresidentofBusinessDevelopmentsaysStudentsactivelyparticipateaspitcrewinNASCARandARCAsanctionedraces.Graduatesfromthisprogramroutinelystepintopositionsintheperformanceracingindustryandimmediatelybeginmakingacontribution.IIindustrynews8APRIL-JUNE2013engineprofessional 10APRIL-JUNE2013engineprofessionalHiTeamGearheadswrench-headsknuckleheadscalluswhatyouwant.Thoseofuswholiketoworkwithourhandsoftengetlabeledthatwerebetterwithourhandsthanourbrains.HeyitmaybetruethatwewouldratherworkwithourhandsbutourhandsneedabraintotellthemwhattodoThebrainstorestheknowledgesoourhandscanperform.Ihavealwayslaughedwhenwegetlabeledthatway.NowIwouldagreethatmostofuswouldratherhaveawrenchinourhandsthanapencilbutweallhaveadesiretolearnandweallhaveaneedtokeeplearning.Withoutquestionourindustryneedstrainingyettraininginourspecializedindustryoutsideofourtechschoolswithournicheprogramshasbecomealmostvoid.Gonearethedaysofeverymanufacturerhavinganautomotivemachiningtrainingprogram.Gonearethedaysofemployersofferinganapprenticeprogramforourindustry.GonearethedaysofASEofferinganautomotivemachiningtestcertificationprogram.TheaboveprogramsmaybegonebutAERAitsboardofdirectorsandspecificallyoneboardmembernamedGaryLewishavetakenthislosstoheartanddesignedanonlinetrainingprogramforautomotivemachinistscompletewithatextbookandcertificationprocessbuiltintoit.InadditiontobeinganAERAdirectorGaryLewisisaninstructorofautomotivemachiningatDeAnzaTechnicalCollegeandauthorofAutomotiveMachiningEngineRepairwhorealizedtheneedforbasicheadandblockmachiningknowledge.Theinformationinthisprogramispresentedfromtheviewofenginemachineshopoperations.Basicproceduresareselectedfromthosewithwideindustryacceptanceandrepresentwell-balancedandcompetentstateoftheartpracticeLewissaid.Nowyouandyouremployeesorifyoureaschoolbothyouandyourstudentscantrainwiththisstep-by-stepautomotivemachiningtrainingprogramandbecomecertifiedintheprocess.Eachprogramisself-pacedwithuptooneyeartocomplete.EachregisteredpersonwillreceivetheGaryLewisbookandAERAoffersadiscountedpriceplanformultipletraineesfromthesameshoporschool.Pleasenotethateachpersonregisteredreceivestheirownbook.IcantstressthisfactenoughtheAERAtrainingprogramhasacertificationprocessbuiltintoit.TestsaftereachchapterandafinalforeachcertificationoneforCylinderHeadandoneforEngineMachinist.Thetestsareopenbookdesignedtohelpyoulearn.Oncecompletedyouwillreceiveanattractiveofficialcertificateofcompletioninadiploma-styleholderalongwithanAERAarmpatchthatproudlydisplaysyourecertifiedinenginemachining.Youllalsoreceiveaskillschecklistcardtobepresentedtoyouremployersotheycansignoffontheareasinwhichyouhavedemonstratedproficiency.continuedNEWSFROMTHEEDITORBYJIMRICKOFFTrainingforGearheadsAERAoffersonlinetrainingforautomotivemachinistsSavetheDateMAY16MAHLEANDDRIVENRACINGOILRichardChildressRacingWelcomeNCJUNE8LIBERTYENGINEPARTSPittsburghPAJUNE22NATIONALPERFORMANCEWAREHOUSECOMPANIESCMASpeedWarehouseLosAngelesCASEPTEMBER18-19AERAANDPERAAERMfg.Inc.CarrolltonTXSEPTEMBER27ROTTLERMFG.KentWAOCTOBER9PARTSWAREHOUSESUPPLYKansasCityMOOCTOBER26SUNNENANDDARTMacombCommunityCollegeWarrenMICONFERENCEHOSTINGOPPORTUNITIESIfyouareinterestedinhostingaconferencenextyearpleasecontactJimRickoffat507-457-8975oremailjimrickoffgmail.com.FormoreinformationaboutAERAsAutomotiveMachinistOnlineTrainingProgramseepage80orgotowww.aera.orgaera-university. engineprofessionalWWW.AERA.ORGEP11 12APRIL-JUNE2013engineprofessionalNEWSFROMTHEEDITORBYJIMRICKOFFBenefitsoftheAERAAutomotiveMachinistOnlineTrainingProgramBenefittotheShopOwnerKnowingthataprospectiveemployeeholdsanAERACertificateofCompletioninCylinderHeadsandorEngineMachinistincreasesyourlikelihoodofhiringaproductiveandtrainableshoptechnician.AnewhirewithanAERAcertificateimprovesyourchanceofhiringandkeepingqualifiedshoppersonnel.BenefittotheTechnicianAnAERACertificateofCompletionmeansyouhavesuccessfullyfinishedadifficultprogramdesignedtoteachandtestdetailedskillsandpracticesofanoperatingenginemachineshop.Itelevatesyourstatusandchancesofhirewithprospectiveemployerslookingforqualifiedteachableemployees.BenefittotheIndustryEveryoneinourindustryneedstodotheirparttoincreaseprofessionalismandprofessionalawareness.PromoteyourshopasanAERAmemberandpromoteyouremployeesasAERAcertifiedmachinists.Manyotherindustriesareabletochargemorefortheworktheircertifiedworkersperform.Nowyoucantoo.AERAhasdonetheirpartnowitstimeyouandyouremployeesandstudentsdotheirs.FredThompsonfromGSAutoPartsinLittletonColoradorecentlycompletedbothtestsandhadthistosayabouttheAERAonlinetrainingprogramIntodaysmarkettrainingandeducationarethekeystosuccessandAERAprovidesthetoolsnecessaryforthatsuccess.TheAERAAutomotiveMachiningOnlineTrainingprogramisacomprehensivetrainingmodulefocusedonthehighstandardssetbyAERAandtheautomotiveindustry.Ihavenumerousyearsofmachineshopexperienceandfoundtheprogramveryinformativeanduseful.IwouldrecommendtheAERAtrainingprogramtoanyone.Pleasenotethatthistrainingisopentoeveryonewhohasadesiretolearn.GetstartedtodayandregisterforAERAsAutomotiveMachiningOnlineTrainingProgrambycontactingKarenatAERAviaemailkarenaera.orgphone888-326-2372ext.202oronlineatwww.aera.orgaera-university.IJimRickoffistheEditorofEngineProfessionalmagazineandAERAsmarketingconsultant.Ifyouhaveanyquestionscommentsorconcernscall507-457-8975ore-mailjimrickoffgmail.com. 14APRIL-JUNE2013engineprofessionalThisallnewvehiclefromDetroitwillfeatureatechnologicalpowerhouseenginecreatedfromthepreviousyear6.2Lengine.Whentheall-new2014ChevroletCorvettearriveslaterthisyearitwillbepoweredbyatechnologicallyadvancedracing-proven6.2LV-8deliveringanestimated450horsepowerandhelpingproduce0-60mphtimesinlessthanfourseconds.ThenewCorvetteLT1enginethefirstoftheGen5familyofsmallblockenginescombinesseveraladvancedtechnologiesincludingdirectinjectionActiveFuelManagementandcontinuouslyvariablevalvetimingtosupportanadvancedcombustionsystem.OutputperformanceandfuelconsumptionnumberswillnotbefinalizeduntilearlynextyearbutthenewLT1engineisexpectedtodeliverThemostpowerfulstandardCorvetteeverwithpreliminaryoutputof450horsepower335kWand450lb.-ft.oftorque610NmThequickeststandardCorvetteeverwithestimated0-60mphperformanceinlessthanfoursecondsThemostfuel-efficientCorvetteeverexpectedtobelowerthan2013models7.7L100kmTheHolyGrailfordevelopingaperformancecarisdeliveringgreaterperformanceandmorepowerwithgreaterfuelefficiencyandthatswhatweveachievedsaidTadgeJuechterCorvettechiefengineer.ByleveragingtechnologyweareabletogetmoreoutofeverydropofgasolineandbecauseofthatweexpectthenewCorvettewillbethemostfuel-efficient450horsepowercaronthemarket.Advancedcombustionsystemoptimizedwith6millionhoursofanalysisIncreasedpowerandefficiencyweremadepossiblebyanunprecedentedlevelofanalysisincludingcomputationalfluiddynamicstooptimizethecombustionsystemthedirectinjectionfuelsystemactivefuelmanagementandvariablevalvetimingsystemsthatsupportit.Morethan10millionhoursofcomputationalanalysiswereconductedontheengineprogramincluding6millionhoursCPUtimededicatedtotheadvancedcombustionsystem.Directinjectionisall-newtotheenginearchitectureandisaprimarycontributortoitsgreatercombustionefficiencybyensuringamorecompleteburnofthefuelintheairfuelmixture.Thisisachievedbypreciselycontrollingthemixturemotionandfuelinjectionspraypattern.Directinjectionalsokeepsthecombustionchambercoolerwhichallowsforahighercompressionratio.Emissionsarealsoreducedparticularlycold-starthydrocarbonemissionswhicharecutbyabout25percent.continuedTheAll-New2014CorvetteLT1V-8NewDirectInjectionFuelSystemfeaturedinthe2014CorvetteLT1V-8.BYDAVEHAGENPHOTOSGENERALMOTORS engineprofessionalWWW.AERA.ORGEP15TheHolyGrailfordevelopingaperformancecarisdeliveringgreaterperformanceandmorepowerwithgreaterfuelefficiencyandthatswhatweveachieved. 16APRIL-JUNE2013engineprofessionalALL-NEW2014CORVETTELT1V-8BYDAVEHAGENActiveFuelManagementAFMafirst-everapplicationonCorvettehelpssavefuelbyimperceptiblyshuttingdownhalfoftheenginescylindersinlight-loaddriving.ContinuouslyvariablevalvetimingwhichGMpioneeredforoverhead-valveenginesisrefinedtosupporttheLT1AFManddirectinjectionsystemstofurtheroptimizeperformanceefficiencyandemissions.Thesetechnologiessupporttheall-newadvancedcombustionsystemwhichincorporatesanewcylinder-headdesignandanewsculptedpistondesignthatisanintegralcontributortothehigh-compressionmixturemotionparametersenabledbydirectinjection.TheLT1headfeaturessmallercombustionchambersdesignedtocomplementthevolumeoftheuniquetopographyofthepistonsheads.Thesmallerchambersizeandsculptedpistonsproducean11.51compressionratiowhiletheheadfeatureslargestraightandrectangularintakeportswithaslighttwisttoenhancemixturemotion.Thisiscomplementedbyareversaloftheintakeandexhaustvalvepositionsascomparedtothepreviousenginedesign.Alsothesparkplugangleanddepthhavebeenrevisedtoprotrudefartherintothechamberplacingtheelectrodeclosertothecenterofthecombustiontosupportoptimalcombustion.Thecontoursofthepistonheadsaremachinedtoensuredimensionalaccuracy.Thepistonsfeatureuniquesculptedtopographythatwasoptimizedviaextensiveanalysistopreciselydirectthefuelsprayforamorecompletecombustion.Thecontoursofthepistonheadsaremachinedtoensuredimensionalaccuracyessentialforprecisecontrolofmixturemotionandthecompressionratio.Race-provenlegacystate-of-the-artperformanceThefirstsmallblockV-8debutedintheCorvettein1955.Itdisplaced4.3L265cubicinchesandwasratedat195horsepowerdrawingairandfuelthroughafour-barrelcarburetor.FiveyearslaterV-8powerhelpedCorvettesecureitsfirstvictoryatthe24HoursofLeMans.ThenewLT1isalsofourinchesshorterinoverallheightthanthecompetitiveDOHCV-8.ThatalsoimproveshandlingbyloweringthecenterofgravitywhileenablingalowhoodlinecontributingtotheCorvettesiconicprofileaswellasensuringexceptionaldrivervisibility.ThenewLT1isthethirdengineintheCorvetteshistorytobeso-namedwithpreviousversionsintroducedin1970Gen1and1992Gen2.AlliterationsoftheLT1andallsmallblockengineshavesharedacompactdesignphilosophythatfostersgreaterpackagingflexibilityinsleekvehiclessuchastheCorvette.ThepowerandefficiencyofthesmallblockV-8arehallmarksofCorvetteperformancesaidJordanLeesmallblockchiefengineerandprogrammanager.Butthecompactsizeandgreatpower-to-weightarejustasimportantfortheoveralldrivingexperience.Theall-newLT1willplayahugeroleinmakingtheall-newCorvetteaworld-classsportscarintermsoftechnologyperformanceandrefinement.ENGINEFEATURESANDHIGHLIGHTSAll-AluminumBlockandOilPanTheGen5blockwasdevelopedwithmath-basedtoolsanddataacquiredinGMsracingprogramsprovidingalightrigidfoundationforanimpressivelysmoothengine.Itsdeep-skirtdesignhelpsmaximizestrengthandminimizevibration.AswiththeGen3andGen4smallblocksthebulkheadsaccommodatesix-boltcross-boltedmain-bearingcapsthatlimitcrankflexandstiffentheenginesstructure.Astructuralaluminumoilpanfurtherstiffensthepowertrain.Theblockfeaturesnodularironmainbearingcapswhichrepresentasignificantupgradeovermoreconventionalpowderedmetalbearingcaps.Theyarestrongerandcanbetterabsorbvibrationsandotherharmonicstohelpproducesmootherquieterperformance.continuedAFMComponentsCloseupofCombustionChamberandDirectInjectionNozzlecircledinred SPECIALIZINGINREPLACEMENTPARTSFORBENDIXCARRIERCATERPILLARCUMMINSDETROITDIESELHINOISUZUMIDLANDNAVISTARTHERMO-KINGTRANE...yourFriendlyalternativeDieselenginepartsESCOINDUSTRIESINC.TOLLFREE1-800-372-6872FAX951-782-2136SALESESCOUSA.COMWWW.ESCOUSA.COMALLOTHERCOMPANYBRANDPRODUCTANDSERVICENAMESAREUSEDHEREINFORIDENTIFICATIONPURPOSESONLYANDMAYBETHETRADEMARKSSERVICEMARKSORTRADENAMESOFTHEIRRESPECTIVEOWNERS.THEREISNOAFFILIATIONORSPONSORSHIPBETWEENTHESECOMPANIESANDESCOUNLESSEXPRESSLYSTATED.CARRIERBENDIXREPLASPECIALIZINGINTERPILLARCARRIERBENDIXARTSFORCEMENTREPLASPECIALIZINGINTHERMONMIDLANDISUZUHINODETROITDIESELCUMMINS-KINGRMIDLANDISUZUHINODETROITDIESELCUMMINSTERPILLARTRANE-KINGTHERMOiend...ourTRANE-KINGyalternativeDieselenginepartsyalternative...yourFDieselenginepartsyalternativeED.XPRETHESECOMPBETWEENSPONSORSHIPTHEREISNOTHEIRRESPECTIVEOWNERS.OFVICEMARKSORTRADEMARKSSERTHEBEBRANDPROANYOTHERCOMPALLANDESCOUNLESSANIESTHESECOMPINRAFFILITHEREISNOTRADENAMESVICEMARKSORANDYTIONPURPOSESONLVICENAMESANDSERBRANDPRODUCT 18APRIL-JUNE2013engineprofessionalComparedtotheGen4enginetheGen5scylinderblockcastingisall-newbutbasedonthesamebasicarchitecture.Itwasrefinedandmodifiedtoaccommodatethemountingoftheengine-drivendirectinjectionhigh-pressurefuelpump.Italsoincorporatesnewenginemountattachmentsnewknocksensorlocationsimprovedsealingandoil-spraypistoncooling.AdvancedOilingSystemwithavailableDry-SumpSystemTheLT1oilingsystemincludingoil-spraypistoncoolingwasalsooptimizedforimprovedperformance.Itisdrivenbyanewvariable-displacementoilpumpthatenablesmoreefficientoildeliverypertheenginesoperatingconditions.Itsdual-pressurecontrolenablesoperationataveryefficientoilpressureatlowerrpmcoordinatedwithAFManddelivershigherpressureathigherenginespeedstoprovideamorerobustlubesystemforaggressiveengineoperation.PistonOilCoolingNozzlesStandardoil-spraypistoncoolingspraystheundersideofeachpistonandthesurroundingcylinderwallwithanextralayerofcoolingoilviasmalljetslocatedatthebottomofthecylinders.Foroptimalefficiencytheoiljetsareusedonlywhentheyareneededthemostatstart-upgivingthecylindersextralubricationthatreducesnoiseandathigherenginespeedswhentheengineloaddemandsforextracoolingandgreaterdurability.Anavailabledry-sumpoilingsystempromotesexceptionallubricationsystemperformanceduringaggressivedrivingmaneuversandhighcorneringloads.Itincludestwostagesapressurestageandascavengestage.Thepressurestageincludesthenewdual-pressure-controlandvariable-displacementvanepump.Seesidebaronpage15.Dexossemi-syntheticmotoroilwitha5W30specificationhelpsreducefrictiontofurtherenhancetheLT1sefficiency.NewTri-LobeCamshaftComparedtotheGen4smallblockthecamshaftremainsinthesamepositionrelativetothecrankshaftandisusedwithanewrearcambearingbutitfeaturesanall-newtri-lobedesignedlobewhichexclusivelydrivestheengine-mounteddirectinjectionhigh-pressurefuelpumpwhichpowersthedirect-injectioncombustionsystem.Thecamsspecificationsinclude14mm13.3mm0.5510.524-inchintakeexhaustlift200207-crankangledegreesintakeexhaustdurationat0.050-inchtappetliftanda116.5-degreecamanglelobeseparation.NewCam-DrivenFuelPumpThedirectinjectionsystemfeaturesavery-high-pressurefuelpumpwhichdeliversupto15Mpa150bar.Thehigh-pressureengine-drivenfuelpumpisfedbyaconventionalfuel-tank-ALL-NEW2014CORVETTELT1V-8BYDAVEHAGENRigidAluminumOilPanCoatedRodBearingsDirectInjectionFuelPumpLobe Allnewforthe2014Corvetteisahighperformanceoptionfortheenginesoilingsystem.Asanoptionaspecificallydesigneddrysumpoilingsystemisavailablefortheextremedrivingenthusiast.Whilethestandardoilingsystemisnewlyrefinedandenhancedthisdrysumpsystemwillbeamuchappreciatedaddon.DrySumpDetailsThedrysumpsystemscavengesliquidoilandanyresultingmixtureofoilairandcrankcasegasesfromthebottomoftheengineoilpanthroughaninternalscavengereturntube.Thisoilmixtureispumpedtothetopofthedrysumptankmountedintheenginecom-partmentbutexternaltotheengine.Withinthetanktheoilmixtureistangentiallyspilledoutonaspiral-shapedinternalbafflewherethecontactandflowabouttheinternalsurfacesofthetankpromoteseparationofairandgassesthatareentrainedintheoil.ThesegassesaredirectedbythePCVsystemseesectionbelowthroughaseriesofbafflesandtubesbacktothecombustionchambertobeburned.Thede-aeratedoilisdirecteddownthewallsofthetanktocollectinthe10.5-quartreservoirwet-sumpapplicationfeaturesasix-quartcapacityconditionedandreadyforuse.Thesecondstageofthedual-stagegerotorpumpthendrawstheconditionedoilfromthetankandpressurizesitfeedingittotheengineviatheoilfilterandoilcooler.Theroutingoftheengineoiltoandfromthedrysumpreservoiralsoprovidestheben-efitofpassiveoilcooling.PCV-IntegratedRockerCoversOneofthemostdistinctivefeaturesoftheall-newGen5engineisitsdomedrockercoverswhichhousepatent-pendingintegratedpositivecrankcaseventilationPCVsystemthatenhancesoileconomyandoillifewhilereducingoilconsumption.ItalsocontributestolowemissionsfortheGen5.Therockercoversalsoholdthedirect-mountigni-tioncoilsforthecoil-near-plugignitionsystem.Betweentheindividualcoilpacksthedomedsectionsofthecoverscontainbafflesthatseparateoilandairfromthecrankcasegasesaboutthreetimestheoilairsepara-tioncapabilityofpreviousengines.Eachcoverfeaturesandinletandoutletpathforthecrankcasegaseswiththeseparatedoildroppingbackontotheenginewithinthecoversandtheremainingairgasescirculatedbackintoairintakestreamforcombustion.Thesystemalsopreventsmoisturefromaccumulatingintheengine.ThisintegratedPCVsystemisanessentialcontrib-utoroftheGen5sefficientperformanceandlong-termdurabilityandthedomesforitontherockercoversmaketheGen5engineinstantlyrecognizable.ITheUltimateOilingSystemengineprofessionalWWW.AERA.ORGEP19 PROVENPERFORMANCEWithadvancedfeaturesengineeredspecicallyfortherepairenvironmentFel-ProPermaTorqueMLSheadgasketswithourLaserWeldstopperlayerarethebestsolutionforvirtuallyallMLS-sealedengines.Thesegasketsdecreasecylinderheadliftandareeffectiveupto3600psideliveringastrongerandfarmorereliablesealforahigherqualityenginerepair.100SEALEDLASERWELDSTOPPERTECHNOLOGYMagniedViewmountedpump.Thedirectinjectionpumpismountedinthevalleybetweencylinderheadsbeneaththeintakemanifoldandisdrivenbythecamshaftattherearoftheengine.Thislocationensuresanynoisegeneratedbythepumpismuffledbytheintakemanifoldandotherinsulationinthevalley.PCV-IntegratedRockerCoversOneofthemostdistinctivefeaturesofthenewengineisitsdomedrockercoverswhichhousethepatent-pendingintegratedpositivecrankcaseventilationPCVsystemthatenhancesoileconomyandoillifewhilereducingoilconsumptionandcontributingtolowemissions.Therockercoversalsoholdthedirect-mountignitioncoilsforthecoil-near-plugignitionsystem.Betweentheindividualcoilpacksthedomedsectionsofthecoverscontainbafflesthatseparateoilandairfromthecrankcasegasesaboutthreetimestheoilairseparationcapabilityofpreviousengines.IntakeManifoldandThrottleBodyAssemblyTheLT1sintakemanifoldfeaturesarunnersinaboxdesignwhereinindividualrunnersinsidethemanifoldfeedaplenumboxthatallowsforexcellenthigh-efficiencyairflowpackagedbeneaththecarslowhoodline.Acousticfoamissandwichedbetweentheoutsidetopoftheintakemanifoldandanadditionalacousticshelltoreduceradiatedenginenoiseaswellasfuelpumpnoise.20APRIL-JUNE2013engineprofessionalThemanifoldispairedwithanelectronicallycontrolledthrottlefeaturingan87mmborediameterandacontactlessthrottlepositionsensordesignthatismoredurableandenablesgreatercontrol.2014LT16.2LV-8DirectInjectionFuelSystem 2013Federal-MogulCorporation.Allrightsreserved.PROVENPERFORMANCEExclusiveMLSaftermarketdesignLaserWeldStopperTechnologySeethefutureofsealingrstatwww.felpro-only.comONLYFEL-PROofferssealingsolutionsdevelopedbyexperiencedengineerswhoworkcloselywithnotedenginebuildersandprofessionalraceteamspredictingtheextremeoperatingdemandsofeachnewenginegenerationanddevelopingthetechnologytosealthem.Lookaheadandyoullsee.OnthewidestvarietyofevolvingengineplatformsFel-Proisthefutureofsealing.Subaru2.5l26415PTengineprofessionalWWW.AERA.ORGEP21 22APRIL-JUNE2013engineprofessionalALL-NEW2014CORVETTELT1V-8BYDAVEHAGENThemanifoldispairedwithanelectronicallycontrolledthrottlefeaturingan87mmborediameterandacontactlessthrottlepositionsensordesignthatismoredurableandenablesgreatercontrol.Four-Into-OneExhaustManifoldsTheLT-1usesacastversionofthefour-into-oneshort-headerexhaustmanifolddesignusedontheGen4LS7engine.Thecastheaderpassagesenableconsistentexhaustflowintothewidemouthcollectorattheconverter.CoolingSystemHumiditySensorandMoreAdditionalfeaturesandtechnologiesoftheGen5smallblockincludeArevisedcoolingsystemwithanoffsetwaterpumpandthermostatformoreefficientperformanceAirinductionhumiditysensorensuresoptimalcombustionefficiencyregardlessofthesurroundingairshumidity58Xignitionsystemwithindividualignitioncoilmodulesandiridium-tipsparkplugsAll-newE92enginecontroller.EvenaNewLogoFortheseventh-generationCorvettethenewCrossedFlagsdesignisamoretechnicalmoreangularandmoresweptappearanceinproportionthatsymbolizesthenewcar.Itisalsoamoredetailedrepresentationshowinggreaterdepthcolorandattentiontodetail.Morethan100variationswereconsideredbeforethefinaldesignwasselected.IAERATechnicalSpecialistDaveHagenhasover41yearsofexperienceinourindustry.AsanASE-certifiedMasterMachinistDavespecializedincylinderheadworkandcompleteengineassemblyforthefirst17yearsofhiscareer.FindenginespecsfastandeasyPRO-SISSAENGINESPECIFICATIONSOFTWAREGIVESYOUACCESSTONEARLY7000ENGINESPECIFICATIONSWITHJUSTACLICKOFYOURMOUSEPLUSYOUCANADDYOUROWNCUSTOMENGINEINFORMATIONTOTHEPRO-SISSADATABASE.SOBYTHETIMEITTAKESYOUTOFINDTHEMANUALWITHPRO-SISSAYOUVEALREADYFOUNDYOURSPECSANDAREBACKTOWORK...THATSAMONEY-MAKINGDIFFERENCEWWW.AERA.ORGPRO-SISTOLL-FREE888-326-2372815-526-7600500COVENTRYLANESTE180CRYSTALLAKEIL60014twitter.comaeraepfacebook.comaeraep 24APRIL-JUNE2013engineprofessional engineprofessionalWWW.AERA.ORGEP25Inthisprojectmygoalwastocombineperformanceanddurabilitywithtotaleye-candyappeal.Whilemostrodderslovetoboastabouthorsepowerallcraveatidyandeye-poppingvisualpackage.Braggingrightsaboutthepowerthatpushesaroddersstreettoyisalwayscoolbutwhenitcomestimetopopthehoodatalocalornationalrodshowhavingahomelywifewhosamastercheftakesadistantbackseattobeingabletodisplayatrophywifewhereherculinaryskillsjustplaindontmatter.Inshortthatseveral-hundred-poundassemblythatperchesintheenginebaysimplymustlooktastyandintheworldofshowngoitsneverabadthingtohavesomethingthatotherscovet.SUMMARYOFENGINENewcustom-builtsmallblockChevyboredandstrokedto383CID.DartSportsman350blockboredto4.0305DartPro-1aluminumheadsScat3.750strokercrankScatH-beam5.700rodsKBpistonsClevitebearingsARPfastenersthroughoutMSDProBilletdistributorCompCamshydraulicrollercamfull-rollerrockersCVbilletfuelpumpATISuperDamperJonesRacingradius-toothbeltdriveEdelbrockaluminumwaterpumpQuickFuel780cfmcarbEdelbrockdualplaneintakeMorosooilpanandvalvecoversPolydynecoatingscustomKNdualairfiltersystem.Allexteriorsurfacessmoothedandcustompainted.Customsparkplugrouting.Colorappropriateforblackwhitegrayorsilvercar.BlockCNCaccurizedrotatingassemblyfinelybalanced.Etc.Firstwelladdressthebasisofthebuildfollowedbydetailsofthecustomtouches.OURDARTBLOCKThestoutfoundationofourbuildfeaturesaDartironblockDartPN31151111.ThisistheirSportsmanLittleMblockthatfeaturesadeckheightof9.025destinedtoaccommodateaminimal4.00boresizeDartalsooffers4.125unfinishedbores.BLOCKSPECSMaterialHighnickelcontentironalloyDeckheight9.025Bore4.00unfinished4.125alsoavailableMainbearingsize2.450Mainbearingbore2.6401-0.001350typeblockWeight205lbs.CamshaftbearingdiameterSBC-2.00with0.002pressfitCamjournalODStandardSBC1.869Cylinderwallthicknessmin0.2754.185boreDeckthicknessmin0.675MaincapsDuctileiron4-boltcenterthreeMaincaptorquespecs1-4716bolts65ft-lbs512bolts100ft-lbsPress-incamplugprovided2.375dia.FreezeplugsPress-incupsprovidedLifterboresSBC0.84270.8437Maincapbolts1two716234two716andtwo716splayed5twoMaincappress0.005MaincapregisterDeep-steppedregisteroneachsidenodowelsOilpumpshaft0.481OD0.425for400blockSerialnumberAppearsonleftfrontandmaincapsStarterAcceptsstandardSBCHeadboltholesBlindAnearlystockSBC2-holeoilfilteradapterisrequired.StandardSBCtimingchaintimingcovergearorbeltdrivecanbeused.TheblockacceptsthestandardSBCoilpandesign.Wheninitiallyremovingthemaincapsthecapsandblockshouldbedeburredbeforereinstallingtoinsuremainboresize.StandardSBCheadboltsorstudscanbeused.Theheadboltholesintheblockareblindanddonotenterwater.Dartrecommendsusingathreadsealantantiseizeonheadstuds.Loctite620isrecommended.Oilpumpdowelpinsshouldbe0.250OD.StockGMpinsareonly0.246OD.Theblockismachinedtoacceptaleft-sidedipsticktube.Abossisprovidedforright-sidebutmustbedrilledifneeded.Thefuelpumppushrodboreismachinedfora0.500rod.Clearanceshouldbecheckedduetovariancesinpushroddiameters.GrantedtheDartblockunlikethetypicalOEcastingisacleantidyandbeautifulcore.Regardlessofhowgoodthisblocklooksas-iswedecidedtogofurther.Inadditiontoboringandhoningthecylinderstosizeforour0.030KBpistonswetravelledtheextramilebymeticulouslysmoothingtheblockexteriortoachieveano-compromisecleanandsmoothappearance.NoteDartoffersspecifichoninginstructionsforthisblockbasedonprocedurestheyvedevelopedintheirProStockprogram.Theyrecommendaspeedof185RPMandafeedof50strokesperminute.Onceyouverough-honed.003fromfinalsizehonetosizeusinga220gritstone.Followthiswiththreestrokeswitha280gritfollowedbythreestrokeswitha400grit.TheRAshouldbe26-28.DartalsooffersahoningshoeassemblytechniquethatinvolvesusingahardshowononesideofthehoningheadandCustomBuildfortheStreetRodMarketCreativeideastocatertothecustomcrowdBYMIKEMAVRIGIAN 26APRIL-JUNE2013engineprofessionalDelronattachedtothebrassshowholderandtrimmedtosizeontheoppositesideofthehoninghead.Dartspecificallywarnsagainstusingabronzeshoe.CYLINDERHEADSOurheadsareDartaluminumPRO1lightweightchunkiesPN11321112.Theseheadsfeature200ccrunners64ccchambersfittedwith2.02intakevalvesand1.60exhaustvalves.Inconcertwithour5.700rodlengthandKBpistonswesettledonacompressionratioof10.781.TheassembledheadsasshippedfromDartfeature1.437ODdualspringsratedat135lbataninstalledheightof1.800.Suitableforamaximumliftof0.600.Flat-typeCompCamsPN4808guideplatesmustbeusedaswellashardened516pushrods.Theseheadsaccept.750-reach58hexsparkplugs.AmongthegasketedplugsrecommendedbyDartareAutolite3933standardtipraceandACFR3LSprojectedtipstreet.Theheadsaredesignedtobeclampedwith70ft-lbs.Rockerarmstudsshouldbetorquedto45ft-lbsandmanifoldboltsat35ft-lbs.Headbolttorquesequenceisprettystandardstartingatthecenterandspiralingoutwardinaclockwisepattern.Pro1aluminumcylinderheadsaredesignedtoproduceoptimumperformanceoutoftheboxaccordingtoDart.Thefinishandwallintegrityarearesultofthelatestimprovedcastingtechniques.Bronzeguidesarestandardwithvalvetoguideclearancesetat0.0018-0.0022.TheboysatDarttellusthatthelatesttechnologyinportdesignproducesanascastportthatperformsasifitwerefullyported.CRANKSHAFTAspartofourstrokersetupwereusingaScat383strokercrank.ScatsPN4-350-3750-5700isa4340forgedunitfeaturingarodpindiameterof2.100and2.450mainjournals.Thecrankhasbeenion-nitridedbyScattoincreasestrength.Thiscrankrequirestheuseaofastandard2-piecerearmainseal.PolydyncoatedthecrankcounterweightswiththeirPD-14oil-sheddingcoating.Thiswillallowoiltoslingoffquicklytoreduceparasiticdrag.Grantedthisisntaracemotorbutitsstillnicetoknowthattheoilslinginganddrippingthoughthecrankcasewonthangaroundwhereitisntneeded.CONNECTINGRODSWeselectedforgedH-beamrodsfromScattheirPN2-350-5700-2100.Rodlengthis5.700.Wristpindiameteris0.927.Bigendsaresizedtoaccommodate2.100crankpindiameterwitha0.940bigendwidth.RodboltsareARP716diameterwith12-pointheadsboltsaredimpledateachendtoacceptaboltstretchgauge.Big-endweightis437gramsandsmall-endweightis180grams.Weweighedeachrodandtheweightsweredead-ontoScatspublishedspecs.TherodshavebeentreatedtoPolydynsPD-14oil-sheddingcoating.PISTONSOurforgedaluminumslugsarefromKBPistonsPNKB-7350.030.Thesepistonscombinedwithour64ccheadchambersallowedustoachieveacompressionratioof101.InordertoprovideanaddedmeasureoflubricitytothepistonskirtswesentthepistonstoPolydynforTeflonskirtcoating.Thiseliminatesanypotentialskirt-to-wallscuffingduringcoldstartsandpistontransitionasthepistonmovestoandfromtop-dead-centerduringoperation.Inadditiontoprovidingaslipperyanti-frictionsurfacetheskirtcoatingalsoprovidesadditionaloilretentionontheskirts.Theresnodownsidetoinvestinginthistypeofcoating.BEARINGSRodbearingsareCleviteCB-663H.MainbearingsareCleviteMS-909H.TheDartblockismachinedtoaccept2smallblockChevycambearingsthroughout.GASKETSAllofourgasketsandsealsareVictorReinzproducts.OurheadgasketsareMLS-typePN54256.Wemeasuredfreethicknessat0.075.Welldetailallofthegasketsduringtheassemblystage.CAMSHAFTVALVETRAINWehitthefolksatCompCamsforourbumpy-sticksetup.WeselectedahydraulicrollercamPNCL12-432-8CSXR282HR-10camlifterkit.Camspecsincludeduration0.050of230degreesintakeand288exhaust.LiftisSTREETRODDERBYMIKEMAVRIGIANTheDartLittleMironblockisanaftermarketperformanceversionoftheChevysmallblockbutwithaslewofimprovements.Thickerdecksandthickerwallsallowformorelatitudeintermsofcylinderboresizinganddeckheightmodification.TheoilingsystemisimprovedovertheGMdesignandthelifterboresvalleywillreadilyaccepteitherflattappetorrollerlifters.Cambearingboresarealsoallthesamesizeinsteadofbeingstepped. ThelayeredlookforChevyandFordV-8sengineprofessionalWWW.AERA.ORGEP27 28APRIL-JUNE2013engineprofessionalSTREETRODDERBYMIKEMAVRIGIAN0.510intakeand0.520exhaust.Lobeseparationis110degrees.TherockersareCompsProMagnumforgedsteelrollersPN1302-16.PerCompsadvicewebumpedrockerarmratioupto1.61.Theserockersaccept38studs.InadditionwelluseCompCams3-piecealuminumtimingcoverPN310alongwiththeirCSUltimateadjustabletimingsetPN8100.The3-piececoveralongwiththeadjustabilityatthecamgearallowsquickeasycamtimingchanges.OILPUMPSincethisbuildistargetedatthestreetrodmarketwedecidedtostickwithaconventionalwetsumpoilsystemmoststreetrodsaretightonspacetobeginwithsotheresnotlikelytoberoomforadrysumppump.Besidesastreetmotorsimplydoesntneedtheadvantagesofadrysumpsystem.Ourpumpisahigh-volumeunitfromClevitePN601-1047P55HV.Thisshouldmovethelubethroughthemotorwithjuicetospare.FASTENERSAllofourthreadedconnectorsweresourcedfromARPincludingheadstudsdowntopanandcoverfasteners.PARTSPREPAswithanycustombuildinvolvingavirginaftermarketblockandastrokersetupwevespentabunchoftimepre-fittingmachiningandcheckingclearances.OurDartblockwasboredoversizeandhonedatBobsMachineShoplocatedontheoutskirtsofFostoriaOhioaboutanhoursouthofToledo.BoringwasaccomplishedonBobDiblesrecently-acquiredRottlerF65Amulti-taskingcomputer-controlledmillingmachinewhichiscapableofperformingallblockmachiningtasksexceptforcylinderhoningavailableaccurizingoperationsincludemainboringcamtunnelboringlifterboreaccurizingcylinderboringanddeckmilling.Sincethemachineoperatesviaspecificdimensionalprogrammingnospecialaccurizingfixturesarerequired.Themachineattheoperatorsdiscretioniscapableofmakinganewroundholeorboringaholebyfirstestablishingablueprintaccuratecenterlineforblockcorrections.Itsareallysweetpieceitshouldbewhenyouconsiderthe85000investment.Fortheboringprocedureoncetheblockismountedandindexedontothemachinealocatingbarrunsthroughthecamtunnelusingdedicatedfrontandrearcamborespacersandregisterstheblockwithahighdegreeofaccuracyanelectronicsensorprobeisruntoadeckdowelpinhole.Theultra-sensitiveself-groundingproberunstothefrontrearX-axisinboardandoutboardedgesoftheholeY-axisandthendeterminestheholesexactcenter.Usingthedowelpinholeastheindexingmarkcylinderborecenteristhendeterminedbythemachinesprogramcustomborecenteringisalsopossibleviaoperatorprogramming.Sinceborecenter-to-centerspacingisalreadyintheprogramthemachinecanthenrapidlyboreallfourcylindersononebank.Theblockisthenflippedtolocatetheopposingdeckat90-degreesthemachinere-determinescenterborespacingandtheremainingfourholesarecut.Theentireboringoperationwhichisextremelyprecisetookonlyabout20minutes.Thetopedgesofeachborewerelightlychamferedtoremovetherazor-edgeandtheblockwasthenmovedtotheRottlerhoningmachine.HoningwasaccomplishedonaRottlerHP6Ahoningmachineusingadiamondstonefollowedbyabrushfinishing.APioneerdeckplatewasfirstsecuredtoeachdeckusing80ft-lbsofclampingtorque.Thecylinderswhichwerefirstboredto4.026werehonedoutbyanadditional0.0045toachieveafinalborediameterof4.0305whichcreated0.0035skirtclearance.TheHP6Afeaturesasomewhatautomatedoperationwiththemachinesprocessormonitoringandcontrollingstoneload.Agraphicdisplayindicateshoningloadonthecylinderfromtoptobottomallowingtheoperatortoeasilykeeptrackofcylinderuniformity.Becauseoftheelectronicfeedbacksystemthemachinedwellsinvariousboreheightlocationsaccordingtoloadsensingproducinganextremelyaccurateboreshapefromtoptobottomwithnooperator-inducedvariables.MeasuredPistonDiameter4.0270KBrecommends0.00350.0045clearanceBoredTo4.026diaHonedTo4.0305diahoningremoved0.0045ENGINEBALANCEAsperusualwehadourbalanceworkperformedbyBobFallownerofFallAutomotiveMachineinToledoOhio.ManyofyouprobablyknowBobfromhisyearsasatrainingguruatboththeDanaMachineShopschoolandtheFederalMogulMachineShopschool.Bobnowoperateshisownperformanceraceengineshoplocatedonthenear-east-sideofToledo.WhenitcomestobalancingBobbystheguy.HismachineofchoiceisaHinescomputerbalancer.OURBOBWEIGHTCARDRodBigEnd438.2gInsertrodBearing45.0gTotal483.2gRodsthrow2Total966.4gOil4.00gRotatingWt970.4gRodSmallEnd179.6gPiston497.2gPin133.0gLocks3.8gRings47.8gTotal861.4gRecip.Wt1722.8gBobWeight1831.8gEachHalf915.9gRecipPercentage50RecipFactor861.4gTheScatrodswerealreadysocloseasamatchingsetthatwedidntneedtotouchthem.OurKBforgedpistonswereallwithin0.5gramsbutwekissedthreeofthemtocreateaperfectlymatchingsetjustforgiggles.OurforgedScatsteelcrankPN4-350-3750-5700isinternallybalancedsotherewasnoneedtoincludeadamperorflywheelduringthebalance.Welluseazero-balancedATIdamperandazero-balancedflywheel.Whilethecrankwasveryclosetobalanceoutoftheboxshewasatickheavyatthefrontandrearbyabout0.8ouncesoBobdrilledthefrontandrearweightsformetalremoval.Therewasnoneedtoaddanyheavymetal.CLEARANCESWeinitiallycheckedcrankcounterweight-to-block-wallclearance.Whileeverythingclearedwenoticedonlyabout0.045clearanceontherightsideinfourspotsnotuncommonwhensettingupabuildwithincreasedstrokedistance.Wegroundtheseareasonaslightradiussweeptogainabout0.060clearanceminimum. Whenhoningablockscylinderstoachievethefinalcylinderdiameterandsurfacefinishtheuseofadeckplatealsocalledatorqueplateshouldbeconsideredmandatory.Thisplatewhichisinstalledtotheblockwithausedcrushedheadgaskethelpstosimulatetheinstalledcylinderheads.Thereasonwhentheheadsareinstalledtheblockanyblockexperiencesslightstressesinamyriadofplaneswhichcanresultinboresthatareslightlyoutofroundbarrel-shapedegg-shapedetc.Inordertoachievethemostaccurateandconsistentdiameterthetorqueplateisinstalledtoapplythesestresses.Whenthecylindersarehonedwiththeplatesinplacetheboresarethenoptimizedforactualassembled-enginestatus.WheneveryouhaveablockrestoredALWAYSuseadeckplateoneachdeckduringthehoningprocess.Honinginvolvestheuseofspecifictypesandgradesofstones.Thisfinalizestheborediameter.Oncetheboreshavebeenhonedexactlytothedesireddiameterthecylindersarethenlightlykissedwithspecialabrasiveshoestoachieveaplateaufinish.Thisprovidesamoreuniformsurfacefinishremovingmicroscopicpeaksleftbythehoningprocess.Theresultismoreimmediatepistonringseatingandringsealingduringengineoperation.OurDartblockwasoverboredonaRottlerCNCmachine.Thismachineindexesboththemainjournalcenterandthecamtunnelforhighaccuracy.Whenthecylinderboresaremachinedweknowthatthedesign-intendedborecenterandaxisarebeingfollowed.Thisassuresthatthecylinderboresareperfectlycenteredandin-linewiththeirrespectiverodjournals.engineprofessionalWWW.AERA.ORGEP29 30APRIL-JUNE2013engineprofessionalSTREETRODDERBYMIKEMAVRIGIANWethencheckedwithrodsandpistonsmock-installedonthecrankforrodbigendtoblockclearance.Noproblemssurfacedaswehadabout0.250minimumclearanceatalllocations.Wealsocheckedclearancebetweencrankcounterweightstopistonskirtbottomsagainwithnoproblems.Minimumclearancewasabout0.230.Oneconcernwithanystrokersetupisrodbigendtocamshaftclearance.Withthecrankinstalledalleightrodspistonstest-installedandthecamtimedwerotatedtoverifyclearancebetweentheupperedgesoftherodbigendstothecamshaft.CrankshaftthrustclearanceinourDartblockwithallmainbearingsinstalledandcapstorquedwasahappy0.006.MainbearingclearancewithourCleviteH-seriesMS909Hbearingswascheckedoneachlocationwithaconsistent0.0020.Whenwecheckedrodbearingclearanceswealsofoundaconsistent0.0019oilclearance.CAMBEARINGSTheDartblockismachinedtoaccept2cambearingsthroughouttheblockdoesnotuseOEstep-sizes.Afullsetof2O.D.cambearings3-holegroovedalreadymolycoatedaresuppliedwiththeblock.Itsimportanttonotethatthecamboresintheblockdonotfeaturecircumferentialoilgroovesbutfeatureanoilfeedholeatthe6-oclockpositionineachbearingbore.Asaresultitsimperativetoalignthecambearingoilholeswiththecamboreoilholes.PLUGGINGBLOCKHOLESThefrontoftheblockrequiresthreeNPTplugsattheoilgalleryholes.Attheblockrearthreethreadedholesadjacenttothecamplugmustbeaddressed.Twoholesare38NPTandoneisNPT.Facingtheblockrearthe38NPTholeattheleftisopentoboththemainfeedandthehorizontalliftergalley.Deepinsidethis38NPTholeisasecondNPTlocation.Ifrunningahydraulicrollerliftersetupthisinteriorpassagecanbeleftopennoplugorrestrictorforadequateoilfeed.IfsolidrollerliftersareusedaNPTplugcenter-drilledwitha0.060orificeshouldbeinstalledinthisdeep-insidelocation.Noteifaninteriorliftergalleyplugisinstalledthedrivefacemustbeflushtopreventrestrictingoilflowfromthemainfeedpassage.Pioneeroffersavarietyofpipepluglengthsthatallowadjustingtheplugdepth.PP584is.325longPP625is.333PP567is.375andPP507is.460long.TheOuter38NPTplugisalsoavailableinthreedifferentlengthPP554is.375PP560is.410andPP637is.460long.Againitsimportantthatboththeinteriorplugandtheouter38plugdonotrestricttherearoilfeedpassagethatconnectsthemainoilgalleytotheliftergalley.Donotuseaconventionalrestrictorasthiswillintersectthroughandwillblockthemainoilfeedbeforeitreachesthemainoilgalley.Sincewereusinghydraulicrollerlifterswelefttheinboardpassageopenandsimplyinstalledthe38NPTplugattherearblockexteriorlocation.AtthebottomofeachblocksideisfeaturedaNPTholewaterjacketdrainholes.WeinstalledNPTplugsfemalehexdrive.Adjacenttotheoilfilterbossisacross-drilledholethatmustbepluggedwithaNPTplug.TheholeimmediatelyabovetheoilfilterbosswasalsopluggedwithaNPTplug.AtthetoprearleftoftheblockaNPTplugisrequiredtoplugthetopoftherearoilfeed.ExpansionplugsfreezeplugsareprovidedwiththeDartblock.Thisincludeseight158plugsforblocksidestwopersideaswellasthefrontandrearoftheblock.Inadditiona238rearcamplugisrequired.Weglass-beadedtheexteriorofall158plugsbeforeinstallingthemintotheblocktopromoteprimeradhesion.OILPUMPDRIVESHAFTAccordingtoDartonblockswith400mainsizeyoumustusea400oilpumpshaftwhichhasadiameterof0.425.Ifyoureusinganaftermarketheavy-dutyshaftora350shaftwhichmeasures0.481diameteryoumustmachinethecenteroftheshaftto0.425inordertocleartheholeintheblock.The400mainblocksfeatureaholethatis0.062smallerindiameterascomparedtoa350sothattheshaftholewillnotbreakthroughtotherearmainbore.Besuretocheckdistributor-to-oil-pumpshaftclearancewiththedistributorintakemanifoldandoilpumpinstalledontheblock.ABOVEInpreparationforcrankshaftbalancingallreciprocatingandrotatingpartswerecarefullyweighedandrecordedonthebobweightcard.Hereaconnectingrodsbigendisweighedonanextremelysensitivedigitalscale.RIGHTOncethebobweightshavebeendeterminedthebobweightareassembledandinstalledontothecrankshaftrodpins.Eachbobweightmustbeinstalled90-degreesfromtheadjacentbobweight. engineprofessionalWWW.AERA.ORGEP31 32APRIL-JUNE2013engineprofessionalDRYSUMPIfadrysumpoilingsystemistobeusedyoumustplugtheinletholeontherearmaincaportheinletholeintheblockunderneaththerearmaincap.ThetoprearoftheblockfeaturesaNPTholethatcanserveasathreadedinletfordrysumpfeedtotherearoftheblock.Sinceourbuildwilluseawetsumpsystemwepluggedthishole.Theblockalsofeaturesabossfordrysumpscavenginginthevalleyareawhichmustbedrilledandtappedforvalleyscavenging.Thisblockfeaturesaprioritymainoilsystemwhichmeansthatoilisdirectedtothemainbearingsfirstthentothecambearings.FUELPUMPPUSHRODThefuelpumppushrodboreismachinedtoaccepta0.500diameterrod.Besuretocheckclearanceduetopotentialinconsistenciesofavailablepushrods.WecleanedtheCompCamsrollerstickandliberallyappliedCompscamlubetoalljournalslobesandthedistributorgear.Thecamwascarefullyinsertedusinga5-long516x18boltinthecamnoseasaguidehandle.WithallsaddlesandbearingscleananddryweinstalledtheCleviteupperoilfeedmainbearingsintheblocksaddlesandthelowerbearingsintothemaincaps.Wethenappliedacoatingofultra-stickyRoyalPurpleMax-Tuffassemblylubetotheexposedbearingfaces.OncetheClevitesiliconetwo-piecerearmainsealwasinstalledintheblockandtherearcapweappliedathindabofultrablackRTVtothemaincapchamferandtothecap-to-blockmatingsurfaceadjacenttoeachsideoftherearseal.TheDartmaincapnumber1featurestwo716bolts.Caps23and4are4-boltcapswiththeoutboardboltlocationssplayedusing716boltsatalllocations.Number5capusestwobolts.Allboltheadsarewitheachboltfeaturingahexheadwiththeexceptionofthesplayedboltswhichfeature12-pointheads.The716boltsforcaps1through4aretightenedtoafinalvalueof65ft-lbs.Number5capboltsaretightenedto100ft-lbs.ADJUSTINGCAMSHAFTENDPLAYOurtimingsetistheCompCamsUltimateAdjustableTimingchainsystemPN8100.Thiskitfeaturesafullyadjustablecamsprocketadoublerollerchaincranksprocketaneccentricadjustmenttoolandabuilt-inthrustbearingontherearofthecamsprocket.OurtimingcoverisCompsnew3-piecealuminumsetPN310.Thisrequirestheuseofaveryhandyadjustablecambuttonincludedtopreventexcesscamwalk.Thesteelbuttonisanassembledbearingtypethatrotatesnotasolidbronzebumpstop.Thebuttoninsertsintothecamgearscenterholecontactingthecamnoseandtheinsideofthefronttimingcoverplate.Adjustmentispossiblebyaddingsuppliedspacershimsbetweenthebuttonandthecamnose.Thetimingcoverbaseringisfirstinstalledontotheblockusingthetwosuppliedx20capscrewsprovidedwiththegasketbetweentheblockandbasering.Notethebasegasketsuppliedwiththecoverkitmeasures0.025thickuncompressed.Ifyouuseathickergasketyoulllikelyneedtousemorebuttonshimsforcamwalkadjustment.Nextinstallthecamgearontothecamsnuggingthethreesuppliedtorx-head516x18x78boltsusingaT-45torxbittosecurethecamgeartothecam.InsertthebottonlargerODheadagainstthecamnose.Installthelowercoverplateandfullysnug-it-uptotheblockusingtheflat-topx20screws.Nextinstalltheuppercoverplatefullytighteningallfourboltsthreeflattopsandonebutton-head.Positionamagnetic-basedialindicatorontotheblockfacepositioningtheindicatorplungerthroughthe18NPTaccessholefeaturedinthelowercoverplatetocontacttheplungerontothetiminggearpreloadtheindicatorandzerothegauge.Carefullyusingaflat-bladescrewdriverinsertthescrewdriverthroughalifterboreandmovethecamshaftfullyrearwardwithlighttomoderatepressureandnotethegaugereading.Thenslidethecamfullyforwardandnotethegaugereading.Ifyoufindexcesscamwalkremovetheuppercoverplateremovethecambuttonandinstalloneormoreshimsreassembleandre-check.Duringseveralcheckingstagesweendedupusingthreeshimstocreateastack-upof0.030total0.0160.0070.0.007.Thisresultedin0.003camendplay.CompCamsspecscallfor0.001to0.005endplay.Withthecamandcrankgearsinstalledweusedastraightedgeacrossthegearfacestocheckalignmentandfoundthatwewerewithin0.0005.OncecamendplayhasbeenadjustedSTREETRODDERBYMIKEMAVRIGIANDuringfinalassemblythecamshaftisinstalledfirsteasieraccessforcamshafthandlingtohelpavoidscarringcamshaftbearings.WiththeuppermainbearingsinplaceeachexposedbearingfaceiscoatedwithRoyalPurpleMaxTuffassemblylube. CALL1-800-527-7604www.regismanufacturing.comREGISMFG.1500CorinthStDallasTX75215800-527-7604214-421-5171Fax800-535-8414214-565-1704RequestacopyofournewlyupdatedcatalogfilledwithhundredsofenginebuildingtoolsandsuppliesNEWREGISCATALOGNOWAVAILABLEengineprofessionalWWW.AERA.ORGEP33 34APRIL-JUNE2013engineprofessionalthetimingchaincanbeinstalled.Thecamgearisadjustable6degreesadvanceorretardin2-degreeincrements.Simplyloosenthe12-pointretainingboltsyoullneeda51612-pointsocketinsertthesuppliedeccentricadjustertoolandrotatethetoolthetoolbodyfeaturesaholeforinsertionofarodorscrewdriverforeasyT-handleturning.Lightlytightenallsixretainingbolts.Oneatatimeremovetheboltsapplythreadlockerandreinstalltheboltstighteningtoafinalvalueof13-14ft-lbs.NoteComprecommendsfirstlooseningallrockerarmstoreducespringpressurebeforemakinganycamtimingadjustments.PISTONRINGGAPTheKBforgedpistonsdonotrequireasmuchtopringendgapasdohypereutecticpistonsbutitisnonethelessvitaltofollowKBsrecommendationsfortopringendgapinordertopreventringend-butting.WhileKBlistsaringendgapfactorof0.0065forhypereutecticpistonsforstreetnormally-aspiratedapplicationswithboresupto4.100theirforgedpistonscallforaringendgapfactorof0.004forthesameapplication.Sinceourboresmeasure4.0305weanticipatedtheneedtofile-fitourtopringstoachieveanendgapof0.01650.004x4.03050.016122.OurPerfectCircletopringsinitiallycheckedat0.0165to0.017soweluckedoutwithnoneedtofile.Wefittedoursecondringswithagapof0.020wereusingPerfectCircleringsandtheyrecommendatadgreatergapforthesecondringstoreducepressurebuildupsoinsteadof0.016-0.017weopenedoursupto0.020.Oursecondringsoutoftheboxcheckedatthetightsideat0.011-0.013soallwerefile-fit.Therings116116316wereinstalledwithgapspositionedperPerfectCirclerecommendationsasviewedfromaboveorientingtothefrontofthemotortheoilexpanderringend-butat3-oclockthetopoilrailat7oclockthebottomoilrailat11oclockthesecondringat9oclockandthetopringat3oclock.SPIRALLOCKSOurKBpistonsweresuppliedwithspirallockpinretainerswhichworkgreatbutanyonewhohasmessedwiththistypeofretaineralreadyknowswhatapaintheycanbespreademaparttrytowindtheminwithbloodyfingertipsetc..Forthisassemblyweagreedtotryoutarecentlyintroducedspirallock-intooldesignedandmadebyPrecisionEngineServiceofWaxhawSouthCarolina.Theyactuallyoffertwotools..oneforinstallingspirallocksandoneforwirelocks.Weusedthespirallock-intoolpartnumberS-927.WherehasthisthingbeenallmylifeThistoolactuallymakesthetaskofinstallingspirallockseasyandwellfun.HeresthedealLubethepistonpinandslideitintothepistonandrod.Installthesuppliedtemporaryclipintoonepinboreplacingtheendsoftheclipintothelockgroove.Thiswillholdthepininplaceasyouworkontheoppositeendofthepin.Nextinstallaspirallockontothetool.Thetoolnosefeaturesaprecision-machinedspiralgroove.Simplyspreadoneendofthespirallockopenwithyourfingertipjustenoughtostartthreadingitontothetool.Theneasilywindthelockfullyontothetooluntilthetopendofthelockmeetsthelaser-etchedindexmarkonthetoolnosetheendofthelockwillbepositionedattheverystartofthemachinedgroove.Inserttheloadedtoolintothepinborethesideoppositethetemporaryclipwiththetoolsindexmarkfacingdowntowardstherodbigend.Cockthetooltotherightslightlyandpushthetoolintowardsthepinwithmoderatepressureandstarttorotatethetoolcounterclockwise.Assoonasthelockbeginstoengageintothegrooveyoullfeelitstraightenoutthetoolandcontinuetorotatethetoolcounterclockwisewhileapplyingmoderatepressure.Thespirallockwindsintothegroovewhilepeelingoffofthetoolsspiralthread.GrantedIexperiencedashortlearningcurveonthefirstonebutonceyouobtainafeelforthetechniqueitsabreeze.Seriouslythistoolisreallycooltransforminganormallytedioustaskintoaneasyandquickprocedure.IguessIllhavetofindsomeothernastyjobthatwillallowmetosliceupmyfingers.Itsfairlycommonforspecialtytoolmakerstosendussamplesforevaluation.Someworkasadvertisedandsomedont.Thisspirallockinstallertoolworksgreatandwefeelgoodaboutrecommendingit.Forthoseofyouwhoaremachoenoughtowranglespirallocksinwithyourfingersmaybeyoudontneedthistool.Howeverforthoseofuswhoarentasdexterouswouldliketoavoidmutilatingourpinkiesthistoolisjustwhatthedocordered.Easyisbetter.WithrodsinstalledontoourpistonsweinstalledourPerfectCircle315-STREETRODDERBYMIKEMAVRIGIANConnectingrodboltsmaybetightenedeitherbyapplyingtorquevalueorbytighteningwhilemonitoringboltstretch.Ipreferusingthestretchmethod.Itsmoretimeconsumingbutyoureabletomorepreciselyachievethedesiredamountofboltstretchandresultingclampingload.Howeverevenwhenusingthestretchmethoditswisetoalsodouble-checktorquevalue.Itmayatfirstseemredundantbutthestretchmethodprovidesahigherdegreeofclampingloadaccuracy. 2013ElginIndustries.Allrightsreserved.ElginRanksAmongFastestGrowingSuppliersFEEDYOURENGINESWITHELGINSWORLD-CLASSCAMSHAFTANDVALVETECHNOLOGIESAskaboutourBLACKICESuper-CryogenicTemperingTechnologyElginCamshaftsMusclecarcamswithoriginalgrindsFullHemiLS1coverageRollercamsforFordGMenginesElginValvesStockStandard.015oversizePerformance-Forged21-4Nmaterialwithhardwafertip-Straightundercutdesigns-Standard.100lengths-ChromestemsFEEOURENGINYESWHELGISWOLD-SSengineprofessionalWWW.AERA.ORGEP35 36APRIL-JUNE2013engineprofessional0036.030rings116116316oiled-uptheslugsandcylinderwallsandinstalledtheassemblieswithRoyalPurpleMax-TuffassemblylubecoatingourCleviteCB-663Hrodbearings.RODBOLTTIGHTENINGOurrodsareScatsforgedsteelH-beamunitswithalengthof5.700ScatPN2-350-5700-2100.TheserodsareequippedwithARP8740716rodbolts.WithARPmolyappliedtoboththethreadsandunder-headScatsspeccallsforalimitof0.0052rodboltstretchbearinginmindthatthelimitoftorquevalueis63ft-lbs.Inotherwordsdontfallintothetrapofchasingthelimitofboltstretchalonewhileblindlyignoringthetorquevalue.Scattellsusthatifyouexceedthetorquelimitevenifyouhaventreachedthespecifiedstretchlimittheboltmayberuinedandpossiblysnap.Whileyoucanmonitorstretchandcertainlyusestretchtoachieveclampingitsimperativenottoexceedthe63ft-lbrecommendedmaximumtorque.Notethatduringthecourseoffittingwecycledourrodbolts3timesbeforefinaltightening.TIMINGCOVERWhiletheCompCams3-piecealuminumtimingcoveriswaycooltobeginwiththebaseringisbilletaluminumwhichpolishestoahighlustereasilyweoptedtopainttheentireassemblytocoordinatewithourcolortheme.Thecoverisshippedwithallmountingscrewsneededbutwethoughtthatpolishedstainlesswouldcontrastwellwithourcolorsowegrabbedahandfulofstainlessflattopbuttonheadandcapscrewsallx20andpolishedtheheadsonourbuffingwheel.Thebasemountingringisfirstattachedtotheblockusingaconventionaltimingcovergasketwithtwo14x20x58socketheadscrews.Thebottomcoverplatewhichfeaturesthefrontcranksealissecuredwithfive14x20x1flat-topscrewsandonex20x1button-headwithsealingaccomplishedwithanarrowbeadofRTVbetweenthebottomcoverandtheoutermountingring.Theuppercoverplateeasilyremovableforconvenientcamtimingadjustmentissecuredwiththreeflat-top14x20x1screwsandonex20x1button-headandissealedwithanarrowbeadofRTV.Wealsochangedthehexheadboltsonthewaterpumprearcovertobuttonheadsforaddedpump-to-timingcoverclearance.CompnotesthatastocktimingpointerorequivalentwillfittheircoverOILPUMPANDPICKUPWeinstalledaClevitehigh-volumepumpandMorosopickupPN24350.Thispickupfeaturesa2-boltmountingbracketthatsharestwoofthepumpscoverbolts.Thepumpcoverwasfirstremovedandthegearswerepackedwithassemblylube.Thecoverwasreplacedandsecuredwithtwobolts.Thepickupeasilyboltedtothepumpcoversharingtwocoverbolts.OILPANOncetheMorosokick-outsumppanwaspaintedandclearedweinstalledthepanusingaVictorReinzPNOS32174GRpangasketwhichisspecificallydesignedforusewiththeDartSportsmanblock.Thesiderailsgasketsarecorkrubberandfeaturesteelboltholeinsertstopreventovertightening.SecuringthepantotheblockisanARPpolishedstainlessoilpanstudkitPN434-1901using516x18x516x24stainlesssteelstudsatthefrontandrearcornersalongwithARPX20xx28stainlesssteelstudsbulletnosedalongthesiderailsweappliedadabofRTVatallfourcornersbeforeinstallingthepan.AllstudsarefittedwithSAEfinethreadARPlockingserratedunderheadnuts.NotetheMorosopandoesnottakeadvantageofalloftheblockspanrailboltlocationsusingonlysixstudsandthefourfrontrear516studs.SincetheuniversalMorosodipsticktubesuppliedwiththepancanbebenttoshapetoclearexhaustprimarytubesorexhaustmanifoldweleftthisoffandpluggedthepanstubeholefornowusingaNPTplug.ATIDAMPERINSTALLEDAfterdeterminingthatwehadanacceptableinterferencefitcranksnouttodamperof0.001welightlycoatedthesnoutandthetimingcoversoilseallipwithRoyalPurpleMaxTuffassemblylubeandneatlywalkedthe6chromedATISuperDamperontothesnoutusingourMorosobalancerinstallertoolPN61744.DISTRIBUTORMSDPro-Billetready-to-rundistributorPN8360.MSDsready-to-rundistributorsfeatureabuilt-inignitionmodulethatproducesahighoutputinductivesparksotheresnoneedtoaddaseparateignitioncontrolbox.Asimplethree-wireharnesswithconnectorrunstothecoilandSTREETRODDERBYMIKEMAVRIGIANNotthatthetypicalstreetrodderwillaltercamtiminginanefforttotunetheengineforloworhighendperformancetheadjustmentfeatureoftheCompCamstiminggearallowstweakingifyousodesire.AhandyeccentricinthecamgearassemblyandsuppliedT-handleadjustertoolmakesthisquickwork. engineprofessionalWWW.AERA.ORGEP37TOLLFREE800.648.7970CheckoutthefullselectionofSilv-O-LiteandKBHighPerformancePistonsatwww.uempistons.comCallusoremailusatsalesuempistons.comforapersonalresponseabouthowUEMpistonscanmakeyourbuildssuccessful.ReinforcedtoplandsCoatedskirtsFloatingwristpinswhereapplicableApplicationspecificaluminumalloysDiamondfinishedskirtsPinholeaccurateto-.0001Morethan485OEreplacementpistons.AsNorthAmericaslargestpistonmanufacturerUEMhasyourpiston.OurprocessesandequipmentfeaturethelatesttechnologyforbothOEreplacementandhigh-performancepistonsforeverytypeofengineyouarebuilding.Wehavebeenmanufacturingaftermarketpistonsforautomotivelighttruckpopularimportandheavydutyapplicationssince1922.390HypereutecticalloyFullymachinedcrownsandvalvereliefsDrilledoildrainbacksFullfloatingwristpinsTriplewoundspirallocksOver190differentoversizepartnumbersReflectivealloyallows2powerincreaseApplicationsavailablewith564thand116thringpacks.VastassortmentofcompressionratiosavailableindishflattopanddomestylesQuenchdometechnologyminimizesdeteriorationZerodeckquenchdesignsLightweightwristpinsavailableinmostapplicationsAllpartnumbersavailableinkitswithringsKBHighPerformancePistonsSilv-O-LiteOEReplacementPistonsBOTHICONSERIESFEATUREOver100applicationsontheshelfOver360differentpartnumberoversizesAvailableinkitswithringsICONFHRForgedHeadReliefPISTONSPremium4032alloySecondlandaccumulatorgroovesToplandminigroovetechnologyDiamondfinishedskirtsTriplewoundspirallocksSpacerringsincludedinshortcompressionheightsthatintersectthewristpinboreICONPREMIUMFORGEDPISTONSPremiumHighductility2618alloyNitrousTurbo-ChargedandSuper-ChargedAppsDualforcedpinoilingonmostapplicationsLateralgasportingonhighercompressionratiosFullymachinedwithdeepvalvepocketsSecondlandaccumulatorgroovesToplandminigroovetechnologyDiamondfinishedskirtsTriplewoundspirallocksSpacerringsincludedinshortcompressionheightsthatintersectthewristpinbore 38APRIL-JUNE2013engineprofessionalSTREETRODDERBYMIKEMAVRIGIANground.Thesefeaturesmaketheready-to-runmodelidealforstreetrodapplicationswherespaceisoftenatapremium.Vacuumadvanceisprovidedtosuitthemajorityofstreetrodsthatarestreet-drivenandareequippedwithautomatictransmissions.Alsothesimplicityoftheelectricalconnectionswillappealtoeventhenovicerodder.OtherfeaturesofthisdistributorworthyofnoteincludearotorthatismoldedofDupontRynitewiththickvanestopreventionizationandsparkscatteraselectionofadvancespringsandstopbushingstomakecustomtimingcurvedial-ineasyhighoutputmagneticpickupandprecisionreluctorsealedballbearingandextra-longsinteredbushingforhighRPMstabilitypolishedsteellow-frictionshaftandapreciseCNC-machinedhousingcutfrom6061-T6aluminum.CYLINDERHEADSEventhoughourDartPro-1aluminumheadsweredarnedprettyoutoftheboxwewantedtocarrythecolorthemefurthersowedisassembledtheheadsspentaboutadayandahalfsmoothingouttheexteriorfinishthenprimedpaintedandclearcoatedthealuminumheadstoachieveaglass-likefinish.Afterallowingtheclearcoattocurefortwodayswereassembledtheheadstakingcaretomatchallvalvesandspringstotheiroriginallocations.Beforewefinal-installedourheadsweclayedthepistonsandcheckedpistontovalveclearance.UsingCompCamsMagnum516pushrodsat7.300lengthandCompsMagnum1.61rockersandwithnoheadgasketinplaceweobserved0.200intakeclearanceand0.240exhaustvalveclearancewhichwasmorethanadequate.Naturallyoncewefactor-inourcrushedgasketclearanceitsobviousthatwewonthaveanycontactconcerns.OurheadgasketsareMLSunitsfromVictorReinzPN54256.WhiletheARPcylinderheadboltsandwashersalreadyfeaturewhatappearstobeablackphosphatecoatingalreadyanexcellentsurfaceprotectantforourexposedheadbolts8perheadwewantedaslightlyglossiershadeofblack.WeturnedtoShawnRitchieatMedinaPlatingwhostrippedtheexistingcoatingandappliedtheirthinandtoughzincironplatingwithblackchromate.Wehadwantedtocolor-codetheexposedboltheadstomatchtheheadsblockbutthiswassimplyimpracticalunlesswesprayedtheblockandheadsasafinish-installedassembly.Wedidntwanttotakethatapproachforanumberofreasonsitwouldbedifficulttoobtainfullpaintcoveragearoundtheboltheadsandtheheadareabehindtheboltheadsandbysquirtingtheurethaneclearoverthehead-to-blockpartinglinetheresalwaysthechancefordown-the-roadclearcoatfractureasthealloyheadsexpandandcontractinrelationtotheironblock.Bypaintingeverythingseparatelyweobtainedacleandetail-orientedresult.OurARPheadboltsfeature12-pointheadsPN134-3701.WetightenedallboltswithARPmolylubeto60ft-lbs.theseboltsfeatureatensilestrengthof170000psi.NoteARPrecommendstightening716headboltstoavalueof65ft-lbswARPmolyassemblylubewhenusingironheads.WithaluminumheadsduetotheheatexpansionrateofaluminumARPrecommendstighteningboltstoavalueof60ft-lbswARPmolyassemblylube.AccordingtoARPtorquevaluesarebasedon75ofthefastenersyieldstrength.Theyrecommendusingtheenginemanufacturerstighteningsequencebutnotthemanufacturerstorquespecs.OncetheheadswereclampedinplaceweinstalledCompCams38rockerstudsalongwithCompCamspushrodguideplatesPN4808perDartthesespecificguideplatesaremandatory.Wetorquedtherockerstudsto45ft-lbs.accordingtoDartsspecs.Notethatateachmountingbosslocationonerockerstudthreadedholeisblindwhiletheadjacentholeisopentowater.WeappliedTeflonthreadsealanttoallrockerstudthreadsbeforescrewingthemintotheheads.BythewayDarthadthepresenceofmindtoprovideadditionalthreadedholesinthecenteroftheheadallowingtheinstallertochooseeitherconventional4-boltvalvecoversorlater-modelcenter-boltvalvecovers.Thatsanicetouch.OurliftersarefromCompCamstheirCSRetrohydraulicrollerliftersPN853-16.Thesearebridgedtogetherinpairstomaintainroller-to-camlobealignment.CompletingthevalvetrainassemblyareCompCams516x7.300MagnumpushrodsPN7609-16andCompCamsProMagnumsteelrollerrockers1.61ratioPN1302-16.WelubedthelifterborespushrodsrockersandvalvetipswithRoyalPurpleMaxTuffsyntheticassemblylube.OurDartPro1aluminumcylinderheadsweretruebolt-ons.Ididntneedtomakeanycorrectionsatallnoportmatchingnochamberworketc..TheseheadsflowliketheywereCNCdandthecombustionchambersallmeasuredatexactlythesamevolume. engineprofessionalWWW.AERA.ORGEP39PROUDTOSERVETHEENGINEREBUILDINGINDUSTRYSINCE1946WatchourTECH-TIPvideosonOILPUMPSOILPUMPSCREENSTIMINGSETSCAMSHAFTSVALVETRAINFREEZEPLUGSSLEEVESfacebook.commellingenginepartsSTOCKINYOURSHOPMELLING-2620SARADANDRIVEJACKSONMICHIGAN49202-517.787.8172-FAX517-787-5304-WWW.MELLING.COMtwitter.commellingpartsyoutube.commellingenginepartsNEEINEEUDIENIUYRIND1YOURSHOPSTOCKIRSCREENPSCREENFFRREZEZEfacebook.commellingengineparWatchourTECH-TIPvideosontsfacebook.commellingengineparWatchourTECH-TIPvideosonfacebook.commellingenginepar20SARADANG-26LLINMEcommeltwtttsfacebook.commellingengineparMICHIGANSONDRIVEJACK20SARADANts.commellingparyoutube.commellingenginepar17.787.8172-F202-549MICHIGANyoutube.commellingenginepar-WWW17-787-5304X52-Ftsyoutube.commellingengineparG.COMLLIN.ME-WWW 40APRIL-JUNE2013engineprofessionalSTREETRODDERBYMIKEMAVRIGIANTHECUSTOMFEATURESOURBLOCKEXTERIORPREPHereswherethecustomaspectbegins.Sinceourgoalwastocustom-painttheblockexteriorwewantedtosmooththeexteriorcastingsurfaces.InitiallywehadplannedtoaccomplishthisonaCNCmillingmachinebuttwofactorscausedachangeinplans.Acustomprogramwasbeingwrittenbyamachinemakerandwasntdoneintimeforourdeadline.Secondlytheprogramwouldnothaveaddressedthesmallnooksandcranniesattheoilfilterbossarea.Asaresultweoptedtogrindtheblockbyhandusingpneumaticgrindersandatonofabrasives.Thisinvolvedaminibeltsanderusing38x13abrasivebeltsingritsrangingfrom50to320andstraightandright-anglediegrindersusinghookloop-attachedScotchbritepadsandRolocScotchbritepads.After4daysofgrindingweatethroughabout150worthofabrasivematerials.Thehookloopstyleisalousychoicesinceafterprolongedusethehook-faceddriveroverheatsreducingtheabilitytoretaintheabrasivepadspadskeepslingingoff.Stickwiththethread-onRoloc-style.GrantedtheDartcastingwasalreadyaverycleanpiecethatwillproperlyacceptpaintbutwewantedtogofurthermostlybecauseweresoanalbyeliminatingallridgesandminimizingthecastsurfacetexture.Oncethegrindingwascompletedwewashedtheblockthoroughlyinajet-wash..Wethenwipedtheexteriorsurfacewithlacquerthinnerblewtheblockdryandcarefullymaskedtheblocktoleaveexposedonlythoseareaswherewewantedpaint.Wethensprayed2coatsofheavy-buildupValsparDTM2004Ddirect-to-metalprimermixedwithValspar2000activatorthisetchedintotheironandfilled-insmallsurfaceirregularities.Wethensandedthisprimerusing3Msuper-finesandingsponge-clothstosmoothouttheprimersorangepeeltexturetheprimerlaysdownverythick.Sincewedidntwantanyexposedbaremetalaroundtheheaddecksthoseareasexposedevenwithgasketsandheadsinstalledwefirstmaskedofftheentiredecksurfaceinpreparationoflayingourheavybuild-upprimer.Wethenpositionedourheadgasketsandscribedapencillinearoundtheoutergasketedges.Wethenremovedthegasketsandusingarazorwecutthemaskingtapeabout116inboardofthescribedlines.Ontheseareaswelaidathincoatofself-etchingprimer.Thisensuresthatthepaintwillslightlytuckundertheoutergasketedgesforacleanappearancewhileavoidingathickridgelinethatwouldotherwisebecreatedwiththeheavyprimerthatmightinterferewiththeheadgasketsealing.Forour3-piecealuminumtimingcoverassemblyfromCompCamswefullypolishedthebaseplatethatwillbolttotheblockthisisaCNC-machinedbilletpiece.Thetwocoverplatesupperandlowerwerepaintedtomatchourblockcolor.Insteadofusingtheblack-oxidecoatedflat-topbutton-headandcapscrewfastenersthatweresuppliedwiththecoverwellsubstitutepolishedstainlesssteelfasteners.Oncewepickedaprimarycolorwelaidtwocoatsofcolorbasecoatfollowedbytwocoatsofurethanecleartopcoat.Againattheexposeddeckedgeareaswekepttheclearcoatlayersataminimum.BLOCKCUSTOMPAINTAfterthumbingthroughdozensofpaintchipbooksIfinallysettledonwhatwethinkisareallysnazzycolor.Thisisafine-metallicbasecoatclearcoatlightroseactuallyValsparcolorPN5170-06butin-housewevehumorouslydubbedthiscolorasFrenchWhoreFrostedLipstickRose.PoliticallycorrectProbablynotbutthenagainnobodyeveraccusedusofcaringaboutpoliticalorsocialcorrectness.Whileourcolorofchoicemaynotbeeverybodyscupofteawethinkitpops.Whetheryoulovethiscolororhateititsnonethelessanexampleofanout-of-the-ordinaryhuethattypifiesthecustomapproachthatmanystreetroddersprefer.Andafterallthatstheintentofthisprojecttoproduceanexampleofhowyoucanaestheticallytreatanenginetoobtainaspecificappearancetheme.WeperformedthefinalprepontheblockheadsoilpantimingcoveroilfilterfuelpumpadapterplateandvalvecoverswithValspardirect-to-metalurethaneetchingprimerthenwet-sandedallofthepiecesforababy-butt-smoothfinalsurface.WethenappliedourFWFLRbasecoatcolorinthreelightcoatapplicationsexecutingaflawlessandevendistributionoftheultra-finemetalflake.WethenappliedtwocoatsofValsparurethaneclearallowinga15-minutewait-timebetweencoats.Theresultisspectacular.Themotorlookslikeitscoatedwithwetglass.InordertocreateacoordinatedappearanceallaluminumpiecesincludingvalvecoverbreatherJonesRacingpulleydrivesANtubenutssleevesNPTfittingsetc.werecustomanodizedinadarkvioletcolorthattastefullycontrastswithourprimaryblockcolor.INTAKEMANIFOLDWhileIhadoriginallyplannedtouseapolishedaluminumintakemanifoldthatwewouldpainttomatchtheblockandheadsIwastalkedintousingEdelbrocksPerformerEPSdualplanemanifoldPN27012whichfeaturestheirPermastarfinish.Thisisaspecializedcoatingthatlookslikechromebutisnotachievedbyaplatingprocess.Ourcontentionwasthat1Edelbrockwantstopushthismanifoldtothestreetrodmarketand2thereflectivefinishwouldpickupthesurroundingcolorfromthevalvecoversandtheundersideoftheaircleanerhousings.IfIhadthingstodooverIwouldhavechosenanuncoatedmanifoldandpainteditblockcolor.InordertosealtheportsidesoftheintakemanifoldwechoseVictorReinzintakemanifoldgasketPNMS15315forthisheadandmanifoldcomboyoullneedintakegasketportsthatareabout1.28widex2.00high.InsteadofusingfrontandrearrubberblockrailsealsweappliedbeadofRTVPermatexTheRightStufftobothfrontandrearblockrails.PriortolayingtheRTVwepulledourtriedtruetrickoffirstapplyingbodyshopmaskingtapetothefrontandrearedgesofthemanifoldandblockwiththetapeflushtothepartinglines.OncethemanifoldisfullytorquedthisallowsyoutowipeanyoutsideexcessRTVusingawetfingertip.ThisprovidesacleanandneatexteriorRTVfinishwhileeliminatingRTVfromsmudgingontothemanifoldorblock.OncetheRTVhasbeenflowedthemaskingtapeisremoved.ARPstainless12-pointintakemanifoldboltsPN434-2101weretightenedto35ft-lbsaccordingtoDartspecificationsfortheirPro-1cylinderhead.NotemanifoldboltholesareopentooilsoweappliedTeflonthreadsealanttoallintakeboltthreads.ForfuelairfeedIgrabbedaHolley7504150carbfromourstockshelfdisassembleditandbasecoatclearedthemainbodyandbowlstomatchourFWFLcolorscheme.Inordertoprovidethemeteringblockswithananodizedlooktomatchourdarkvioletaluminumpieceswemixedpainttomatchandsprayedtheblocks.FeedingfromourCVProductsaluminumfuelpumpwe engineprofessionalWWW.AERA.ORGEP41AlthoughDartsblocksfeatureaverynicecastsurfaceexteriortobeginwithmuchbetterthanaGMfactoryblockforthisbuildIwantedaglass-likepaintfinishsoIspentmanyhourssmoothingtheentireexteriorsurfaceareapolishingouteverynookcranny.Thisisverylabor-intensivesoifyouchoosetodothispreparethecustomerfortheaddedlaborcost.AfterapplyingValsparsdirect-to-metaletchinghigh-buildprimertheprimedsurfaceswerelightlywet-sandedtoremoveanydustimperfectionsthencarefullycleaned.Thecolorbasecoatwasthenapplied.Notethattheblocksexpansionplugswerealreadyinplacetoallowtheplugedgestoblendintothecasting.Heresasimpletrickforinstallinganyintakemanifold.Sincerubberorcorkendsealsareoftenasourceofleaksmanybuildersprefertouseahigh-solidsRTVinstead.InordertoavoidmakinganunsightlymesswherethesealantoozesoutfromthematingareaIfirstapplybodymaskingtapetoboththemanifoldlipandtheblock.AfterinstallingthemanifoldandfullytorquingthemanifoldboltstospecIthencarefullywipeanyexcesssiliconefromthematingarea.Theremovedsiliconecontactsthetapeinsteadofthecomponentsurfaces. 42APRIL-JUNE2013engineprofessionalSTREETRODDERBYMIKEMAVRIGIANplumbedtheto-carblineusing38aluminumtubingthatweformedandflaredusingAeroquip6tubeferrulesandnuts.Atthecarbfeedthefuellineentersa6T-fittingwiththetopfittingfeedingofftothefrontbowlanda90-degree6fittingtofeedtherearbowl.Apairof78x20to6bowlfittingsareinstalledatthebowls.Allofthe6AeroquipfuellinefittingsferrulesandnutswereanodizedindarkvioletbyMetfinAnodizinginPennsyvlania.PAINTINGTIPIfyoudecidetoapplyabasecoatclearcoatfinishtoanintakemanifoldorcylinderheadsbeawarethattheclearcoatwillcreateathicksurfaceontopofthecomponent.Atcriticalboltholelocationssuchastheouterheadboltholesandalloftheintakemanifoldboltholesasyoutightentheboltswasherstheclearcoatwillcompressandbulgeoutaroundtheperimeterofthewashers.Ifthewashersrotateduringtighteningtheclearcoatmayalsotwistandpossiblytear.Toavoidthisinstallthecorrectwasherstheexactsizeofwasherthatwillbeusedduringfinalinstallationalongwithspareboltstoholdthewashersinplace.Thenapplytheprimercolorbasecoatandclearcoats.Oncetheclearhastacked-offanddriedtothetouchcarefullyremovetheboltsandwashers.Thiswillprovideacleanmetalbaseforthefootprintofthefinalwashersprovidingproperclampingwithoutdamagingtheclearcoat.Alsosincethesamesizewashersareusedinbothpaintingandfinalinstallationcolorwillmeetthewasheredgeswithnounpaintedsurfacerevealed.CUSTOM-COLORANODIZINGAbatchofpartswerecustom-anodizedatthesametime.ThisincludedallofourNPTplugsapairofbilletaluminumvalvecoverbreathersallofourAeroquipfuellinefittingsthe6ferrulesandtubenutsthatweusedtomakeoursparkplugtubesaJonesRacingthermostatblock-offplateasetofJonesRacingexhaustportblock-offplatesandourJonesRacingradius-toothcogdrivewaterpumpandcrankpulleys.Thechallengewefacedwithregardtocustomanodizinginvolvedobtainingexactlythecolorwewantedthatwouldcoordinatewithourlavenderenginecolor.DuringthesearchwesentsamplestothreedifferentanodizersMetfinFortWayneAnodizingandMcNicholsPolishingAnodizingtryingtofindexactlytherightvioletcolorthatourschemedemanded.Whileallofoursampleswereofhighqualityandlookedreallycoolmostweretoopurpleandwouldclashwithouralready-selectedpaintcolor.WeluckedoutatMetfinananodizingshopinNorthWalesPennsylvaniawhoprovidedjusttherighthueforourneeds.Hadwefirstchosentheanodizecolorfromanyoftheothershopswecouldhavethenpickedanenginecolortocoordinatewiththeanodizedcolor.AIRCLEANEROuroriginalintentwastoobtainanenginecoverthatwouldnotonlyencapsulatethecarbbutthatwouldcoverthedistributoraswellweweretryingtoobtainasansappearancethatmanyoftodaysrodderslike.Justaswehaddecidedtofabricateacustomcoverwestumbledacrossaverycooldual-quadaircleanersetupfromKNEngineering.WithintheirCustom66Serieswefoundastunningly-executedretro-stylesystemthatfeaturesthickaluminumlowerbasesandupperlids.Thealloypiecesareextremelywell-polishedtoachrome-likefinishsomeofthefinestaluminumpolishingIveeverseenwhichInaturallyscuffedinourglassbeadcabinetinordertoprepforpaintwork.ThisisavailableasafrontcarbrearcarbsetunderPN66-5080.TheaircleanersarealsoofferedseparatelythefrontarrowunitisPN66-5080FandtherearovalunitisPN66-5080R.Actuallydesignedasadual-quadsetupwechosethissysteminordertoachieveourdesignideawhichwastocreateadistributorcoverintowhichoursparkplugwireswouldpass.Thefrontaircleaneranarrowheadorflying-VguitarshapewithaconcaveVattherearcoversourcarb.Therearaircleanerasmallersomewhatovalshapewithaconvexfrontedgethatmatchestheanglesoftheforwardhousingsrearfaceistheonethatwemodified.Sinceusingtheexistingcarb-holeinthebottomtraywouldpositiontheassemblyfartoorearwardwhenmountedtoourdistributorwecutanewholeusinga5diameterholesawinordertorelocatethetrayasfarforwardaspossible.Wethenmadeacrescent-shapedfillerplatetocovertheremainingarealeft-overfromtheoriginalhole.Inordertomounttherearaircleanerweneededtofabricateamountingadapterthatwouldpermitattachingtheaircleanerbasetothedistributor.Wegrabbedalengthof4.955O.D.aluminumtubingthatfeatureda0.100wallthickness.Afterpainstakinglymeasuringforpropermountingheightwecutthetubetoalengthof5.0.Wethenusedourlathetostep-cutthebottomofthetubeinsidediametertoprovideazero-clearancefitovertheMSDdistributorsbilletbase.Takingadvantageofthethreesmallbossesthatappearonthedistributorsbilletbasewedrilledthreeholesinboththetubesanddistributorbasebossestappingtheholestoaccommodate8x32stainlessbutton-headscrews.Sincethedistributornaturallymountsatananglerelativetothecrankcenterlineandblockdecksweagainpainstakinglytailor-fittherearaircleanerlowerplateoverourcustomaluminumdrop-tubeinordertoachieveafitthatpositionstherearaircleanerinacenteredleft-to-rightlocationrelativetothefrontaircleanerandthatplacestherearaircleanerlevelinbothXandYaxisrelativetothefrontaircleaner.Therearaircleanerlowertrayissecuredtothedistributordroptubeviaaseriesof8x32setscrews.Asyoumightimaginethiswasalongandverytediousprocess.Howeverwefeelthattheendresultwasworththeaggravation.Thealignmentfitisperfect.Oncetherearaircleanermountingfabricationwasaccomplishedwethenturnedourattentiontomountingourcustomsparkplugtubes.Ourtreatmentofthesparkplugwireroutingisoneofthemostcustomaspectsofthisproject.Ourideaagainistoaddressthecleanappearancethatsomanystreetroddersprefertodaywastorunallplugwiresinsidepolishedtubinginauniqueflowpatternterminatingintotherearaircleanerbase.Inordertosecureoursparkplugtubepass-throughontherearaircleanerassemblyslowertraywedrilledaseriesofeightholesspaced1.125aparton-centeraboutaninchinboardfromtheouteredge.Westartedwith116pilotholestoobtaindecentpositionthendrilledtheseopento716andtappedeachholetoNPT.EachholethenreceivesanAeroquip6ANtoNPTmale-to-malefitting.Thisprovidestheattachmentforeachofour38ODaluminumsparkplugwiretubesthatwethenflaredusinga37-degreeflaringtooltomatchtheAeroquipANfittingsandequippedwithAeroquiptubenutsandferrulesSPARKPLUGWIREROUTINGSinceIwantedtoprovideauniqueexampleofwhatspossiblethroughouttheaestheticportionofthebuildIdecidedtoroutetheplugwiresin38polishedaluminumtubing.Actuallythetubing engineprofessionalWWW.AERA.ORGEP43WhencreatingthefakedualquadlookwithourKNaluminumaircleanersystemIfirstmountedthefrontaircleanertothecarb.Thisdictatedthelocationandanglefortherearsection.ToprovideamountinglocationfortherearsectionIinstalledanaluminumtubeoverthedistributor.Theanglebarsseenheresimplyservedasplanereferenceduringdesignandfitting.Sincethecarbisatthetypicaloff-centerfore-aftangledictatedbythemanifoldandthedistributorlocationfeaturesalateralangleestablishingtherearaircleanerbaselocationwascriticalandtimeconsuming.Ifcenterlineoreitherangleforeaftorlateralwastheleastbitoffthetwoaircleanerlidswouldneveralignandtheresultwouldlookterrible.Atthispointthefabricationandfittingwasdone.Hereweperformafinalchecktoverifyfitbeforepaintingtheaircleanerlidsandbases.Heresthefinishedproduct.Thetwoaircleanersareperfectlyalignedandin-planeandthegapbetweenthefrontandrearisexactlyuniform.AfterpaintingandcustomengravingbyArtCarltonatInnovatorsWestthevalvecoverswerenaileddownwithARPstainlessfasteners.Notewheneverinstallingvalvecoverssteeloralloyitsbesttouseaninch-poundtorquewrenchtoachieveevenclamping.Alotofvalvecoveroilleakissuescanbeavoidedbysimplytakingafewextraminutes.WhenusingfastenersIusuallytightenvalvecoverfastenerstoabout50to60in-lbdependingonwhattypeofgasketisused.DependingonthestyleofgasketanddesignofthevalvecovergasketlipItendtolightlyadherethegaskettothevalvecoverwithUltrablackgrayorcopperRTVwithnoadhesiveontheheadside.Thismakesiteasytoperformfuturevalvecoverservicingwithouttheneedtoscrapegasketmaterialfromtheheads. 44APRIL-JUNE2013engineprofessionalSTREETRODDERBYMIKEMAVRIGIANworkinvolvednotonlytheplugwireroutingbutfuellineandPCVlineaswell.Thisinvolvedover11hoursoftediousmeasuringbendingflaringandpolishingwork.Nocomputerbenderswereusedhere.itwasalldonebyhandandeyewiththehelpofa35Rigidhand-heldmandrel-typetubingbender.Eachtubeclimbsupwardfromthesparkpluglocationstocompletelyavoidanyfutureexhaustheaderplacement.Eachsidessetoffourtubesmergeandflowinparallelhorizontallytowardstherearoftheheadswheretheysweepuptotherearaircleanerbase.Alsowhenviewedfromthefrontorrearyoucanseethateachsetoftubesarestep-stackedcreatinganarrowersideprofilefromthebottomtubetothetoptube.Onceallofthetubeswerefabricatedwepolishedthemonourbuffingwheelfirstsandingwith2000-gritwetpaperthenbuffingwithredrougethenwithwhiterouge.ThetubesAeroquip6barrelnutsandferruleswerethensentouttoMetfinforcustomanodizinginourdarkvioletsecondarycolor.Oncetheanodizedpiecesreturnedweassembledbyfirstslippingferrulesandbarrelnutsoverthetubesallthewayuptotheflaredendsthatwillseatagainstthe6fittingsattherearaircleaner.WetheninstalledMSD90-degreesparkplugbootsonto7mmsuppressorwire.Ferrulesandbarrelnutsweretheninstalledagainsttheplugbootends.Thewireswerethenlightlycoatedwithlithiumlubeandpushedthroughthealready-benttubing.Thelowerbarrelnutsseatagainsttheplugbootsferrulesareepoxiedinplaceonthetubes.Theupperbarrelnutssecurethetubingattherearaircleanerbottomtray.TheplugwiresentertheinsideoftherearaircleanerwheretheyconnecttotheMSDdistributorcapwithshortstraightboots.Alotofmind-numbingworkYep.WasitworththeeffortItdependsonyourtaste.Wethinkitswaycool.Itsnotapracticalsetuplotsofdisassemblyworkwouldbeinvolvedtoservicethewiresbutforcertainstreetrodapplicationsthisisntreallyanissueaslongastheworkisperformedcorrectlyfromthestart.WATERPUMPAtonepointwhenwewerepersuadedtousethePermastarchrome-like-finishedEdelbrockintakemanifoldwealsoobtainedanEdelbrockVictorPermastar-finishedaluminumwaterpumpshortstylePN88102.Aftersomedebatehereinourshopwechangedourmindsanddecidedthatinthiscasethewaterpumpshouldbepaintedtomatchtheblock.AsaresultweswappedoutthePermastarpumpforapolishedaluminumpumpEdelbrockVictorPN8820.Wethenscuffedprimedcoloredandclearedthispreviouslyuncoatedwaterpump.Thisisashortpumpfeaturinga58shaftanddesignedforstandardclockwiserotation.ThepumpwassecuredusingARPstainless12-pointwaterpumpboltkitPN430-3201.Priortofinalinstallationwealsotrimmedtheexcesswaterpumpgasketmaterialthatwouldotherwiseremainexposed.Againourintentwastoprovideahighlevelofdetailthatsomanyroddersexpect.Aswenotedearlierweremovedtheoriginalhex-headboltsfromthewaterpumprearcoverandinstalledlower-profilex20x38polishedstainlessbutton-heads.Eventhoughthehexheadboltsdidinfactclearthetimingcoverjustbarelywethoughtitwasanicetouchtogowiththebuttonheadsbothforaddedclearanceincasethewaterpumpeverneedstobetightenedfurtherdowntheroadandforacleanerappearance.InhindsightIshouldhavestucktomygunsandobtainedapolishedintakemanifold.Myoriginalplanwastomillthefrontlipofthemanifoldbacktoconformtotheblockeliminatinganymanifoldedgeoverhangradius-rollthefrontedgeofthemanifoldandpainttheintakemanifoldusingtheblockcolor.BELTDRIVEInsteadofgoingwithacommonV-beltorserpentinesetupweoptedforaway-coolradius-toothcogdriveradius-toothsystemfromJonesRacing.Thisconsistsofanaluminumwaterpumppulleyandamulti-piececrankpulley.ThecrankpulleysetupfeaturesanaluminummandrelthatJusttoaddadifferentelementtotheenginedesign38I.D.aluminumtubingwasusedtocoverthesparkplugwires.Theuseof7mmsiliconewirewasidealsinceitcouldbesnakedthroughthetubing. engineprofessionalWWW.AERA.ORGEP45ThebilletCVfuelpumpwasalsoplumbedusing38aluminumtubingandviolet-anodizedhoseendandfittings.EventhoughnobodywilleverseeitoncethetransmissionisinstalledtheFidanzaaluminumflywheelwasalsocolorcodedyeahIknowbutIjustcouldntresist.Istartedwithanalready-polishedEdelbrockaluminumwaterpumpandsimplyscuffedthesurfacestoacceptthedirect-to-metalprimerandpaintsystem.Thetoothedbeltdriveshownherewithonlythewaterpumpdrivenasanexamplealongerbeltwouldapplyonceanyaccessoriesareaddedprovidesapositivedriveforthewaterpumppulleywithoutapplyinganystrainonthepumpshaft. 46APRIL-JUNE2013engineprofessionalSTREETRODDERBYMIKEMAVRIGIANChooseHighPerformanceProductsfromGOODSONaspartofyourwinningstrategy1-800-533-8010www.goodson.comtwitter.comGoodsonToolsfacebook.comGoodsonToolsAndSupplies3-DFastCutToolingHyper-FinishGuideHonePistolGripVacuumTesterPneumaticSpringCompressorFullycompatiblewithmostpopular3-anglecuttingsystemsSizeguidesfrom3.9to14.4mmPullsholdsupto24PSIvacuumVacuumreliefvalveHandlesspringsupto1500lbs.at90PSIFREEFreightwithpurchaseofoneoftheseitemsMentionCodePEP2ExpiresJune292013keysontothecrankthemandrelisadjustableviaaluminumringspacerstoachieveproperbeltalignmentandfeaturesalargehexforcrankrotationduringengineassembly.Thecogpulleyalsofeaturestwoaluminumbeltguidesonefrontandonereartoretainthetoothedbelt.Wehadthemandrelspacerringsthetoothedcrankpulleyandthewaterpumppulleycustom-anodizedindarkvioletbutleftthecrankpulleybeltguidesinnaturalaluminum.InordertodressthenoseofthewaterpumppulleyImachinedanosecoveronourlathestartingwithachunkof3-diameterx1aluminumfinishingthisdowntoanO.D.of2.665andanoverallthicknessof0.635.Thenosefacefeaturesa1.240-diameterflatfaceatthecentersweepingbackwitha0.635chamferangleleavingabasethicknesswhereitmatestothepulleyof0.250.InordertomountthenosecoverIdrilledfourholesinthechamferareaat1.750on-centerapartwithallholescountersunktoaccommodate6x32stainlesshexcapscrews.Thefour6x32screwsthreadintoa0.125-thickspacerbetweenthepulleyandthepumpflange.OncethenosecoverwasmadeIthengaveitaquickpolishonourbuffingwheel.JonesRacingoffersahugeselectionofextremelyhigh-qualityprecisionpulleysystemsprimarilyforraceenginesbutstreetmotorscanbeaccommodatedaswellVserpentineradius-toothandsquare-toothGilmerstyles.Fornowweoptedtosimplydrivethewaterpump.DowntheroadwhenaccessoriesareaddedsuchasanalternatorACcompressoretc.thesecanbelow-mountedtoavoidcoveringtheheadswithonlytheadditionofalongerbeltrequired.OurlightweightFidanzaaluminumflywheelPN198681isathingofbeauty.Whilethismotormaybeboltedtoanautomaticatsomepointfornowwedecidedtoprepitforusewithamanual4-speed.WecinchedthisdownusingARPflywheelboltstightenedto62ft-lbswithARPmoly.Foraddedpizzazwesenttheflat-topvalvecoversouttoInnovatorsWestforCNClogoengravingwiththeengravingscolored-intomatchouranodizedaccents.Finishinganyprojectisalwayssatisfyingandthisdealsnoexception.Wethinkitturnedoutfairlywell.Whilethecolorandorsomeofthecustomtouchesmaynotbeeveryonescupofteawemetourobjectivetoprovideafewcreativeideasthatcantranslateintofulfillingtheneedsofthecustomrodbuilder.IMikeMavrigianhaswrittenthousandsoftechnicalarticlesoverthepast30yearsforavarietyofautomotivepublications.InadditionMikehaswrittenmanybooksforHPBooks.ContacthimatBirchwoodAutomotiveGroupCrestonOH.Call330435-6347ore-mailmikebirchwoodautomotive.com.Websitewww.birchwoodautomotive.com engineprofessionalWWW.AERA.ORGEP47FASTENERTORQUEMainCapBoltscaps1-465ft-lbswARPmolyMainCapBoltscap5100ft-lbs.wARPmolyCylinderHeadboltsDartspecs70ft-lbsARPspecs60ft-lbswmolyRockerArmStuds45ft-lbsthreadsealantrequiredIntakeManifoldBolts35ft-lbsWaterPumpBolts30ft-lbsOilPanNuts1485in-lbs51615ft-lbsTimingCover85in-lbs.Flywheel62ft-lbswmolyor80ft-lbswoilRodBoltsARP874071662ft-lbsmax0.0052stretchmaxNotemustnotexceed62ft-lbswhentighteningviastretch.PARTNUMBERSOFOURSTUFFDartSportsman350IronBlock31151111DartPro-1AluminumHeads11321112ScatForged3.75StrokeCrank4-350-3750-5700ScatForged5.700ConRods2-350-5700-2100KBForged0.030PistonsKB-7350.030CleviteMainBearingsMs-909hCleviteRodBearingsCb-663hCleviteHi-volOilPump601-1047P55hvCleviteOilPumpDriveShaft601-1409CompCamsHyd.RollerCamCl12-432-8CompCamsHyd.RollerLifters853-16CompCamsProMagnum1.61RollerRockers1302-16CompCamsUltimateAdj.TimingSet8100CompCams3-pcTimingCover310KNDualAirCleanerSet66-5080MSDReady-to-runProBilletDistributor8360CVProductsSportsmanBilletFuelPumpCV2705PerfectCirclePistonRings315-0036.030CompCams516x7.300MagnumPushrods7609-16ATISuperDamperA324451EdelbrockIntakeManifold27012Moroso8QtOil20195MorosoOilPickup24350MorosoValveCovers68405FidanzaAluminumFlywheel198681ARPHeadBolts134-3701ARPIntakeManifoldBolts434-2101ARPWaterPumpBolts430-3201ARPOilPanStudKit434-1901ARPDistributorStudKit430-1701ARPCarbStudKit400-2401ARPFuelPumpBoltKit430-1601ARPAirCleanerStudKit400-0302ARPValveCoverBolts400-7504ARPCoilBracketBolts430-2301ARPThermostatHousingBolts430-7401ARPHarmonicBalancerBoltKit134-2501AEROQUIP-EATON14615LoneOakRd.EdenPrairieMN55344419-891-7635ARPINC.1863EastmanAve.VenturaCA93003800-826-3045www.arp-bolts.comATIPERFORMANCEPRODUCTS6747WhitestoneRd.BaltimoreMD21207800-284-3433BIRCHWOODAUTOMOTIVEGROUP10205WoosterPikeRd.CrestonOH44217-2221330-435-6347BOBSMACHINESHOPLLC7315N.TwpRd.63FostoriaOH44830419-436-8348CAMMOTION2092DallasDr.BatonRougeLA70806225-926-6110CLEVITEENGINEPARTS1350EisenhowerPlaceAnnArborMI48108-3282800-338-8786COMPCAMSINC.3406DemocratRd.MemphisTN38118800-999-0853CVPRODUCTS42HighTechBlvd.ThomasvilleNC27360-5560800-448-1223DARTMACHINERYLTD353OliverSt.TroyMI48084248-362-1188www.dartheads.comDENSO888-511-4312ext.6723www.DensoIridium.comEDELBROCKCORP.2700CaliforniaSt.TorranceCA90503310-781-2222FALLAUTOMOTIVEMACHINE3519JackmanRd.ToledoOH43612419-473-1557FIDANZA4285MAINST.PERRYOH44081440-259-5656GEARHEADTOOLSP.O.Box21887CarsonCityNV89721775-841-4008GOODSONTOOLSSUPPLIES156GalewskiDr.WinonaMN55987800-533-8010INNOVATORSWESTvalvecoverCNCengraving1800E.4THAVE.HUTCHINSONKS67501800-816-2393JONESRACINGPRODUCTS72AnnawandaRd.OttsvillePA18942610-847-2028KBPERFORMANCEPISTONS4909GoniRd.CarsonCityNV89706-0351800-648-7970www.kb-silvolite.comKNENGINEERINGP.O.Box1329RiversideCA92502-1329909-826-4000MEDINAPLATINGCORP.940W.LafayetteRd..MedinaOH44256330-725-4155METFIN4THST.atRRTracksNorthWalesPA19454215-699-3505MSDIGNITION1490HenryBrennanDr.ElPasoTX79936-6805915-857-5200www.msdignition.comMOROSOPERFORMANCEPRODUCTSINC.80CarterDr.GuilfordCT06437203-453-6571POLYMERDYNAMICSINC.11211NeeshawDr.HoustonTX77065281-894-6382800-POLYDYNPRECISIONENGINESERVICE2511ProvidenceRd.SouthWaxhawNC28173704-843-5477ROTTLERMFG.8029S.200thSt.KentWA98032-1114800-452-0534253-872-7050www.rottlermfg.comSCATENTERPRISESINC.1400KingsdaleAve.RedondoBeachCA90278-3983www.scatcrankshafts.comSUPPLIERLISTING ThesophisticationandprecisionofOEMautomotiveenginestodayoftenexceedthatofraceenginesfromafewyearsagoleavingnomarginforerrorinhoning.Combustionefficiencyisupoilconsumptionisdownpartlyasaresultofimprovedboregeometryandringseal.Clearancesandsurfacefinishspecshavetighteneddramaticallyasnewringandpistontechnologiesproliferate.Materialsandsurfacecoatingshaveevolvedandsomenowrequirediamondhoning.KeepingpacewiththesechangesandstayingaheadofthemtwobusinesseswithvastlydifferenttypesofworkWhitePerformanceandJasperEnginesTransmissionsillustratehownewhoningtechnologyandparticularlydiamondhoningabrasivescanimprovecycletimeproductqualityandcostnottomentionhorsepowerandtorque.PerformancebuildercutshoningcyclebyhalfimprovesdynoresultsWhitePerformanceownerFredWhiteisaformerdragracerwithafull-service16000-square-footshopandeightemployeeslocatedinKingsportTennessee.Ourbreadandbutteriscustomhigh-performanceenginesforstreetrodsandcircletrackandwevebuiltastrongbusinessinhigh-performancemarineenginestooWhitesaid.Wealsobuildstockenginesandshipcratemotorsallovertheworldaswellasprovidemachineservicestoothershops.Thedyno-equippedshopisself-sufficientwithfiveCNCmachinesincludingEDMalongwithcrankshaftgrindersbalancersassortedmanualmachinesandalltypesofgagingandmeasurementequipment.WhitePerformancedoesitallfromcontractmachineworktoengineinstallation.Wehoneabout200blockspermonthforourselvesandothersincludinghighnickelCGINickasilaluminumregularcastironGMBowTieDartHondaToyotaalongwithbig-boreChevyandFordblockswhatevercomesthroughthedoorevenaircompressorswith7-inchboressaidChrisWebba40-year-experiencedmachinistwhocametoWhitesshopseveralyearsagofromMorgan-McClureRacingwhereheworkedfortheSprintCupKodakNo.4team.WhitewasusinganolderSunnenCV616honingmachinewithvitrifiedabrasiveswhenWebbcameonboardwithNASCARshopexperience.Eventhemostexperiencedoperatorcanstruggletogetdecentresultswiththe616andvitrifiedabrasivesanditwillstillnevermatchtheroundnessstraightnessandfinishqualitythatnewermachinesanddiamondabrasivescanproduceWebbsaid.Ittakesanexperiencedoperatorandalotofworktogetacceptableresultswiththeoldertechnology.Changeoversfromonefinishtoanotherrequiredseveralbeltchangesonthemachineandtooktimetosetandadjust.Allthisaddsuptolongcycletimesonthehoneandreducedperformanceonthedyno.HavingusedaSunnenCK21anddiamondtoolinginhispriorjobWebbwasinstrumentalinconvincingWhitetopurchaseinlate2009thenewestSunnenSV-10withdiamondtooling.TheSV-10essentiallydoubledourcapacitybycuttingcycletimeinhalfwhileourqualityanddynoresultsimprovedimmediatelysaidWhite.ThePLC-controlledSV-10hasaseparate3-hp2.25kWspindlemotoraswellasastrokermotorsoithasplentyoftorquetodrivethediamondhonehead.ThePLCandvariablespeedmotorsallowinfinitelyvariablecrosshatchanglesforanyborediameterandcylinderlengthallofwhichcanbechangedonthefly.Apatentedfull-boreprofiledisplayshowsareal-timecrosssectionoftheborewhichtakestheguessworkoutofremovingtaper.Forunattendedoperationtheautodwellfeaturewillautomaticallydwellthehoningactioninthetightestareasofthebore.YoucanseeexactlywhatsgoingonduringthehoningcycleWebbsaid.TheDHdiamondhoneheadprovidesmulti-pointabrasivecontactontheboreandacone-stylefeedsystemproducesuniformfeedpressureonthecircumferenceofthetoolforexceptionalroundness.EvenputtingatorqueplateonnearlyeverypartwehoneIcandoallthisandstillcompleteablockinhalftotwo-thirdsthetimeittookonour616withouttorqueplatingthepartWebbadded.Withallthedifferenttypesofblocksandcylinderswerunitsagreatadvantagetohaveyourcurrentsetupatyourfingertipsinthecontroltoquicklymakechanges.OnceyousetyourstrokespeedloadandcrosshatcheverycylinderisthesamewithnotaperorroundnessvariationsandIcandootherjobsintheshopwhilethemachineruns.WiththenewhoneanddiamondtoolingourhorsepowerandDiamondsareablocksbestfriendforhoningTwoshopswithdifferentneedsillustratehownewmachinetechnologiesanddiamondabrasivessimplifytheprocesscutcycletimesasmuchashalfandimprovedynoresults.BYRAYKEMBLE48APRIL-JUNE2013engineprofessional ABOVEMachinistChrisWebbdoesthefinalsequenceonthetorqueplateashesetsupaChevysmallblockforhoning.Whitehonesabout200blockspermonthforitselfandothersincludingoddjobslikecompressorswith7-inchbores.BELOWSunnenDHdiamondhoneheadprovidesmulti-pointabrasivecontactontheboreandacone-stylefeedsystemproducesuniformfeedpressureonthecircumferenceofthetoolforexceptionalroundness.Whitesoriginalsetofabrasiveslasted18months.RIGHTApatentedfull-boreprofiledisplayontheS-10scontrolshowsareal-timecrosssectionoftheborewhichtakestheguessworkoutofremovingtaper.RIGHTWhitesayshorsepowerandtorqueareuponetotwopercentonvariousenginepackageshisshopbuildsandrun-intimeonthedynohasbeenreducedsincethecompanyacquiredtheSV-10machineanddiamondhonetooling.engineprofessionalWWW.AERA.ORGEP49 DIAMONDSAREABLOCKSBESTFRIENDBYRAYKEMBLEtorqueareuponetotwopercentonvariousenginepackageswebuildandourrun-intimeonthedynohaslessened.WhiterunsroughingandfinishingcycleswiththediamondtoolthenplateauhoneswithaSunnenbrushtool.Ourtargetsare0.0002orbetteronsizelessthan0.0001onout-of-roundwithfinishesintherangeof35-40Rvk8-12Rpkand23-28RkdependingontheringsusedWebbexplained.WetakeourmeasurementswithaMitutoyoSurfaceFinishAnalyzerandSunnenboregages.ThismachinewillmakeaninexperiencedoperatorlookreallygoodwhileanexperiencedoperatorwillputoutmuchmoreworkwithlowercycletimesWhiteadded.ThevariablespeedmotorsandPLCcontrolpermitinfinitecrosshatchanglesforanycylinderlengthordiameterontheflywithoutbeltchanges.Wetakeout0.007-0.009workingonalotofbowtieandDartblockswhichareharderyetouroriginalabrasiveslasted18months.Myoneregretisthatwedidnotmoveuptothismachinemuchsooner.Idrecommenditasafirstmachineforanyautomotiveshop.ProductionremanufacturerautomateshoningforlaborefficiencyTheJasperEnginesandTransmissionsplantinWillowSpringsMissouriopenedin2004andhasriddenthemarketupswingforremanufacturedenginesbroughtonbytheeconomythecommon-senseenvironmentalrationaleforrecyclingsoundcomponentsandhighdemandfromthemarinemarket.Originallydedicatedtosmallblock350stheplantprocessesabout15000enginesperyearandplanstomoveintobigblockandperformancework.WearebuildingstockenginesnowbutarealreadydoingcrankbalancingforbigblocksandexpecttomoveintolightperformanceenginessaidPlantManagerMattGregory.AsoriginallyconfiguredtheplantusedtwopairingsofaboringmillandaSunnenCK-21honewitheachmillhonepairrunbyoneoperator.TheCK-21requiresthehoningtooltobemanuallystartedineachcylinderboresothedemandontheoperatorstimeishighadrawbackinaproductionenvironment.TherewasnogoodalternativefortheCK-21atourproductionlevelsatthetimeandwehadbeenreluctanttomoveintoaverticalhoningmachinebecauseoffixturingcostsbutSunnenshowedusthenewSV-410automatedverticalhonebeforeitsintroductionatIMTS2010Gregoryexplained.ThisisamuchheavierdutyCNCmachinewitha10-hpservo-controlledspindleandpowerfultool-feedsystemtodrivediamondorCBNtooling.Theautomationfeaturesofthismachinewouldallowustoimmediatelyincreaseourcapacitywhilethepowerofthemachinemakesitcapableforhardermetalsandheavierblocksifourpartmixchanges.Aftertheoperatorhitscycle-startontheSV-410theentireprocessisautomated.Themachineusesaguidepottostartthehoneheadineachbore.Itthenindexesthehoningtoolbetweeneachboretiltstheblockforaccesstoeachbankofcylindersandautomaticallyrollstheblockoverattheendoftheprocessto50APRIL-JUNE2013engineprofessionalNOWISAGREATTIMETOVISITK-LINEINDUSTRIESONLINEFORGREATDEALSONOURSURPLUSINVENTORY.WEARECLEARINGOURSHELVESOFMANYPOPULARITEMSLIKEVALVESPRINGCOMPRESSORSGRINDINGWHEELSGEARPULLERSANDMOREATGREATPRICES.MANYOFTHESEITEMSAREBEINGDISCONTINUEDSOWHENTHEYREGONETHEYAREGONE.VISITKLINEIND.COMANDCLICKONOURLINKFORALLOFOURSALEITEMSTODAYSURPLUSNVENTORYSALEEBAYS-PALVESGSALVESCGWALVEG-LORE www.jamisonequipment.comLarryandJeremyDemersfromNapainCarrollIAJeremyDemerswiththeRottlerATCLarryDemerswiththeirCobaltdragsterJeremyDemerswiththeirrearenginedragsterWiththemarkayslookingtobeontopayslookingtobeontopWiththemarkTCisthemacAtheRottlerfasterturourselvesbecomeChampions.BeingperfectisevereareAuthorizedDealersforthefollowinglinesofpartsequipmentangnganrhinetCisthemaaround.ItdeniourselvesbecomeChampions.BeingperfectiseverTCputsoutnothingbutperfectRottlerAeareAuthorizedDealersforthefollowinglinesofpartsequipmentyaoevehinetodothejobwithprnaround.ItdenitelyhelpsnotonlyourcustomersbutourselvesbecomeChampions.BeingperfectiseverTCputsoutnothingbutperfecteareAuthorizedDealersforthefollowinglinesofpartsequipmentayslookingtobeontophiningcisionmanaround.ItdenitelyhelpsnotonlyourcustomersbutthingandtheveTCputsoutnothingbutperfecteareAuthorizedDealersforthefollowinglinesofpartsequipmentayslookingtobeontophiningandythingandtheeareAuthorizedDealersforthefollowinglinesofpartsequipmenteareAuthorizedDealersforthefollowinglinesofpartsequipmenteareAuthorizedDealersforthefollowinglinesofpartsequipmenteareAuthorizedDealersforthefollowinglinesofpartsequipmentamsww.jamisonequipment.com.jamisonequipment.comengineprofessionalWWW.AERA.ORGEP51 DIAMONDSAREABLOCKSBESTFRIENDBYRAYKEMBLE52APRIL-JUNE2013engineprofessionaldumptheoil.Crosshatchangleissetviathecontrolscreenandeasilychangedforanyringapplication.TheservofixtureadaptstoanyangleV-blockviathesetupscreenandcanrotatea500-poundblockinonesecondbanktobank.Full-heightwalk-inaccessdoorsalloweasypartloading.Setupissimplifiedwithamulti-axishandwheelforfine-tuningverticalstroketoolfeedcolumnpositionandoptionalcradleposition.Themachineisalsodesignedtousein-processorpost-processairgagingforintegratedSPCdatacollectionaswellasautomaticcompensationofsizetaperandstraightness.Ourincomingboresizeisgeneratedbyaboringbarthatistargetedtoleave0.0035-0.0055ofstockintheboreGregorysaid.ThehoningoperatorsimplytellsthecontrolwhatblockisinthefixtureandwhattheoversizeshouldAnoperatoratJasperEnginesandTransmissionsinWillowSpringsMOinstallstorqueplateontheblockbeforesetupintheSunnenSV-410machineorCK-21immediatelytotherightinphoto. engineprofessionalWWW.AERA.ORGEP53 54APRIL-JUNE2013engineprofessionalDIAMONDSAREABLOCKSBESTFRIENDBYRAYKEMBLEbethenhitscyclestart.Thehoningmachinesensesthesizeandknowswhattodotoproducethefinishedbore.Itsarealadvantagetohavetheprogramssetupfora350or262andactuallyhavetheoversizesfortheboresprogrammedin.ThehoninglinehassincebeenreconfiguredsothatoneoperatornowrunstwohonesaCK-21andtheSV-410andoneoperatorrunsbothmillsandinstallsthetorqueplates.ThebigadvantageisthesimplesetupandthefullyautomatedcyclewhichallowustoproducehighqualitycylindersforthelowestcostperboresaidGregory.Stonewearisautomaticallycompensatedanditsprecisewhichisagreatadvantageinourapplication.TheknowledgeinthecontrolisheadandshouldersovertheCK-21.Wehavealsobeenimpressedwithhoweasyitistokeepthismachineclean.Thecoolantismagneticallyfilteredandhasapaperseparatortoo.ThiseasesTheSV-410featuresfull-heightwalk-inaccessdoorsandstainlesssteelenclosuretoeasepartloadunloadandimprovemaintenance. ABOVEANDBEYONDHONINGDesignedforperformanceandbuiltforproductiontheSV-20istrulyinaclassofitsown.Formoreinformationvisitsunnen.comorcontactyourSunnenrepresentativeat1-800-325-3670.Cylinderhoningmachinesgenerallyfallintotwocategorieslowerpricedmachineswithfeaturestomatchorproductionmachinesthatcostasmallfortune.DevelopedinpartnershipwithindustryleaderJasperEnginesandTransmissionstheSV-20incorporatesthehigh-endfeaturesthatsatisfybothproductionbuildersandperformanceshopsbutatacostthatwontbreakthebank.HereiswhatyougetwiththeSV-20Truelinearstrokingsystemkeepsthehoningtoolconcentricfortheentireborelengthtoproduceconsistentdiameterfromtoptobot-tomcylinderaftercylinderRobust5.5HpspindlemotorispowerfulenoughtodriveSunnensheavy-dutytwo-stagediamondhoneheadsforshortercycletimesandsuperaccuracyRotaryservotoolfeedsystemallowsautomatic2-stagehoning--aroughcycleforfaststockremovalandanishcycleforoptimumboregeometry--withoutstoppingtochangeabrasivesbetweencyclesAdvancedPLCcontrolwithcolortouchscreenallowseasycontrolofallhoningparameterssuchascrosshatchangleautodwellandon-the-ychangingofspindleandstrokespeedsFullboreproledisplayprojectsareal-timeimageoftheborecrosssectionallowingtheusertoquicklyseeproblemareasandnetunetheresultsOptionalrolloverxtureaccommodateslargeV-blockswithdeckplatesattachedevenextrememountainmotorsandmanydieselsInaclassbyitself......SunnensnewSV-202012SunnenSt.LouisMOUSAA12-1engineprofessionalWWW.AERA.ORGEP55 56APRIL-JUNE2013engineprofessionalDIAMONDSAREABLOCKSBESTFRIENDBYRAYKEMBLEmaintenanceandkeepsthemachineinproductionformorehours.Oneadjustmentwehadtomakewastocheckforobstructionfromthetorqueplategaskethangingoutintheborewhichanoperatorwouldcatchonamanualmachine.Anobstructedborecanwreckasetofhoningstones.AsabuilderofstockenginesJasperaimsfor0.0005to-0.0003onboresizewitharangeof15-25Raonfinishandlessthan0.0005outofround.UsingasinglestagehoningtoolontheSV-410thehoningcycleisprogrammedfor90percentroughingand10percentfinishingwithaslowfeedrateontheabrasives.Plateauingisdoneoffline.Severalbrandsofpistonringsmaybeusedallofthemlowtension.TheautomationofthismachinemakesmuchbetteruseofourlaborfreeingtheoperatortorunthemanualhonewhileanotheroperatorcanruntwomillsanddotorqueplateinstallationsaidGregory.Wealsohavethehoningcapacityandtechnologytohandlegrowingvolumeandvarietyinourblocksasourbusinessevolves.IEditorsNoteSincethisarticlewaswrittenSunnenhasupgradedtheSV-410nowtheSV-2410andintroducedthenewmodelSV-20honingmachine.ABOVEThehoningoperatorsimplytellsthecontrolwhatblockisinthefixtureandwhattheoversizeshouldbethenhitscyclestart.ThehoningmachinesensesthesizeandknowswhattodotoproducethefinishedborewhiletheoperatortendstheCK-21machine.RIGHTSetupissimplifiedwithamulti-axishandwheelforfine-tuningverticalstroketoolfeedcolumnpositionandoptionalcradleposition.ThefullyautomatedsystemindexesthetoolfromboretoboreandforV-blockstheservofixturerollstheblockforaccesstoallcylindersendingwitharolloveroftheblocktodumpoilcoolant.ForadditionalinformationonSunnenmachinestoolsandabrasivescontactSunnenProductsCompany7910ManchesterRd.St.LouisMO63143.Tel1-800-325-3670fax314-781-2268oremailsalessunnen.com. engineprofessionalWWW.AERA.ORGEP57 56APRIL-JUNE2013engineprofessionalAutomotiveOEMsareunderconstantpressuretoenhancefuelefficiencywithoutsacrificingperformance.Thishasledtoanumberofinnovationsintheengineandtransmissiontechnologies.Thisalmostalwaysleadsintoextremelytighttolerancesforthemissioncriticalengineandtransmissioncomponents.Considertheexampleofanautomotivepiniongear.Figure1illustratestighteningofsurfacefinishtolerancesoverthelastthreedecadesforautomotivepiniongearschallengingthemanufacturingengineerstoproducehigherqualitygears.SurfacefinishRaspecificationsof20uinwascommoninthe1980sitwasthenloweredto8uinRainthe1990s.Itisnotuncommontoseespecificationslike4uinRaforsurfacefinishonbores.Asthecomponentmanufacturersareawarethetrendhascontinuedtoahostofothercomponentssuchasconnectingrodsfuelinjectioncomponentsturbochargerimpellersrockerarmsetc.Figure1illustratestighteningofsurfacefinishtolerancesoverthelastthreedecadesforautomotivepiniongearschallengingthemanufacturingengineerstoproducehigherqualitygears.Honingtechnologyhaskeptpacewiththeserequirements.HighvolumepiniongearhonessuchasHS6producedbyNagelcanproducegearsatarateofoneevery5secthatisfromheattreattomirrorfinishandsubmicronboregeometries.continuedChallengesinLowVolumeHighAccuracyBoreHoningBYSANJAIKESHAVANHerearesixapplicationexamplesproducedintheNagelECOHhorizontalhoneandthequalitythatcanbeachieved.PinionGearRa0.05um2uinLay45degreeCrossHatchRoundness0.25um10uinStraightness0.5um20uinSizeTolerance.003mmConnectingRodRa0.037umLay45degreeCrossHatchRoundness0.002mmStraightness0.0015mmSizeTolerance.005mm engineprofessionalWWW.AERA.ORGEP57RockerArmRa0.2umLay45degreeCrossHatchRoundness1.3umSizeTolerance-.003mmTurboChargerRa0.15umLay45degreeCrossHatchSizeTolerance.005mmFuelPumpCylinderRa0.025umLay45degreeCrossHatchRoundness0.5umStraightness1umSizeTolerance.005mmFuelInjectorHousingRpk0.01umLay45degreeCrossHatchRoundness0.3umStraightness0.2umSizeTolerance.004mm CHALLENGESINBOREHONINGBYSANJAIKESHAVAN58APRIL-JUNE2013engineprofessionalHoweverforsmalllowvolumemanufacturerstherewasnosuchmagicbulletupuntilnow.Lowproductionrunsarepredominantlyperformedonhandhoningmachinesoronautomaticstrokinghones.ThisisaneconomicalsolutionbuthasthefollowingsignificantdownsideQualityishighlydependentontheskillofoperatorHighsetupandcycletimesInabilityofthesehandhonesandautostrokerstomatchOEMproductionprocessandqualityInabilitytoutilizesuperabrasivesWearcompensationismanualNagelhasdevelopedECOHanewgenerationofhorizontalhoningmachinesforlowproductionrunstobridgethegapbetweenahandhoningmachineandafullblownproductionhoningmachine.Thisnowpermitssmallshopstousethesamecostsavingandqualityenhancingadvancedhoningtechnologiesusedbylargerhighvolumemanufacturers.TheECOHconsistsof3servodrivesandABPLCandABoperatorpanelabigimprovementoverarchaicmechanicalsystemsinhandhonesandautostrokersfoundintodaysmarket.Thehoningspindleisdrivenbya3HP4000rpmservomotor.Thestrokingisagaincontrolledbya3HPservomotor.Heavydutyprecisionballscrewsreachstrokingspeedsgreaterthan25mminandhaveamaximumtravelrangeof250mm.ToolexpansionsystemiscontrolledbyanABservoanindustryfirstfeatureforalowvolumehone.Theservocontrolenablesabrasivestorapidlyexpandat200micronspersecondwhenexpandinginsidetheboretoreducenoncuttingidletime.TheServocontrolsenseswhenthetoolcontactstheboreandreducesexpansionratetoupto40micronspersecprogrammableandgoesintoroughhoningmodewhichhelpsinaggressivestockremoval.TowardstheendoftheNagelhasdevelopedECOHanewgenerationofhorizontalhoningmachinesforlowproductionrunstobridgethegapbetweenahandhoningmachineandafullblownproductionhoningmachine. engineprofessionalWWW.AERA.ORGEP59 cyclethetoolexpansiongoesintofinishingmodeandthespeedisfurtherreducedtoabout2micronspersec.Insetupswheremultiplepassesarerequiredthetoolexpansionsystemspermithoningwithconstantpressurewhichisbetterforgeneratingfinersurfacefinish.Thisabilitytoslowlyexpandtowardstheendofthecyclecoupledwithcapabilitytohoneinconstantpressuremodeproducesboreswithexcellentgeometryandsurfacefinishasillustratedintheapplicationexamplesinthefollowingtables.Thestonewearcanbecompensatedquicklybyapressofabuttonintheoperatorpanelbasedonofflinegagereadingeliminatingoperatorfeelandresultingvariations.NagelECOHcanhoneupto40mmbores.Fullyenclosedguardingensuresdryfloorconditionsandasafetylightcurtainprotectsoperatorsfrominjury.Thesystemhastheabilitytostoremultiplepartprogramsmakingchangeoversabreeze.TheECOHhoningsystemisdesignedforsuperabrasivesbutconventionalabrasivescanalsobeused.InadditionECOHhoningmachinecanaccepttoolsmanufacturedbyothermanufacturersasmanyoftheshopsthatusehandhonestypicallymaintainalargeinventoryofconventionalabrasivetools.UnlikeconventionalabrasivestheDiamondCBNusedinECOHlastsalotlongerandasaresultrequiresveryminimalin-processinspectionandwearcompensation.Thisresultsinmoreuptimeandbetterborequality.I60APRIL-JUNE2013engineprofessionalCHALLENGESINBOREHONINGBYSANJAIKESHAVANSanjaiKeshavanhasmanyyearsofexperienceinthesuperfinishingandhoningindustry.HeiscurrentlyemployedbyNagelPrecisionInc.aworldleaderinsupplyinghoningandsuperfinishingequipmentthatrecentlyhasdevelopedequipmentforlowervolumeshops.Formoreinformationgotowww.nagelusa.comorcontactSanjaiat734-426-1812oremailsanjai.keshavannagelusa.com. engineprofessionalWWW.AERA.ORGEP61 62APRIL-JUNE2013engineprofessionalFromtheEditorRunningasmallorfamilybusinesshasalwaysbeenatoughjobbutalsoveryrewardingforthosewhoenjoythechallengesandrewardsthatownershipbrings.Inadditiontotheeverydayeconomicsalesandoverheadchallengesthatmostbusinessesfaceourindustryhasalwayshadthetechnicalchallengesthatgoalongwithbuildingandrebuildingeverchangingengines.ButImnottellingyouanythingherethatyoudontalreadyknow.Weallagreethatplanningiscriticaltoourbusiness.Theunfortunatethingisthatwhenwedoinvestinsomeplanningtimeweusuallyconcentrateoureffortsonthetopicsabove.Toooftenwhenrunningourbusinesseswefocusonissuesofthedayweekandmaybemonth.Wetendtofocusongettingthejobsathandoutthedoorandhopefullyturnaprofit.HowevertodayIwanttobeginaddressingabusinessplanningtopicthatIhavebeenaskedaboutnumeroustimesandatopicthattrulytakesprofessionalstohelpusunderstandandaddress.Thetopiciscalledsuccessionplanningoralsoreferredtoasexitorretirementplanning.Manyofyouhavespentyourentirecareerbuildingyourbusinessoryouvetakenoverafamilybusinessanditstimeforyoutobeginplanninganexit.Likeanychallengeyoufaceinbusinessspendingqualityplanningtimewithprofessionalscanpaybigdividends.Iamverypleasedtobringyouanarticleandintroduceyoutoatrueprofessionalintheareaofsuccessionplanning.LetshearwhatIrvingKatzhastoofferusonthistopicFamilybusinessesandfamilieshavealwaysbeenthestrengthofAmerica.Nowhereelseintheworldhavesomanyrisenfrommodestmeanstogreatsuccess.HoweverthestatisticsoffamilybusinesssurvivalarediscouragingbecauseOfeveryonehundredAmericanfamilybusinessesonlythirty-threemakeittothesecondgeneration.Ofthosethirty-threeAmericanfamilybusinessesonlytwelvemakeittothirdgeneration.OfthosetwelveAmericanfamilybusinessesonlythreemakeittothefourthgeneration.Somefactorsthatcauseprematurefailureofafamilybusinessarefamilystrifeinheritedentitlementmentalitymanagementrolesbasedonbloodlinesratherthanperformanceanddifferencesinstrategicgoals.Manytimescompanieswherethefoundersintendedforthebusinesstosustainseveralgenerationsendupcrashingandburning.Notonlycanthebusinessbedestroyedbuttherelationshipsbetweensiblingsparentschildrenandextendedfamilymaybedamagedforever.Manynewclientscontactmebecauseofthehorrorstoriestheyhaveheardorwitnessedandwanttopreventthoseoutcomesfromhappeningtotheircompaniesandtheirfamilies.WHYCOMPANIESANDFAMILIESNEEDTOPLANNOWNoonewantstothinkaboutafter-deathscenariosfortheirbusinessesbutwithoutasuccessionplankeyemployeesmayleavethebusinesscouldbedismantledandlifetimesofhardworkandsacrificecouldgodownthedrain.Successionplanningisdisasterplanning.AsabusinessownerhaveyouconsideredthefollowingHasmyfamilyaccumulatedassetsoutsideofthebusinesstoprotectthemagainstbusinessproblemsthatcouldwipeoutmyfamilysincomeCanacostlylawsuitdestroymycompanyIfyescanstepsbetakennowtobothpreventthislawsuitfromhappeningandcandamagecontrolbedonetoreducemylossesWhyisfamilybusinessplanningcriticaltoyourbusinessandyourfamilyBYIRVINGKATZ 64APRIL-JUNE2013engineprofessionalIsthereabusinesssuccessionandbusinesscontinuityagreementinplaceArethosewishesalsoexplicitinmytrustIfIdiedsuddenlywhowillrunmybusinessIsthesuccessorkeypersonorbuyerinplaceandlockedinCouldmyprematuredisabilityordeathforcemycompanyintoliquidationwhereitissoldforpenniesonthedollarifitcanbesoldatallLackofaSuccessionandExitPlanWhenthereisnosuccessionorexitplanemployeesfeelinsecureanduncomfortable.Theyfeartheworsttheunknown.Theyaskthemselveswhatwillhappentothemifthecompanygoesunderandtheylosetheirjobs.WouldtheirlifesavingsandtheirjobsdisappearLosingKeyEmployeesNon-familykeyemployeesleavethebusinessprematurelyusuallybecausetheyseelittleornochanceforadvancementorfinancialrewardsdespiteout-performingfamilymemberemployees.Losingkeyemployeescanhurtthecompanysbottomlineandvaluationforfuturesaletoanoutsidebuyershouldthatbethegoal.GROOMINGANEMPLOYEETOTAKEOVERManysmallbusinessesmayhavealotinvestedinequipmentbuttheproblemisthattheirequipmentisntworthmuchontheopenmarket.Suchbusinessownersmaybefarmoreinterestedingroominganemployeetobuythemoutandtakeoverthebusiness.Asaletokeyemployeesisagreatoptionforcompaniesthatdontreachthesaletothirdpartythreshold.Typicallythisthresholdisaround10million.OvertheyearswevefoundthatownerschoosetotransfertheircompaniestokeyemployeesfordifferentreasonsincludingthesesevenSomeownersfeelthattheyowetheiremployeessomething.Theyfeelthattheirkeyemployeeshavehelpedcreatethecompanyandcertainlyhavecontributedtoitssuccess.Theseemployeesdeservetheopportunitytopurchasethebusiness.Avariationonthisoweideaisownerswhowanttoprovidetheirkeyemployeesthesameopportunitytheyhadtobecomefinanciallysuccessful.Otherownerschoosethistransferbecausetheyhavealreadypromisedtheiremployeesthattheywouldselltothem.Theyfeelcommittedtofollowingthroughonthisoften-timesvaguepromise.Someownersfeelthattheonlywaytocontinuetheirlegaciesdorightbytheircustomersorcarryontheculturethattheyhaveworkedsohardtocreateistotransfertotheirkeyemployees.Someownersareconvincedandsomecorrectlysothattheircompaniesareonlyvaluabletothekeyemployeeswhoworkthere.Withfewexceptionsthereisamarketforcompaniesworthmorethan2million.Historicallybusinessesworthlessthan2millionbusinesseswithfreecashflowoflessthanbetween300000to500000holdlittleattractiontooutsidethirdparties.Maximizingtheirownincomemotivatessomeowners.Theymaybelievethatkeyemployeeswillpaymorefortheircompaniesthananyothertypeofbuyer.Thisassumptioninturnmaybebasedonanotherassumptionthatthebusinessisnotattractivetoorwouldbemisunderstoodbyoutsidebuyers.Lastlysomeownersusethegradualsaleofownershipinteresttokeyemployeesasawaytomotivatethoseemployeestostaywiththecompany.EventhoughonemayseethereasonstoselltheircompanytoakeyemployeehowmightonegoaboutdoingsoHAVINGYOUREMPLOYEESCASHYOUOUTOFYOURBUSINESSManyprobablymostbusinessownerswouldliketoselltheirbusinessestotheiremployeesbutforonenaggingproblemTheiremployeeshavenomoney.Theemployeeshavenomoney.Ownerscannotrisksellingabusinesstoemployeeswithoutcash.WhatcanbedoneHerearesomeideasCreateanincentivecompensationplanforyourKeyEmployeeGroupKEG.DesigntheplansothatastheprofitsofthebusinessincreasetheKEGsbonusincreasesrightalongwithit.InsteadofpayingthemthefullbonusthecompanydefershalfofitandpromisestopaytheKEGthebalanceatafuturedateifeachmemberremainswiththecompany.ThisisanexampleofaplancalledaNonqualifiedDeferredCompensationPlananditissubjecttovesting.SinceyouplannedaheadyoucanevaluateeachmemberoftheKEGtodeterminewhichemployeeswouldbestserveasowners.OffertoselltheKEGasignificantportionofthecompanytypicallyaboutthirtytoforty-fivepercentoftheoverallownershipofthecompany.OffertohavethecompanyvesteachinterestedKEGmembersDeferredCompensation100percentifitwouldbeusedaspaymentforhisstock.Iftheplaniswelldesignedandfundedtherecouldbehundredsofthousandsofdollarsofdeferredbonusmoneybelongingtotheemployeesatthecompanylevel.SelltheKEGanothertwentypercentofthestockusinganInstallmentNote.Withtheexpecteddistributionsforthe40percentofthestocktheynowowned.Finallywiththekeyemployeesnowowningandhavingpaidfor40percentownershipofthecompanytheycansecurebankfinancingtopurchasethebalanceofthestock.Theaboveplanwontapplytoallbusinessscenarios.Itworksbestforcompanieshavingavaluebetween500000and2to3million.Typicallyyouwillwanttospend5yearsfundingtheDeferredCompensationPlan.Communicateyourplantoacooperativebankthatwillunderstandyourintentionswellinadvance.Finallythisplanrequiresastrongmanagementteaminterestedinowningacompanyfinanciallyfitenoughthatcanusemostoftheavailablecashflowtopaydownthepurchaseddebt.THREECORRECTIVEACTIONSTOCONSIDERFORYOURBUSINESSOvertheyearsbusinesseshaveupsanddowns.Whenthingsareupitisagoodtimetotakemoneyoffthetable.SomecallthatrainydaymoneyIcallitagoodbusinesspractice.CorrectiveActionNumberOneSetuparainydayfundSteponeEstablishtheaccount.Thismaybeabankaccountthatiseasytogettooranaccountthatmaybemoreofalongertermlongertermsavingsaccount.SteptwoSetupguidelinesfordeposits.Forexamplewhenthereispositivecashflowtakeapercentageofthatcashflowforthemonthorweekandputitintotheaccount.Mostofmyclientsdepositbetweenfiveandfifteenpercentofnetprofitsduringpositivecashflowmonths.SUCCESSIONPLANNINGBYIRVINGKATZ engineprofessionalWWW.AERA.ORGEP65CorrectiveActionNumberTwoSetupABuy-SellorBusinessContinuityAgreementthatcontrolsthetransferofownershipofthebusinesswhenstatedeventsoccur.Thetriggerscouldbethedeathorpermanentdisabilityofanownerthesaletransferofstockbetweenownersoranoutsidepartyandretirementofanowner.Familybusinessesthatremainfocusedonthenearfutureandonlyworkintheirbusinessesinvariablyneglectingtoputabuy-sellagreementinplace.Gettingthisagreementdonetakesworkingonyourbusiness.Awrittenandfundedbuy-sellagreementallowsfortheorderlydispositionofyourbusiness.Theagreementcanbebetweenshareholdersofacorporationpartnersofapartnershiporakeyemployeeandtheowner.Theagreementobligatesremainingbusinessownerskeyemployeesorthebusinessitselftopurchasetheinterestoftheowner.KeyadvantagestobegainedareCreationofamarketforthebusinessinterest.Itallowsforthoseinterestedincontinuingthebusinesstodosowithoutinterferencefromtheownersheirs.Itprovidesliquidityforthedeceasedownersestatebyturningtheilliquidbusinessinterestintocash.Itestablishesthevalueofthebusinessforfederalestatetaxpurposes.CorrectiveActiveActionNumberThreeFinishYourEstatePlanProperestateplanningcansaveabusiness-owningfamilyhundredsofthousandsofdollarsormore.ThemainbenefitsofestateplanningareFinancialsecurityisprovidedforthefamily.Theyknowexactlywhattoexpect.Businessandfamilyassetsaredistributedaccordingtothewishesofthebusinessownerandnotthearbitrarydesiresofanimpersonalcourt.Childrenwillnotbegiventheirinheritancesbeforetheyarematureenoughtousethemwisely.Mostimportantlyifyouplantohaveyourchildrensucceedyouinyourbusinesspleasemakecertainyourestateplanreflectsthatwish.Thesestepsandseveralmoreareneededtosuccessfullyplanforyourfamilyownedbusiness.IIrvingKatzspecializesinsuccessionexitretirementandestateplanningforbusinessowners.Overtheyearshisclientshaveretainedhimforhisexpertiseandhisabilitytoworkwiththeclientsotheradvisors.IfbyreadingthisarticleyouarehungrytolearnmoredownloadacopyofhisfreeeBookFamilyBusinessBlundersSevenMistakesFamilyBusinessesMakeandHowtoCorrectThemBeforeItIsTooLate.Getyourstodaybyvisitingwww.familybusinesssecrets.com.ContactIrvingKatzat877-847-4952orirvingirvingkatz.com.PleaseaddFreeEBookinyouremailsubjectline.Copyright2013KatzFinancialLLC.Allrightsreserved. 68APRIL-JUNE2013engineprofessionalTheopportunitiesforthemodernmachineshopsoftodayareplentifulregardingdieselengines.Themediumandheavydutymarketshavegrownwiththeheavymarketsaturationofdieselpickuptrucksontheroadtoday.HavingwrittenpreviousarticlesonthecompactdieselmarketandtheBseriesCumminsthisarticlewillexploreotheropportunitiespresentinthecurrentmarket.Whetheryouaredoingcomponentworkorcompleteengineassembliesalmostanyshopcanusetheircurrentequipmenttoperformservicesforcustomerswithdieselengines.Thesourceoftheseenginesisplentifulfromthedieselpickuptruckstotractorsandconstructionequipmentaircompressorspumpsandgeneratorsandovertheroadtrucks.Letsvisitsomeenginecomponentsandhowtheycanbehandledinalmostanyshop.CYLINDERHEADSCylinderheadsareprobablythemostcommoncomponentashopwillsee.Therearemanysimilaritieswiththegasolineengineheadsmostshopsareworkingontoday.Withthenewerenginesmeetingemissionregulationsmanydieselenginesarenowusingfourvalvespercylinder.Sincegasengineshaveutilizedthistechnologyforsometimenowitisaneasytasktousethesameprocessondieselheads.Inolderdieselenginesvalverecessionprotrusionismeasuredinsteadofvalvestemheight.Thisisacriticalstepinworkingondieselheadsascompressionandpistontovalveclearancecanbeaffectedifthisspecificationisoutofrange.Onheadswithvalvesoperatedbyacommonbridgevariationsinstemheightcancausevalvevalveguideorbridgefailure.ThisappliestomanydifferentenginesusingthisstylebridgefromtheCaterpillar3406whichhasbeenaroundmanyyearstothenewerTier4enginesfrommanydifferentmanufacturers.Therecessionprotrusionandthestemheightmustbecheckedwhenrebuildingtheseheads.Manyapplicationsinconstructionandstationaryuseareexposedtotheelements.ForexamplemanytractorsusingtheCseriesCumminshaveexhaustmanifoldswhichareexposedtotheelementsandcausemanyproblemswithexhaustleaks.Theseheadsareusuallypresentedwithbrokenexhaustboltsandadamagedgasketsurfaceontheheadandmanifold.Theinjectorsarealsoexposedtotheelementsanditisverycommontohavetheinjectorsstuckinthehead.Alloftheseproblemsareaneasyrepairandagreatopportunityfortheshop.RemovalofbrokenDieselEnginesOpportunityforAllBYDWAYNEDUGASCaterpillar3406cylinderheadintheprocessofbeingrebuilt. engineprofessionalWWW.AERA.ORGEP69boltsisaprocessallshopsperformonaregularbasis.Theexhaustsidecanberesurfacedandcanbeagreataddontoaheadrebuild.Alsoresurfacingthemanifoldisanothersalesopportunityandcansavethecustomermoneyoverreplacingthemanifold.Injectorsthatarestuckintheheadcanberemovedafewdifferentways.Ifitisatwopieceinjectorthetopcanberemovedbyunscrewingit.Thebottompiecewillbestuckintheheadandcanberemovedbyscrewingaslidehammerintothebottompiece.Alsoitcanbethreadedandaboltscrewedintoit.Thenusingapunchthatfitsthroughtheinjectortipholedrivetheinjectoroutoftheheadcasting.Foronepieceinjectorsseizedinthecastingrunningthecastingthroughthecleaningprocesswillaidinitsremoval.Aftercleaningtheinjectorcanusuallybedrivenoutofthecasting.Theinjectorholemustalwaysbeinspectedandrepairedasneeded.Therearealsoheadsthatuseascrew-ininjectortube.Thecaterpillar3406isanexampleofthis.ThesetubesusegasketsO-ringsorboth.Thesewillrequireaspecialtooltoremoveandinstallthetubebutisacriticaliteminrebuildingtheseheads.Asmallinvestmentintoolingcanbringasubstantialreturn.Manyshopssaytheirequipmentcannothandledieselheads.Manycommondieselheadsarelessthanfortyinchesinlengthandlessthanfourteenincheswide.Manyofthecommonresurfacingmachinesinshopstodaycanhandletheseheads.ResurfacetheseheadswithCBNjustlikeothercastirongasolineheads.Theseheadsmayweighalittlemoreinsomecasesbutasmallinvestmentinliftingequipmentcansolvethisproblem.Inmanyapplicationsthevalveguidesarenotpartoftheheadcasting.Therearemanyairdriverremoverandinstallationtoolsavailabletoeasethereplacementoftheseguides.CONNECTINGRODSDieselconnectingrodspresentagreatopportunityforanyshopwiththeequipmenttorebuildrods.Replacingthepistonpinbushingsinrodscanbeachallenge.RodsinmanydieselenginesLEFTCaterpillar3306headisonly37incheslong.BELOWCummins8.3exhaustmanifoldtoberebuilt.Thisistheconditiontheyusuallyarriveinandcanberebuilt. 70APRIL-JUNE2013engineprofessionalDIESELENGINESBYDWAYNEDUGAShavetaperedsidesandcanbeachallengetoinstall.Therearetoolsavailableforthisprocessorifyouhavecapabilitycanbemadeinhouse.Anothertrickistofreezethebushingandheattherodwhilebeingcarefulnottooverheatthecasting.Onceanewbushingisinstalleditmustbefinishedtospecifications.Indieselenginesthepistonheightinrelationtotheblockdeckiscritical.Perkinshasusedseveraldifferentlengthrodsinthesameenginetoachievetheproperpistonheight.Whenrebuildingtheserodsforablockthathasbeenresurfaceditisagreatopportunitytocompensatethecenter-to-centerlengthoftherodbyoffsetboringthepistonpinbushing.Thereducedcenter-to-centerlengthwillprovidetheproperpistonheight.Therestoftherodcanberebuiltjustlikeanyotherrodyouworkoninyourshop.BALANCINGDIESELCRANKSHAFTSCrankshaftsindieselenginesutilizethesamebasicrebuildingprocessasgasolinecrankshafts.Crackinspectionisacriticalpartoftheprocess.Indieselenginestherearehardnessrequirementsandsomerequireatreatmentprocessaftergrinding.Dieselcrankshaftsalsoprovideopportunityforkeywayrepairweldingandsealarearepair.ThereareapplicationssuchastheJohnDeerePowertechwheregrindingthecrankislimitedtoonly.010.ThePRO-SISsoftwarebyAERAisagreatsourceforallthesespecificationsandfinishrequirements.CrankshaftsinperformanceenginesarebalancedasitiscommontohearsomeonesaytheenginewillmakemorepowerifDieselconnectingrodsbeforeandafterbeingrebuilt.Center-to-centerlengthcanbecorrectedbyoffsetboringpinbushings. engineprofessionalWWW.AERA.ORGEP71thecrankshaftisbalanced.Thesamecanbesaidaboutdieselcrankshaftsandbalancingthesecrankshaftswillincreasethelifeofadieselengine.Reducingtheharmonicdistortioninanenginedesignedtorunthousandsofhourswillincreasetheperformanceandthelifeoftheenginethusprovidingthecustomerwithincreasedserviceoutofhisrebuiltengine.DIESELBLOCKREPAIRDieselblockrepaircanpresentseveraldifferentopportunities.OnsomeblocksliketheBseriesCumminsthecylinderiscastaspartoftheblock.Incasesofthewearexceedingoversizelimitsthecylinderscanbereplacedutilizingthesameprocessinwhichgasolineblocksarerepaired.ApplicationswherethecylindersareremovablelinerssomearedrypresslinersandothersarewetlinersusingO-ringstosealtheliner.TheareawheretheselinerO-ringssealagainsttheblockarepronetodamagethatisrepairable.ThesealareacanbesleevedwitharepairsleevethatwillaccepttheO-rings.Theuppersleeveareaoftheblockcanhavedamagetothesleeveflangecounterbore.Thiscanbecorrectedbyeithersleevingthisareaorresurfacingtheblockandmachiningthecounterboretotheproperdepth.Lineborerepairontheseblockswillbeanothergreatopportunity.Lineborerepaircanconsistofreplacingmaincapsrepairingtheregisterbyweldingsprayweldingtheboresandtheactuallineboreprocess.ASSEMBLINGDIESELENGINESAssemblingacompletedieselenginecanbeagreatprofitcenter.Thismaynotbesuitedforeveryshopasinvestmentinhandlingandassemblytoolswillbegreaterthantoolingforcomponentrepair.TherearemanyaspectsofdieselCaterpillar3306longblockisawetlinerenginethatcanbehandledbymostshops. 72APRIL-JUNE2013engineprofessionalDIESELENGINESBYDWAYNEDUGASengineassemblythatdifferfromagasolineengine.Whenassemblingadieselwithwetlinersitwillrequiretestingthelinersealsforleaksbeforeassembly.Assemblingacompleteorbuildingarunnerwillrequireinstallingandtimingthefuelinjectionpump.Ashopwillingtoassembleandruncompletedieselenginescanprovideagreatservicefortheircustomerswithgreatrewardsfortheshop.FOODFORTHOUGHTWhatIhavepresentedherearebriefideasforshopstoincreasetheservicestheyprovide.Ifyouarereadingthisandthinkingthisarticlejustskimmedthesurfaceanddidnotgivein-depthdetailitdiditsjobandhopefullyyouarethinkingaboutwhatyoucandoinyourshoptoincreaseservicesprovided.InfutureissuesofthispublicationIwillcoverindeptheachtopicdiscussedinthisarticle.AERATechDepartmentalsowillprovideallmembersinformationtohelpwithanyoftheseprocesses.Itistimeformodernshopstothinkoutoftheboxandutilizetheirabilitiesandequipmenttogrowtheirbusiness.Dieselenginesareoneofmanyopportunitiesfacingshopstoday.Shopsneedtofindawaytosayyeswecandothatinsteadoftheoldsayingsorrywedonotdothathere.Alwaysrememberitmustbeprofitablefortheshopandbeneficialtothecustomer.Donotbeafraidtoinvestinthefutureofyourshopasashopcannotgrowtheirbusinesswithoutthecapabilitiestogrow.ISM1000ForOnly21250TheBestSurfacerOnThePlanetPrecisionsurfacingthatyoucanrelyontolastmanygenerations.Bercohas90plusyearsofmanufacturingqualitymachinesthatlastalifetimeJointhethousandsofshopsthathaveexperiencedthequalityofBercobutnowatanaffordableprice.DwayneDugasistheownerofDugasEngineServiceandalsoholdsthepositionofchairmanontheAERABoardofDirectors.DugasEngineServicewasstartedin1969byhisfatherClouresDugas.Dwayneboughtthebusinessfromhisfatherin1999.Formoreinformationemaildugasengineservibellsouth.net. 74APRIL-JUNE2013engineprofessionalTECHSIDEBYLAKESPEEDJR.Injustthreeshortyears0W-16grademotoroilwillbecalledforinnewcarsandsometrucks.Both0W-16and5W-16viscositygradesaimtosqueezeafewmoredropsoffueleconomyfromthenewenginesbeingdesignedforthe2016modelyear.WhyallofthischangeandeffortSimplyputCAFEbetterknownasCorporateAverageFuelEconomy.TheEPAandWashingtonbureaucratssetthefueleconomytargetscarandtruckOEMsmustmeettoavoidmassivefines.By2016allcarandtruckOEMsmustincreasefueleconomyconsiderably.Asaresultnewenginedesignsaretakingformandnewoilsarebeingdesignedforthesenewenginesenter0W-16and5W-16.Whilethesenewoilgradesmaydeliverfueleconomygainsdontplanonusingtheminyour2012Chevyinaefforttoincreasethedistancebetweentripstothegaspump.Thesenewoilswillnotbebackwardscompatiblewhichmeanstheycantbeusedinvehiclesbuiltbeforethe2016modelyear.Thesamethinggoesfordieselenginesin2016.NewAPIoilspecificationsfordieselengineswillcreateanew5W-30dieseloilspecification.Againthegoalhereissqueezingoutanextrafewdropsoffueleconomyandthesenewdieseloilswillonlyworkinnewdieselenginesdesignedforthenew5W-30dieseloil.Inordertomakethesenewoilsdistinguishablefromoilsmeantforcarsandtrucksbuiltpriorto2016newlabelingrequirementswillbeintroduced.Atthistimenobodyknowswhatthatwillbeorwhatitwilllooklike.OntopofthesenewviscositygradesandAPIoilspecificationsmanyOEMsareaddingnewspecificationslikeGMsdexos1specification.Unfortunatelyallofthischangecreatesconfusionandsegmentation.Gonearethedaysofjustchoosingyourfavoritebrand10W-30andusingitinyourwifesChevyminivanandyourFordtruck.Enginesarechangingfuelsarechangingandoilsarechanging.FortunatelyspecialtyoilcompanieslikeDrivenRacingOilprovideapplicationspecificproductstomeettheneedsofoldervehiclesperformanceapplicationsincludingMarineandPowersportsandracing.DrivenRacingOilwasbornasaresultofthesechanges.WhenJoeGibbsRacingbeganhavingengineproblemsduetothelackofZincZDDPinregularoilstheteamhiredthetopchemistsintheworldtoformulateasolutionandthatishowourcompanybegan.AsoilcontinuedtochangeandmorepeoplebegantohaveengineproblemsrelatedtooilDrivenformulatedsolutionstothoseproblemsandthatishowwegotintotheoilmarket.Weareasolutionsprovider.Wedomorethanprovideaband-aidtolubricationproblemsweprovideproductsthatmakeenginestransmissionsandreargearsrunbetterandlastlonger.ForhelpwithselectingtherightoilforyourapplicationvisitDrivenRacingOil.comorcall1-866-611-1820tospeakwiththeirtechdepartment.Youhavealotinvestedinyourenginesomakesureyouareusingthebestlubricantforyourapplication.Motoroilsarenotjustmotoroilsanymoresolettheexpertshelpyouchoosetheoilthatgivesyouthebestperformanceandlongevityforyourengine.ILakeSpeedJr.fromDrivenRacingOilisthesonofLakeSpeedSr.whoracedinNASCARfrom1980to1998.Formoreinformationcallat704239-4401ore-maillspeeddrivenracingoil.com.Findmoretechnicaldataatwww.drivenracingoil.com.0W-16in2016 DRIVENRACINGOIL.COM866611-1820Oilisthelifebloodofanyengine.Whenitcomestohighlycomplexper-formanceenginesitscriticaltochoosetheoilthatmeetsyourenginesspecif-engineoilsrestassuredthatlubricanttechnologyisconstantlyevolvingatthehighestlevelsofmotorsportsandDrivenRacingOilisamajorplayerinthosedevelopments.Onesuchbreak-throughthatDrivenhasrecentlyincor-poratedintoallitssyntheticoptionsismPAOanext-generationsyntheticbaselubricant.Whileyoumayneverhaveheardthisnamebeforewhatthisstuffdoeswillimpressanyonewhoun-derstandsthedifferencebetweenpis-tonsandpetunias.ByusinganmPAObaseforcreatingitsperformancelubri-cantsDrivenisabletocreatealight-weightmotoroilthatretainsahighHTHSHighTemperatureHighShearviscositytogiveyouthebestlubricantpossible-anoilthatslesssensitivetoheatdoesntbreakdownunderextremefrictionandjustplainworksbetter.WinningchampionshipsatthehighestlevelsofmotorsportsistheprimarygoalofDrivenRacingOilsowhileotherbrandsmayclaimtobeperfor-manceoilsonlyDrivenbacksitupbyactuallyracingthesamestuffyoucanbuyofftheshelf.OnlyDrivenRacingOilputstheverysameoilitsellstoyouineveryJoeGibbsracingengine.Fromfullsyntheticraceoilstoenginebreak-inoilsDrivenRacingOiloffersawiderangeofrace-winningproductsthatdeliverperformanceprotectionandvalue.CountlesshoursoftestingandmillionsofdollarsinRDhavebeendevotedtoDrivenRacingOilproducts-andtheresultsspeakforthemselves.untilnowhasbeenPAOwhichisquiteabitbetterthananyconventionalasitfeaturesanindexnumberof140.mPAOhasaviscosityindexof200solidevidenceofitsenhancedlubri-cationpropertiesDynotestsshowthatenginesconsis-tentlygainone-and-a-halfhorsepow-erwiththenewoilformulationscon-tainingmPAO.AsyoucanseethisisahugeadvanceinoiltechnologyandDrivenincludeditinallofitssynthet-icoilsautomatically.Manymotoroilmanufacturersifgiventheopportu-nitywouldhavecreatedabrand-newproductusingmPAOandgivenitanultra-premiumpricetomatchitsper-formance.ButDrivenwhichcurrent-lyistheonlycompanywithaccesstothisnext-generationtechnologyhaschosentouseiteverywhereitcanatnoadditionalcosttoitscustomers.9106jInnovationsInLubricantTechnology-ZeroCompromisesConsiderthatlubricationscientistsusetocomparethequalityofdifferentbaseoils.TheindexisbasedonPenn-sylvaniaCrudewhichisthehighestqualityconventionaloilyoucandrillfor.PACrudehasaviscosityindexof100.Theverybestsyntheticbaseoil 76APRIL-JUNE2013engineprofessionalPRO-SISCORNERBYSTEVEFOXAERAsPRO-SISprogramoffersmanyspecificationstomachineshopsbuttherearesomeoccasionswhentheOEdoesnotsupplyaspecificationintheirservicemanual.Thisismorecommonthanmostofthemachineshopsthink.AERAtriesitsbesttogetasmuchinformationonaparticularengineasitcanbutsometimesaspeconsomethingisjustnotsupplied.SoyouhaveanengineintheshopandyouseethatAERAdoesnothavethespecinthePRO-SISprogramwewillshowyouhowtoaddthatspecsothatyouhaveitforreferencelater.ThisiswhatwearegoingtotalkaboutinthisarticleaddingacustomspectoPRO-SIS.OfcourseonewaytomakesurethatthespecificationgetsintoPRO-SISistocallAERAandprovidethemwiththeinformationsothatwecanaddittotheprogram.WithtwoversionsofPRO-SIStherearetwodifferentstepsthatneedtobefollowed.WewillcoverbothPRO-SISandPRO-SISSAinthisarticle.PRO-SISWehavefoundourengineinPRO-SISandforthisexamplewearelookingataJaguar2000-024.0Lengineinthecylinderheadsection.Youcanseethatthecylinderheadheightdoesnotshowaspecification.NowyouwanttoaddaspectoyourversionofPRO-SISbuthowdoyoudoitWewillnowshowyou.Locatingpenciliconforcustomspecdatainput.OntherighthandsideofPRO-SISyoucanseeapencilgoaheadandclickontheicon.OnceyouhavedonesoyoushouldseeawindowpopupthatsaidyouaregoingtoaddacustomspectoPRO-SISgoaheadandclickYES.Nowyoucanaddthespectotheheadsection.Justclickinthecylinderheadheightandstartenteringyourspecwhichforthisexamplewearegoingtouse4.000asthespec.Onceyouhavethespecenteredontherighthandsideofthescreenyouwillseeadisciconthatwillneedtobeclickedinordertosavethespec.OnceyouhavesavedthedatatotheheadsectiongoaheadandclickontheENGINEStabatthetop.YouwillseethatthereisaredXintheCUSTOMcolumnoftheenginewewerejustenteringdatainto.ThatmeansthatyouhaveenteredcustomspecstothatenginethatAERAdidnothave.WhenyoureceiveyournextupdateandloaditintothemachineanycustomdatathatyouhaveenteredintoPRO-SISwillbesaved.EnteringCustomSpecs engineprofessionalWWW.AERA.ORGEP77PRO-SISSAForenteringcustomspecsintoPRO-SISSAtheprocedureisprettymuchthesameexcepttheiconsarelocatedinadifferentlocation.TobeginletslocatethesameengineJaguar2000-20024.0LengineintheprogrambyfillinginMAKEandLITERandhittingtheSEARCHbutton.AftertheenginesearchresultshavecomebacktousyouwillwanttoclickontheAtogettothespecsoftheengine.OnceyouhaveselectedtheengineyouwillwanttoclickontheHEADsectionunderSELECTENGINEsection.TheHEADsectionwillopenuprighttothecastingtabwhichiswherewewanttobe.InthetoprightjustabovethegreenSEARCHbuttonyouwillseethehandwithapencil.Goaheadandclickonthaticonandanotherboxwillpopupjusttomakesurethatyouwanttoaddspecstothisrecord.YouwillwanttoclickYEStoallowdatatobeenteredtothisrecord.Nowyouarereadytoaddyourspectotherecord.GoaheadandclickintheNEWTHICKNESSsectionandstarttypingthe4.000whichisonlyusedforanexampleforthisarticleintothecylinderheadheightsection.Afterthespechasbeenenteredyouwillwanttosavetheinformationintotherecordbyclickingonthedisciconwhichwillbeinthesamelocationasthehandwithpencilweclickedtoaddthespecs.NowthatwehaveclickedtheSAVEbuttonwecanclickontheENGINEStabagainandyouwillseeagreenCthatislocatedrightnexttotheAweclickedtoentertheengine.SameasregularPRO-SISthegreenCmeansyouhaveenteredcustomdataintotheprogram.Yourcustomdatawillalsobesavedwhenthenextupdateisenteredintothecomputer.ThatcoverstheabilitytoentercustomspecsintoeitherPRO-SISorPRO-SISSA.IfyouhaveanyquestionsregardingthisarticleorneedadditionalhelpwithenteringdatatotheprogramfeelfreetocallAERAat888-326-2372andwewillbehappytoassistyou.IAERATechnicalSpecialistSteveFoxhasover25yearsexperienceintheenginebuildingindustrywith10ofthoseyearsspentworkinginthemachineshop.SteveisanASE-certifiedMasterMachinistaswellasalongtimememberofthedragracingcircuit. 78APRIL-JUNE2013engineprofessional engineprofessionalWWW.AERA.ORGEP79 80APRIL-JUNE2013engineprofessionalAbouttheProgramEachprogramisanonlineself-pacedcoursewithuptooneyeartocomplete.GaryLewisbookAutomotiveMachiningEngineRepairwillbeincludedwiththe150registrationfee.Everythingatechnicianwillneediscontainedintheprogramwithvideoclipsandsupplementalreadingsatkeylocationswithintheprogram.Thebookwillbeusedasasyllabuswhennotonline.Eachchapterwillbefollowedbyamultiplechoicetest.TherewillbeafinalexamforeachcertificationCylinderHeadandorEngineMachinist.AERAoffersacomprehensiveonlinetrainingprogramnotjustatestleadingtodiploma-qualitycertificatesinCylinderHeadsandEngineMachinist.Technicianswhosuccessfullyearneithercertificatewillholdproofthattheyhaveaprofessionalunderstandingofautomotivemachiningfundamentalsmeasuringtoolsshopsafetyfastenersenginetheoryenginediagnosisenginedisassemblycomponentcleaninginspectioncrackdetectionandrepaircomponentreconditioningandcylinderheadandblockresurfacing.Theinformationinthisprogramispresentedfromtheviewofenginemachineshopoperations.Basicproceduresareselectedfromthosewithwideindustryacceptanceandrepresentwell-balancedandcompetentstateoftheartpractice.GaryLewisInstructorandAuthorFormoreinformationcallAERAat815-526-7600ext.202oremailkarenaera.org.CylinderHeadandMachinistCertificateProgram engineprofessionalWWW.AERA.ORGEP81AERAONLINETRAININGREGISTRATIONFORMNAMECOMPANYNAMEAERAIDNUMBERCOMPANYADDRESSCITYSTATEZIPPHONEE-MAILADDRESSREQUIREDSIGNEDBYFEES150perpersonINCLUDESGaryLewisbookI2-4PEOPLEfromthesameshop.................................................................125perpersonI5-9PEOPLEfromthesameshop.................................................................100perpersonI10PEOPLEfromthesameshop..................................................................75perpersonEachpersonregisteredwillreceiveaGaryLewisbook.PleaselistadditionalnamesbelowTOTALAMOUNTENCLOSEDICHECKPLEASEMAKEPAYABLETOAERA.CREDITCARDIVISAIMASTERCARDIDISCOVERIAMERICANEXPRESSCARDNUMBEREXPIRATIONMMYY3-DIGITCSSCARDHOLDERNAMECARDHOLDERSIGNATUREIfpayingbycreditcardpleasefaxcompletedregistrationformtoAERAtoll-freefax888-329-2372OrmailyourcompletedformwithpaymenttoAERA500CoventryLaneSuite180CrystalLakeIL60014.CallAERAtoll-freeifyouhaveanyquestions888-326-2372ordirectat815-526-7600. 82APRIL-JUNE2013engineprofessionalTB2609ValveLashAdjustmenton2005-2012Nissan4.0LVQ40DEEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingvalvelashadjustmentfor2005-2012NissanVQ40DEengines.Thisengineusesuniquemechanicalliftersforitstwelveintakeandexhaustlocations.Therearetwenty-fivedifferentexhaustliftersandtwentysevendifferentintakelifters.TohelpdetermineifadriveabilityissuemaybetheresultofimpropervalveadjustmentNissansuppliesbothhotandcoldlashadjustmentvaluesasshowninthechartbelow.ValveLashAdjustmentValuesVQ40DEEngineTemperatureColdEngineTemperatureHotIntake.010-.013.260-.340MM.012-.016.304-.419MMExhaust.011-.015.290-.370MM.012-.017.308-.432MMTheclearanceshouldbemeasuredbyplacingaflatfeelergaugewiththecamshaftstorquedintheproperpositionsandthecheckinglocationcamlobepointingupandawayfromthelifter.Measureandrecordall24locationsanddeterminewhichlocationsneedadjustmentbyreferringtothechartabove.Thecamshaftswillhavetobemarkedforspecificlocationandremovedtoallowaccesstoeachlifter.Theliftersareofdifferentthicknessesandshouldbemeasuredwitha0-10-25.4Mmicrometerasshowninthelifterchartbelow.TheuniquepartnumberisetchedoneachliftertohelpdeterminewhatthicknessaNEWliftershouldbe.Besuretomeasureallusedliftersaswearmaybepresentasshowninthediagrambelow.Newliftersareavailablewiththepartnumberplusthethicknessmeasurement.TheexhaustliftersareslightlytallerthantheintakesandhaveanNprecedingtheirnumber.TheexhaustliftersusePart132317S806whiletheintakesareavailablewithpartnumber132312Y806andhaveaUaftertheirthicknessnumber.TB2609Figure1.31738.06MMIntakeLifterThecamshaftsmustbereinstalledintheirpreviousnotedlocationsandthecamcapstorquedinthesequenceshownbelowinthestepsindicatedhere.Recheckyourlashmeasurementstoverifyallarewithinspecifications.Step1bolts7-101.96Nm0.2kg-m17inchlbs.Step2bolts1-61.96Nm0.2kg-m17inchlbs.Step3AllBolts5.88Nm0.6kg-m52inchlbs.Step4AllBolts10.4Nm1.1kg-m92inchlbs.TB2609Figure2AvailableLifterChartTB2609Figure3CamshaftCapTorqueSequencetech engineprofessionalWWW.AERA.ORGEP83TB2610LifterNoiseon1997-2012GM4.8L5.3L5.76.0LEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardinglifernoiseon1997-2012GM4.8L5.3L5.7L6.0Lengines.ThisnoiseisonlynoticeableatidleandaslightincreaseinRPMwilldiminishthenoise.Thenoiseisalsoonlypresentonaenginethathasbeenbroughttonormaloperatingtemperatures.Thisconditionmayalsobenotedbyaloweroilpressurereadingonvehicleoilpressuregaugesorwarninglightsmaycomeonatlowidleconditions.Itsbeenreportedtheseenginesmaystarttoloseoilpressureaftermanyenginetemperaturecycles.Reportsofsuddenlytheoilpressurelightstartedflashinghavebeenheardonwell-maintainedvehicles.Onvehicleswithinstalledoilpressuregaugestheengineidlemaybelowerthan10psi.Thecauseofthisconditionmaybealeakingcamshaftthrustplateatthefrontoftheengine.TheplateisboltedtothefrontoftheblockandsealsthefrontlifteroilgallerieswithacapturedrubberOringtypeseal.Overtimethissealbecomeshardenedandlosesitssealingability.Thegasketflattensoutandallowsoilpressuretogointotheoilpanratherthantothelifters.TB2610Figure1.LowerEngineOilPressureAdaptorTohelpdetermineifthisconditionispresenttheobservedoilpressureonaHotenginewilldifferwhenmeasuredatthetopoftheengineandcomparedtothebottomoftheengine.TodosoaspecialadaptorisavailablefromGMwithPartJ42907andJ21867tomeasureoilpressureattheoilfilterbaseSeeFigure1.Ifthereisa15-30differenceinupperandlowerpsireadingstherearesealsleaking.OriginallyGMmaysaythattheOringgasketsarereusablebutitisgoodinsurancetoalwaysreplacethoseaffectedcomponents.TB2611CylinderSleeveInstallationon2001-2012GM6.6LDieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingcylindersleeveinstallationon2001-2012GM6.6Ldieselengines.Thiscanbeusedtorepaironeormoredamagedboresonthesecylinderblocks.Thisengineblockundergoesaspecialtreatmentprocessduringoriginalmanufacturingtoenhancethedurabilityofpistonringsandcylinderwallcompatibility.Theprocessinvolvesinductionhardeningoftheuppercylinderboreinauniformandconsistentpatterntodeterwear.AsshownintheenclosedphotoinFigure1onlytheupperboreistreatedasthisistheareathepistonringsareunderthemostextremepressure.TB2611Figure1.InductionHardenedUpperBoreThedepthofhardnessintheseupperboresisveryuniformandapproximately.1002.540MMdeep.Boringfora18wallsleevewillremovetheaffectedhardenedareas.Installingaconventionalsleeverepairlinerwithastepinthebottomofthelowerborehasbeenreportedsuccessfuleventhoughthehardnessisnotthere.Asanotherrepairoptionsomesleevemanufacturersofferanupperflangedtypesleevewithenhancedimprovedmetalcharacteristicswhichhasalsobeenreportedassuccessful.AERATechnicalBulletinsalsoavailableonlineAERAmailsEngineProfessionalmagazinequarterly.ThetechnicalbulletinsinEnglishandSpanishcanbefoundonlineatwww.aera.orgep.Ifyouhaveanyquestionsorifyouneedtechnicalsupportsendane-mailtoinfoaera.orgorcalltoll-free888326-2372.www.aera.orgep TB2612CylinderSleeveInstallationon2008-2010Ford6.4LDieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingcylindersleeveinstallationfor2008-2010Ford6.4Ldieselengines.Thissalvagerepairusuallyoccursafteronecylinderborebecomesexcessivelyscoredfromabnormalcombustionactivity.Thecylinderblockforthisenginehascylindersthatextenddownintothelowercrankcaseandaresomewhatfreestandingorunsupportedasshowninthephotobelow.Thatfacthasledsometobelievethatinstallingaconventionalsleeverepairusingalowerledgetorestthesleeveonmaypresentaninstallationconcern.Thefearistheremaybeinsufficientthicknessoftheremainingcylindertosupportthenewrepairliner.Astherepairsleevecomestoitsfinalrestingpositiontheledgemayfractureorbreakoutcausingadditionalconcern.Visuallyviewingasingleblockitisapparentthevarianceinblockcasting.Tohelpreducethepossibilityofabreak-outconditionfromaconventionalrepairsleeveinstallationanavailableflangedsleevehasbeencreatedandisavailableunderPartFORD64FLG.Theflangeallowsforastraightthroughoversizeboringoperationatthebottomofthecylinderreducinganyadditionalblockstress.Thesleeverestsupatthetopdeckandiscoveredbytheheadgasket.ThisflangedsleeveismadefromahardenedMoly2000DuctileIronmaterialwhichmimicstheoriginalblockcasting.Thesleevedimensionsareshownbelow.SleeveOutsidediameter4.000SleeveInsideDiameter3.800FlangeOutsideDiameter4.200SleeveOverallLength6.75084APRIL-JUNE2013engineprofessionaltechLetusstraightenyourlogisticsout.IfyouneedalogisticspartnerwhocansteeryourshippingbusinessintherightdirectionyouneedFreightquote.com.Weofferavastarrayofproductsandservicesspecificallydesignedtogiveyouanoptimalshippingexperience.Dontgetlostinamazeoflogistics.VisitFreightquote.comorcallusat800.323.5441today. engineprofessionalWWW.AERA.ORGEP85TB2613InjectionPumpGearInstallationTorqueon1983-2000Cummins5.9LDieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationconcerningtheinjectionpumpgearinstallationtorquevaluesfor1983-2000Cummins5.9Ldieselengines.Thistorquevaluefortheinjectionpumpgearnutdependsentirelyonwhichofthemanydifferentpumpsbeinginstalled.Theenginesaremanufacturedindifferentlocationsaroundtheworldandhavebeenfittedwithmultiplepumpmanufacturersaswell.Usethechartsbelowforbothin-lineandrotarystylepumpsbeforeinstallingtheinjectionpumpgear.Thenpriortotorqueingthefuelpumpgearnutmakesuretheengineislockedandcannotrotateduringfinaltorqueingofthefuelpumpnut.Pushthefuelpumpgearontotheshaftandassemblethewasherandnut.Removethetopdeadcentertimingpinfromthecamshaftandthetimingpinonthedamperifused.RotaryPumpsBoschVEM14-1.5nut72FTLBS98NmBoschVEM12nut48FTLBS65NmLucasCAVDPA60FTLBS81NmStanadyne48FTLBS60NmDelphiDP2168FTLBS93NmNOTEBoschVEpumpsLoosentheBoschfuelpumplocktimingscrewandinstallthespecialwasherthatiswiredtothefuelpump.TightentheBoschfuelpumplocktimingscrewto115INLBS13NmInlinePumpsAPump63FTLBS85NmP3000andP7100144FTLBS195NmNippondenso91FTLBS123NmTB2614RevisedHeadGasketHeadBolton2002-20098.5LDDCSeries50EnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingarevisedcylinderheadgasketandheadbolton2002-20098.5LDDCSeries50engines.ThisbulletinappliestoenginesthatwereproducedafterSeptember2002.AnewcylinderheadgasketunderPart23531306andcylinderheadboltPart23530768havebeenreleasedtoimproveclampingloadofthecylinderhead.Theheadgaskethasarevisedcompressionsealdesignedtoworkwiththeincreasedclampingloadofthenewheadbolt.Thehigherrevisedtorqueontheheadboltis220FTLBS298Nm.ReferencethesequenceshowninFigure1belowtotorquethenewheadbolts.TB2614Figure1.CylinderHeadBoltTorqueSequenceTherevisedheadgasketcanbeidentifiedwithanewpartnumberanddatecode.ThenewcylinderheadboltcanbeidentifiedwithwhitepaintandagrooveonthetopoftheboltasshowninFigure2.TB2614Figure2.RevisedHeadBoltIdentificationThenewcylinderheadgasketmustbeusedwiththenewcylinderheadbolts.Thereisnochangetotheprocedureotherthanthenewtorquevalue.Thenewcylinderheadboltscanbeusedwiththeolderheadgaskethoweverthenewheadgasketcannotbeusedwiththeformerheadbolts.Formerandnewheadboltsmustnotbemixed.AreyouanengineguyWeareContactusbecausewehavetheanswersforengines.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372.JointodayGotopage90foramembershipapplication. 86APRIL-JUNE2013engineprofessionaltechTB2615CoolantLeakOn2000-2012GM2.2LVINFDEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardinganenginecoolantleakon2000-2012GM2.2LVINFDengines.Inthissituationmostoftenthisleakisreportedafterthecylinderheadhadbeenremovedforservice.Enginecoolanthasbeenreportedtobefillingoneofthesparkplugwellsatopthecylinderhead.Inmanyinstancesthisisafterthecylinderheadhadbeenremovedandservicedforvalvetrainoroverheatingissues.Manyheadshadalsobeenpressuretestedasanormalpartoftheseservicesandpassedthatinspectionwithnocoolantleaks.Subsequentlyafterreinstallingthecylinderheadandreplacingthefluidsandthenenginestart-upcoolantleakagehasbeenobserved.Inotherinstancesaperiodoftimeafterthevehiclewasreturnedtoserviceleakagewasreported.Itappearssomecastingshavecompromisedintegrityandre-torqueingtheheadbackontotheenginecreatesapassagetoallowcoolanttoexpelintoanyofthefoursparkplugwells.Somehavebeenobservedlaterascracksandsomeasporosityleaks.Theareaofleakageisveryconcealedanddifficulttovisuallyseeclearly.Atthistimenoeffectiverepairhasbeenreported.Unfortunatelyapositivewayofdetectingthisproblembeforeinstallingandstartingtheenginehasnotbeendetermined.Onethoughtwouldbetoassimilatetheheadtorqueandsparkplugtorqueof15ftlbswhilepressuretestingthehead.TB2616RattlingNoiseOn2011-2012Ford5.0LVINFEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardinganenginerattlingorscratchingnoiseon2011-2012Ford5.0LVINFengines.Thisconditionisnoticeableatengineidleonawarmengine.Some2011-2012F-150andMustangvehiclesexcludingBossequippedwitha5.0Lenginemayexhibitanintermittentmetallicrattleorscratchingtypenoiseintheareaatthefrontofthelefthandordriversidecylinderheadatidlewiththeengineatoperatingtemperature.1.Determineenginebuilddate.a.Ifenginebuilddateisonorbefore11102011proceedtoStep2.b.Ifenginebuilddateisonorafter11112011donotcontinuewiththisprocedure.RefertotheWSMSection303-00fornormaldiagnostics.2.Warmtheenginetooperatingtemperature.3.UsingamechanicsstethoscopeorEngineEARlistenforametallictyperattleorscratchingtypenoiseatthefrontofLHcylinderhead.4.IsthenoiseheardinareasshownSeeFigures1and2below.a.YesProceedtoStep5.b.NoThisarticledoesnotapply.5.RemoveaccessorydrivebeltrefertoWSMSection303-05.Isnoisestillpresenta.YesProceedtoStep6.b.NoReplacethecoolantpump.RefertoWSMSection303-03A.6.IsthenoiseheardintheareasshownSeeFigures1and2below.a.YesReplacetheLHprimarytensionerandtimingchaintensionerarmusingthekitpartnumberprovidedinthisarticle.RefertoWSMSection303-01B.b.NoThisarticledoesnotapply.RefertoWSMSection303-00fornormaldiagnostics.NOTEFailuretoreplaceboththeprimarytensionerandtimingchaintensionerarmmayresultinoverloadingofthetimingchainandundercertainconditionscouldleadtotimingchainfailure.TB2616Figure1TB2616Figure2 PEGGYGREENCall507-457-0755or866-457-8975peggybigrivergmail.comRepresentinganumberofqualitylinestobringyouthebestvalueforallyourshopsupplyneeds.HOMEOFREGISNORTH35517SkyviewDriveWinonaMN55987HOMEOFREGISNORTHCallengineprofessionalWWW.AERA.ORGEP87IPDHeavyDutyEngineRepairParts800299-4248310602-5399salesipdparts.comwww.ipdparts.comMORETHAN75YEARSSTRONGOriginalqualityreplacementenginepartsforclassicBritishvehicleswww.gosnays.co.ukemailsalesgosnays.co.ukTel4401708748320MARKETPLACEYOURADHEREBusinessCardAd3.5x21xRate2004xRate170FormoreinformationseetheMARKETPLACEAdFormonthefollowingpage.ToadvertiseinMARKETPLACEyoumustbeanAERAmember.Seepage89inthisissuetolearnmoreaboutallthebenefitsofanAERAmembership.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372. 88APRIL-JUNE2013engineprofessionalMARKETPLACEAttentionAERAMembersAdvertiseyourbusinesscardwithEngineProfessionalmagazineandcapitalizeonthefastestgrowinghardcoreenginepublicationintheaftermarketMarketplaceBusinessCardAdOrderFormNameCompanyAERAIDAddressCityStateZIPPhoneFaxE-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.engineprofessionalWWW.AERA.ORGEP89AERAEngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600fax888-329-2372815-526-7601www.aera.orgemailinfoaera.orgtwitter.comaeraepfacebook.comaeraep 90APRIL-JUNE2013engineprofessionalAPPLICATIONFORU.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........................................35929.92monthI4-8........................................44036.67monthI9-24......................................56847.33monthI25ormore............................67155.92month 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92APRIL-JUNE2013engineprofessionalANAERAINTERNATIONALQUARTERLYPUBLICATIONTHECUTTINGEDGEThestandardforenginebuildingequipmentsince1923Over20F79ACNCMachiningCentersinstalledworldwidein2012RottereivssomuchfCaliforniBradAndDennisineoringorouptesaretpaceacyanccudvantagefavemathiuction.pnaveeasytoashingtonUSAWInc.BGMachineidBiDrtingsooeeantoeutespi.aeccuequipmenottlerRashingtonUSAInc..mteirsourwicismostimportaiacisiontemacineteirpsequipmentistechnologicallyadvancedandextrwhichismostimportantwhenyouvensaveprmeynextEnglandManagingDirectoridLeD.sizeenginesLHGroupSertaffordshirEnglandLHGroupServicesManagingDirectorrmeiumJohannesburgSouthAfricatomoMetrcrDaryJohannesburgSouthAfricaeEngineeringutomotivbuildingeqbuildingeqandarThestuipmentsince1orenginedfandar923uipmentsince1orengine923emailcontactrottlermfg.com.facebook.comrottlermfgwww.youtube.comrottlermfgwwwottlerrwTHECUTemailcontactrottlermfg.com.facebook.comrottlermfg.youtube.comrottlermfgmfg.comottlerTINGEDGETHECUT1-800-452-0534125387270502entW8029South200thStreet1-800-452-0534