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AluminumWeldingandErosionRepairItsthePitsMercuryRacingsExtremeQuadCamFourValve1650engineValveSpringsTruthbeToldLiarLiarYourTemperatureGaugeLiesABASICUNDERSTANDINGOF-ANHOSESANDHARDWARE632CIDBASEDONBIG-BLOCKCHEVYFORMAT.ENGINEBUILDANDPHOTOBYMIKEMAVRIGIAN.ANAERAINTERNATIONALQUARTERLYPUBLICATIONOCTOBER-DECEMBER2013 2OCT-DEC2013engineprofessional4FROMTHEPUBLISHER6INDUSTRYNEWSWelcometonewAERAmemberscalendarofeventsnewsandviews12NEWSFROMTHEEDITORByJimRickoff16EXTREME1650MERCURYRACINGENGINEByDaveHagenandMikeCaruso22-ANHOSEAND-ANHARDWAREByMikeMavrigian40LIARLIARByRayT.Bohacz46ALUMINUMWELDINGANDEROSIONREPAIRBySteveSchoeben54HOWTOMAINTAINORREBUILDENGINESCERTIFIEDTOEPASTANDARDSByTheU.S.EnvironmentalProtectionAgency56AETCCONFERENCEHELDDAYSPRIORTOPRISHOWBySteveFox58THETRUTHABOUTVALVESPRINGSBySteveFoxandCompCams64EMCCHAMPIONByStephenKim702015NISSANTITANWILLFEATURENEWCUMMINSTURBODIESELV8ENGINEByDaveHagen72PRO-SISCORNERBySteveFox74A15LENGINEFORCATSWORKTRUCKLINEByMikeOsenga78TECHSKILLSCONFERENCERECAPBySteveFox80TECHSIDEByLakeSpeedJr.RememberZincMotorOilGetreadyforEthanolandGasoline84AERAAUTOMOTIVEMACHINISTONLINETRAINING86TECHBULLETINS92PRODUCTNEWS94ONTHESAMEPAGEEnginebuildingbookreviewsbyAERATechnicalSpecialistMikeCaruso95MARKETPLACECONTENTSEngineProfessionalmagazineISSN1945-7634ispublishedquarterlybyAutomotiveEngineRebuildersAssociationAERA.Copyright2013AERA.Subscriptionrates70peryearoutsidetheUnitedStates90singlecopy20.Publicationedito-rialandbusinessoffice500CoventryLaneSte180CrystalLakeIL60014.Editorial815-526-7600Advertising507-457-8975Circulation815-526-7600.Sendchangeofaddresstotheabove.TheopinionsbeliefsandviewpointsexpressedbythevariousauthorsinthismagazinearethoseoftheindividualauthorsandnotoftheAutomotiveEngineRebuildersAssociationwhichdisclaimsallresponsibilityforthem.VOLUME6NUMBER4PUBLISHERAERA-EngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014815-526-7600815-526-7601faxChairmanoftheBoardRonMcMorrisMapleRidgeBCCANADAFirstViceChairmanSteveSchoebenBloomingtonMNSecondViceChairmanRexCrumptonTulsaOKTreasurerDwayneDugasNewIberiaLAPresidentPaulHauglieEDITORJimRickoffjimrickoffgmail.comTECHNICALEDITORSDaveHagendaveaera.orgSteveFoxsteveaera.orgMikeCarusomikeaera.orgGaryLewisenginesmsn.comMikeEighmymikeeighmygmail.comCONTROLLERMelissaRizzimelissaaera.orgGRAPHICDESIGNMariaBeyerstedtmariamcreative.usADVERTISINGSALESJimRickoffjimrickoffgmail.comHalFowlerhalfowlersales.comPRODUCTIONJanJuhljanaera.orgCIRCULATIONKarenTenderingkarenaera.orgINTERNATIONALLIAISONYolandaCarranzayolandaaera.orgCHIEFTECHNOLOGYARCHITECTRichardRooksrichardaera.org16586874 httpwww.sbi-e-catalog.com2013S.B.InternationalInc.Allrightsreserved.OcengineprofessionalWWW.AERA.ORGEP3 4OCT-DEC2013engineprofessionalFROMTHEPUBLISHERBYPAULHAUGLIEAERAPRESIDENTAuthorsNoteForpurposesinthiscolumnthetermsenginebuildingandenginerebuildingwillbeusedinterchangeablyandwillbemeanttorefertothesamething.Anyquestionspleasecall815-526-7343.SowhatisthestateofenginerebuildingtodaySomesayitsgoingthewayoftherotarydialphonewhileothersassumethatitwillalwaysbethere.Stilltherearethosethatbelieveenginerebuildingisjustnowhittingitsstrideandagrowingnumberthatfirmlybelievethingsareonlygettingbetter.Ifollowtheschoolofthoughtthatlikeothermajorindustriesenginebuildingandrebuildingexperiencesupsanddowns.Howthosewithinthatindustryhandlethemiswhatdefinesit.DotheylooktheotherwayhopingthatthestormspassordotheylookwithinthestormtofindopportunitiesItssafetosaythatthepast5-6yearshavebeenchallenging.Howeverthroughthesechallengestherehasbeengrowthandnewopportunities.Thosewhohaveseizedtheseopportunitiesandfacedthechallengeshead-onaregoingstrongtoday.Unfortunatelythosethathavechosentositandwaitforthephonetoringorforthenextpersontowalkthroughthedoorhavemostlikelyclosedtheirdoors.Thisisatoughbusinesswereintheresnodenyingbutshowmeonethatisnt.SohowdoesonestaystrongintheenginebuildingbusinessObviouslybymakingsureyoureprofitablewevetouchedonthatbefore20132ndquarterissuebutalsobykeepinganeyeandearoutfornewopportunities.Notbeingafraidtobranchoutintootherareasbyfocusingmoreonyourspecialtieswhileremainingopentoexistingbusiness.LetmebeclearImnotsuggestingthatanyoneabandontheircurrentbusiness.Asanexampleyourshopdoescompleteengineworktoptobottombutyoualsohaveagoodbusinessinjustcylinderheads.Ifyouputalittlemorefocusonthecylinderheadonlysidewhilestilldoingthecompleteengineworkthatisawaytohighlightyourspecialty.IhavebeenintomanyshopsinthepasteightmonthsandhaveseenexampleafterexampleofwhatIjustdescribed.AlmosteveryshopownerIvisitedwithnotedthatinorderforthemtoremainprofitabletheyneededtolookforotheropportunities.Evenpartsmanufacturersarefollowingthisformulaanditisprovidingthemwithfantasticopportunities.Thisisagreatbusinessthatwereallintoughyesbutgreatandletsfaceitwewouldnthavestayedinthissolongifwedidntenjoyitjustalittle.WritersLibertyIwouldliketotaketheselastfewparagraphsanddedicatethemtoJanJuhl.JanhasbeenwithAERAfor37yearsandshewillberetiringonOctober172013.TosayJanisdedicatedtoAERAisanunderstatement.Shehasbeenwiththeassociationthroughsomeofitsbesttimesandsomeofthenotsobesttimes.Janslovefortheassociationanditsentirecastofcharactersisunparalleled.Ihaveonlyknownherforalittlemorethanayearbutcantellyouwithoutherknowledgehistoryandbackgroundoftheassociationthesefirst12monthswouldhaveseemedawholelotlonger.IhavemetmanypeoplethathavebeenassociatedwithAERAforyearsandoneoftheirfirstquestionsisHowsJanorIsJanstillthereFromtheretheconversationsalwaysbecomereminiscentbutitsaidmoretomeaboutthetypeofpersonJanisandthetremendousamountofrespectandadmirationthatmembershaveforher.JanIpersonallywanttothankyouforallyouhavedoneforAERAandforhelpingtoguidemethroughmyfirstyear.Icertainlywishyouthebestandhopeyouenjoyeveryminuteofretirementyoudeserveit.CongratulationsJanJuhl.IPriortobecomingpresidentofAERAPaulHauglieworkedforMellingEnginePartsasCanadianSalesManagerandPerformanceProductManagerforMellingSelectPerformance.WhosknockingOpportunityisthatyou 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 AERAwelcomesnewmembersACTIVEAJsSmallEngineLawrenceMAAtlanticMarinePowerSystemsFtLauderdaleFLBoretekDieselPowerProductsRiversideCABrewsEngineLLCElkRiverMNCockrellRacingEnginesBarstowCAColumbiaSteelWorksLakeCityFLDavesHeadShopKannapolisNCDiamondAutomotiveOshkoshWIEdsAutoMachineComptonCAEngineLineMachineShopPalmdaleCAFranksDieselAutomotiveBillingsMTHPEngineSpecialtiesVictorCALazarusEnginesHollyMIMatraMotorYenilemeSanayiSSIstanbulTURKEYOmnitekEngineeringCorpVistaCAParkersHeavyEquipmentServicesColumbiaLAPowayAutoMachinePowayCARectificadoraJoarMedellinCOLOMBIARectificadoraSuroesteMedellinCOLOMBIAScarboroughEnginesSaucierMSStationAutoPartsCoraopolisPASunValleyPartsEnginesSunValleyCATNTPerformanceSalemINASSOCIATEDieselRebuildKitsMiamiFLFrontierCoresWyomingMILNEngineeringLLCMomenceILMaxspeedingrodsCongQingCHINANPRofAmericaBuenaParkCAMEMBERGETTERGaryThompsonABSProductsBreaCAMellingOpensNorthAmericanRDTechCenterMellingannouncedinJulythatphaseoneoftheir10000squarefootNorthAmericanResearchandDevelopmentTechCenterfacilityinJacksonMich.hasbeencompleted.WiththeopeningofthisnewTechCentertheircapabilitieshavedoubledandnowincludetheabilitytotestOilPumpsandWaterPumpsforperformanceanddurabilityaswellasworkonprototypeassembly.TherearefiveMellingEmployeesonstaffinthefacilitywithexpansionplansofadding9more.MellinghasalongtermmanufacturingvisionandiscommittedtoprovidingqualityproductsfortheiraftermarketandOEMcustomersbydevelopingthelatesttechnologyinfluidsystems.CurrentlyMellinghasseveralinnovativeproductsandconceptsinthepipelinebeingtestedinthenewTechCenter.TheyareconfidentthatthisnewdevelopmentwillshowthecommitmenttheyhavetotheIndustry.MellinghasbeentheoilpumpleaderinNorthAmericaforover60yearsandthisinvestmentwillhelpsetthefutureforthemtocontinueforthenext60.FormoreinformationcallMellingat517-787-8172orvisitwww.melling.com.IInmemoryofLewisE.LewWellerLewisE.LewWellerofLakeViewNYpassedawayonJuly202013.BelovedhusbandofJoanneneeMarciszewskiWellerdearestfatherofRobertTaraWellerandAshleyWellerAlexDorofylovinggrandfatherofZacharyandIsabellesonofthelateEarlandEllenWellerbrotherofJoannelateEugeneSalisburybrother-in-lawofDavidLoriMarciszewskiandDianeDavidRobinsonalsosurvivedbyniecesandnephews.Lewwasanindependentmachinetoolrepresentative.HelovedraisingandbreedingLabradorRetrieversandhadapassionforhuntinganddragracing.IInmemoryofRicHavelRicA.HavelofWestSalemOhiopassedawayonSeptember62013.Hewas61yearsyoung.Ricwasaformerowneroperatorofanautomotivemachineshop.Withover20yearsofweldingandconsultingexperienceintheautomotiveandmachineshopindustrieshealsomadepresentationstoassociationsandtrainedmachineshopemployeesatmanycompanies.HemostrecentlyhelpedAERAtrainautomotivemachinistsinaluminumweldinginMexico.IInmemoryofLenStevensLenStevensofBarrieOntarioCanadapassedawayonMay252013fromcomplicationsduetoParkinsonsdiseaseandpneumonia.Asperhisrequestnofuneralormemorialservicewasheldandnoobituarywaspublished.HeissurvivedbyhiswifeDorissonTrevorBarbdaughterJoanneDwaingrandchildrenandgreatgrandchildren.LenwasanoperatingmanagerforLansairanenginepartsdistributioncompanycoveringallofCanada.Heretiredin1992.Hewasarealpeoplepersonandagreatleaderwithafun-lovingattitude.Hehelpedlaunchthecareersofmanyenginepartsspecialistswhoarestillintheindustrytoday.IIindustrynewscalendarOCTOBER9AERATECHSKILLSCONFERENCEHostedbyPartsWarehouseSupplyatArrowheadStadiumKansasCityMOOCTOBER26AERATECHSKILLSCONFERENCEHostedbySunnenandDartatMacombCommunityCollegeWarrenMINOVEMBER5-7AAPEXSHOWSandsExpoCenterLasVegasNVwww.aapexshow.comNOVEMBER5-8SEMASHOWLasVegasConventionCenterLasVegasNVwww.semashow.comAERABooth22431DECEMBER12-14PRISHOWIndianapolisConventionCenterIndianapolisINwww.performanceracing.comAERABooth55166OCT-DEC2013engineprofessional ONASTRONGFOUNDATION.SUCCESSISBUILTThebestenginebuildersintheworldknowthatwhentheyarebuildingengineseventhebesttechniquesandhighestprecisionwillnotmakeupforinferiorparts.ThatiswhythecornerstoneofeveryengineshouldbeCleviteenginebearings.Afterallitisyourreputationontheline-wouldyoutrustittoanythingelsewww.mahle-aftermarket.comengineprofessionalWWW.AERA.ORGEP7 AERAcongratulatesthosewhohavecompletedtheAERAOnlineTrainingProgramAsofSeptember182013208peoplehaveenrolledintheAERAOnlineTrainingProgramforCylinderHeadandEngineMachinistcertificates.Foracompletelistofgraduatesgotowww.aera.orgaera-universitycertificates.PhillipCreweisthefirstprofessionalorchestralmusiciantocompletetheAERAOnlineCylinderHeadandEngineMachinistCertificateProgram.HeisthePrincipalTimpanistkettle-drummerforVancouverOperainVancouverBCCanada.YouarenodoubtcurioustoknowhowanorchestralmusiciancametobeinterestedintheAERAmachiningcourse.Sincehewasateenagerhehasbeeninterestedinmuscle-carsandhighperformanceV-8swhichculminatedwithhimtuninganddrivingdragracecarsinhisearlytwenties.Althoughsomewhatsuccessfulhisracingcareerhadtobeputonhiatusafteronlytwoyearssohecouldpursuehiscareerinmusic.Twentyyearsauniversitydegreemarriageahouseasuccessfulmusiccareerandtwochildrenlaterhewasabletopickupwhereheleftoff.Heboughta1980Camaroandatrailerguttedandrebuiltthecarandwentracing.Resurrectinghisoldpassionforracingalsorekindledhisinterestinrebuildingperformanceengines.Althoughhehadalreadyrebuiltanumberofenginesandhadagoodgeneralunderstandingoftuningforperformancehereallywantedtomorefullyunderstandtheintimatedetailsandtheoryinvolvedinmachiningandassemblingperformanceengines.HislatestracingendeavorintroducedhimtotwogreatsponsorsLordcoAutoPartsandMachineShopsandtheInternationalAssociationofMachinistsandAerospaceWorkers.ItwasataLordcotradeshowthathewasgivenacomplimentarycopyoftheAERApublicationEngineProfessional.WhilereadingitcovertocoverhecameacrossbothanadvertisementandanarticleabouttheAERAonlinemachiningcourse.Afewemailslaterhewasenrolled.IhavethoroughlyenjoyedtakingthecourseandamecstaticwiththeamountofknowledgeIlearnedfromboththebookandtheonlinevideostutorialsandexamsPhillipsaid.Iputtheinformationtouseimmediatelywhiletakingthecoursebyconcurrentlybuildinganewstrokerracingengine.IwassoinspiredbytheAERAprogramthatIamactuallynowlookingattakingapracticalmachiningcourseatmylocaltechnicalinstitute.IndividualslikePhillipleadthewayformanyotherdedicatedenginemachinistsinterestedinprovingwhattheyknow.IfinterestedinaddingtoyourresumeofengineexperiencecallAERAat815-526-7600ext.202andaskforKarenTenderingore-mailkarenaera.org.Shecanansweryourquestionsandwhenreadyregisteryoutobegintheprogram.Formoreinformationseepage84.IIindustrynews8OCT-DEC2013engineprofessionalAERAOnlineTrainingGraduatePhillipCreweisthefoundercrew-chiefanddriverforPRCRacinginNewWestminsterBritishColumbiaCanada.AreyouanengineguyWeareContactusbecausewehavetheanswersforengines.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372.JointodayGotopage98foramembershipapplication.500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600www.aera.orgemailinfoaera.orgtwitter.comaeraepfacebook.comaeraep MichiganRacerWins20000EngineProRacingEngineAGrassLakeMich.racerwasthelastmanstandinginadrawingforanewracingengineheldatUS131MotorsportsParkinMartinMich.TracyMuchlerwasawardedtheenginewhichwasprovidedbyEngineProandPro-FilerPerformanceProducts.Thisisthesixthyearforthepromotionwhichisheldtowardtheendoftheracingseasonatthetrack.Theenginevaluedat20000wasassembledbyPerformanceEngineeringwithpartsandservicessuppliedbyPro-FilerMellingPerformanceHastingsRacingOliverFerreaCompCamsJEPistonsCleviteFel-ProMilodonRRWireloomandProFinishing.Racershadtoearntheirwayintothedrawingbybeinginthetopteninpointsstandingsintworacingclasses.TheeventwasheldduringtheNinthAnnualFunnyCarNationalsSeptember72013.Threeotherracersalsowonprizescontributedbythesponsors.TheyincludeRustyBaadKevinGroenveldandDavidMarckini.ScottOverlundsalesmarketingmanagerforEngineProPerfitcommentedEngineProsannualenginegiveawayisagreatwaytohelptheracerssupportalocaltrackandprovidesmanufacturerswithawaytosupportautoracingatthegrassrootslevel.IIindustrynewsRACEPROVEN.TIMETESTED.3200ArrowheadDr.CarsonCityNV89706TEL800227-8360FAX775883-9497www.dura-bondbearing.comPerformanceEnginesDeserveHIGHPERFORMANCECamBearings.IfyouwanttomatchperformancelevelsandgetthemostoutofyourenginesuseDura-BondRedBoxHighPerformanceCamBearingsHIGHPERFORMANCECAMBEARINGSPrecisionMachined-CenterlessGroundBoredMoreThanDoubletheFatigueStrengthofStandardBearings-WithstandsRacingSpringLoadsMicro-BabbittGrain-ControlledBabbittRollerBurnishedCOATEDHIGHPERFORMANCECAMBEARINGSRetainsEngineOilOntheSurfaceEvenUnderExtremeHeatandPressureSecondaryLubricationIntheEventMomentaryOilStarvationOccursQualityCamshaftBearingsSince194710OCT-DEC2013engineprofessionalTracyMuchleraboverightfromGrassLakeMich.celebratesafterwinningtheEnginePro2013EngineGiveawayheldattheNinthAnnualFunnyCarNationalsUS131MotorsportsParkMartinMich. engineprofessionalWWW.AERA.ORGEP11 12OCT-DEC2013engineprofessionalJanJuhlAERAVicePresidentandCorporateSecretaryretiresafter37yearsofdedicatedserviceItwasabigmoveformebackin1999whenIacceptedthepositionwithAERAtoheaduptheirmarketingefforts.IleftapositionwhereIhad65peopletoworkwithandgettasksdonetoanassociationwithonly13employees.WithamarketconsolidationinfullswingwehadourworkcutoutforusChangingourprogramstomeettheneedsofourmembersalongwithapresidentchangehadmanychallenges.JanJuhlquicklybecamemypartnerofstrengthandprofessionalismaswehelpedchartthenecessarychanges.Janhasaheartofgoldandherdedicationtotheassociationhashelpedmakeitwhatitistoday.Itiswithgreatsadnesstoannouncethatmypartnerisretiringbutonthebrightsideitiswonderfultoseeherhavetheopportunitytoenjoyherchildrenandgrandchildreninherretirement.ShesbeenatrueprofessionalarockhereatAERAandwewishhertheverybestinherretirement.OnapersonalnoteIlltrulymissJanbecauseshemademeabetterprofessionalperson.ThanksforallyourhelppartnerJanJuhlstartedatAERAparttimeonApril151976tohelpprepareforthe1976ConventioninNewOrleansinJune.ShehadsmallchildrensosheonlyworkedfortwomonthsbuttheyaskedhertoreturninSeptemberandatfirstshareajobwiththesecretarywhocouldntworkfivedaysaweek.JanwasthefourthpersonatAERA.StaffatthattimeincludedthePresidentCorporateSecretaryandBookkeeperPrinterandJan.In1980Janbeganworkingfulltime.AERAdidnothaveatechpersonuntil1986.Ofcoursetherewerenocomputers.Allmembercompanieshadatyped3x5indexcardfiledinlongcabinetdrawers.Inordertosendoutduesinvoicesandmonthlymailingstheyhadanaddressographmachineandhadplatescreatedforeachmembercompany.Whennewmembersjoinedorpeoplechangedtheirmailinginformationwesentalisttotheaddressographplatecompanyandhadtowaitatleastaweektoreceivetheupdatedplate.Alltheletterstomemberswerepersonalizedandtypedwithacarbonandacopyforthefiles.Theletterscouldnotbecorrectedsoeverythinghadtobeperfectthefirsttimeoritwasnecessarytostartallover.Intheearly1980sAERApurchasedawordprocesserandJanalongwithRuthGuthriewhoretiredin2001enteredallthecompanynamesover3000onthisprocesser.TheAERAofficedidallitsownprintingforthemembersandrentedasmallofficeinGlenviewIll.AERAhousedthesupplieswesoldtoourmembersinanearbyrentedwarehouse.In1987AERAboughtlandandbuiltalargeofficeinBuffaloGroveIll.Aftersellingthatbuildingin2008AERAhasleasedofficesinCrystalLakeIll.AERAheldaconventioneveryyeartheywerethesmallpaperortechshows.In1978thefirstEXPOoperatingmachineryshowwasheldinKansasCityMo.ThiswasalsothefirstconventionJanattended.JanalsoattendedthelastAERAconventionheldin2006inIndianapolis.NEWSFROMTHEEDITORBYJIMRICKOFFAERArecognizesstaffmembersfortheiryearsofdedicatedserviceJanJuhlaboverightispicturedwithAERAPresidentPaulHauglietopleftandAERAsMarketingConsultantJimRickoffbottomleftattheAERAMidyearBoardMeetingheldinKelownaBritishColumbiaCanadathispastSeptember.Itwasher31standlastBoardMeeting. engineprofessionalWWW.AERA.ORGEP13In1983JanbeganattendingtheMidyearBoardMeetingsasCorporateSecretarytakingtheminutesfromthemeetingsafterLaRueLundinretired.JustlastmonthJanreturnedfromher31standlastBoardMeeting.Oneofthehighlightsofherworkwiththeassociationhasbeenthepeopleshehasmet.AllthemembersandparticularlytheBoardofDirectorsareagreatgroupofpeopleandIhavebeenprivilegedtohaveknownthemJansaid.JansproudestprofessionalmomentwaswhenshereceivedtheCharlesW.YountAwardinApril2005.Ithasbeenonherofficewallsincethenandwillmovetoherhomeaftersheretires.ShehaslivedinatownhouseinBuffaloGroveIll.forover20yearsandplansonstayingthereinretirement.ShehasbeenamemberofalocalBookClubfor40yearsandhastraveledtotheStratfordShakespeareFestivalinCanadaforcloseto20years.JanhastwosonsDavidandStevenandadaughterLynne.DavidhastwodaughtersMadeleine12andSophie9.StevenhasasonAidan20whoisinhisthirdyearatKnoxCollegeandadaughterOlivia17aseniorinhighschool.AllherchildrenliveintheChicagoareaaswellasherextendedfamilyofnephewsniecesandcousins.SinceshehaslivedintheChicagoareaherwholelifeshealsohasmanyfriendstheresomesinceelementaryandhighschool.Duringherretirementshelooksforwardtospendingmoretimewithfamilyandfriends.Shealsoplansondoingsomevolunteerworkandpossiblytakingsomecourses.JansaidIwillmissallmyfriendsatAERAbutIeagerlylookforwardtothenextchapterinmylife.ABOVEPastChairmanoftheBoardRichardHartmannpresentedJanJuhlwiththeCharlesW.YountAwardattheAERABusinessMeetingandIndustryAwardsduringEXPO2005inLasVegas.Thisawardisgiveninrecognitionofoutstandingservicetoourindustry.LEFTJanispicturedinherofficeinBuffaloGroveIll.whereAERAwasheadquarteredfrom1987-2008.LEFTJanworkingwithJimTemplinattheAERAofficeinGlenviewIll.JimTemplinwasAERAspresidentfrom1959to1984.Hewasthe2ndAERAPresident.PaulHauglieisthe5thpresidentsince1932.JanatherdeskattheAERAofficeinGlenviewIll. 14OCT-DEC2013engineprofessionalNEWSFROMTHEEDITORBYJIMRICKOFFAERAhonorsstaffmembersDaveHagenandKarenTenderingfor25yearsofserviceOnSeptember52013twoAERAkeyemployeeswerehonoredfor25yearsofdedicatedservice.BothhaveveryfamiliarfacesandhavehadextensiveinteractionwithAERAmembers.NodoubtyouwillrecognizethemourassociationispleasedtohonorDaveHagenandKarenTenderingfortheir25yearsofservice.AERATechnicalSpecialistDaveHagenbeganhisenginebuildingcareerinMooreheadMinn.atSturdevantsAutoParts.SeventeenyearsofvalvejobsandcompleteengineassemblyinDaveshometownlaunchedhiscareerinourindustry.ButconcretefloorsandheavyliftinghadhiminterestedinanewtechnicalpositionatAERAheadquartersinBuffaloGroveIll.DavewashiredbyAERAin1988whereheandJoePolichstartedtheAERATechnicalDepartment.HebeganasaTechResearcherwherehecatalogedenginespecdataforanewsoftwareprogram.Hesoonbeganansweringtechcallsfrommembersandatonepointwasoneoffivemembersinthetechdepartmentansweringover100callsperday.WhilethedepartmenthasdownsizedtothreefulltimetechspecialiststodayDavetrulyenjoyshisrollofseekingandfindinganswerstomembersquestions.DavealsoenjoystravelingforAERAtotradeshowsandourregionalTechSkillsConferencespromotingAERAspremiereenginespecificationsoftwarePRO-SIS.DaveismarriedtoTrishandthefatherofDavidandEmilybothcurrentlyattendingcollege.Heenjoysspendingtimeoutdoorsboatingandfishingwhentimeallowsalongwithwatchinglocalsportsteamsplayfootballandsoccer.KarenTenderinggraduatedfromhighschoolandimmediatelyattendedHarperCommunityCollegefortwoyearsbeforestartingatAERAinAugustof1988.Shestartedintheshippingdepartmentandpassedthroughthereceptionistdeskaccountingdepartmentandontoconventionregistration.Returningfrommaternityleavein2000afterthebirthofherdaughterKarencamebacktoapositioninContractServices.TodayshehandlesmembershiprenewalsinvoicingPRO-SISrenewalsEngineProfessionalmagazineadcontractsandregistrationforTechSkillsConferencesalongwithAERAOnlineTrainingregistration.InadditionKarenalsohelpsmemberswithPRO-SISinstallationandoperation.YessheisabusygalwithalotofmembershipinteractionTosaysheiscross-trainedisanunderstatement.IliketosayifyoudontknowwhotocallcallKarenshellknowKarenhasbeenmarriedtoherhusbandJackfor24yearsandtogethertheyhavea13yearolddaughterAlana.Theyenjoycampingcampfiresandlisteningtomusic.KarenexercisesdailyandisanavidChicagoBlackhawksandChicagoCubsfan.IJimRickoffistheEditorofEngineProfessionalmagazineandAERAsmarketingconsultant.Ifyouhaveanyquestionscommentsorconcernscall507-457-8975ore-mailjimrickoffgmail.com.SavetheDateOCTOBER9PARTSWAREHOUSESUPPLYArrowheadStadiumKansasCityMOOCTOBER26SUNNENANDDARTMacombCommunityCollegeWarrenMICONFERENCEHOSTINGOPPORTUNITIESIfyouareinterestedinhostingaconferencenextyearpleasecontactJimRickoffat507-457-8975oremailjimrickoffgmail.com.AERAPresidentPaulHaugliecenterpresentedawardstoKarenTenderingleftandDaveHagenrightfortheir25yearsofserviceduringaspecialdinnerheldintheirhonor. 16OCT-DEC2013engineprofessionalIn2010MercuryRacingrevolutionizedtherecreationalsportboatindustrywiththereleaseofthequadcamsfourvalveQC4v1100and1350sterndriveenginepackages.Nowin2013thenewQC4v1650Raceengineissettoagainraisethebarandcapturecheckeredflagsinthesportofoffshorepowerboatracing.Thenew1650isbasedonthesamefourvalvetechnologywithquadcamsanddrysumpefficiencyasitsconsumersiblings.Largerturbochargerspackedwithanimprovedcompressorwheeldesignprovidegreaterairflowforenhancedpowerandtorque.The9.0literquadcamfourvalveQC4vcylinderblockandheaddesigncombinedwithSmartCraftDigitalThrottleShiftDTSprovidesbigpowerwithluxury-car-likedrivability.TheDTSsystemalsofeaturesone-touchSmartStartandautomaticthrottlesynchronizationaswellasshadowmodefortripleorquadengineapplicationswheretwothrottleleversoperateallengines.ZeroEffortDigitalcontrolsprovideanintuitivecontrolexperiencepreciselysignalingdriverintenttothepotentpowerhouses.Whenthe1350wasbeingdevelopedafewyearsagoitdidnttakelongtorealizealargerstrongerdrivewasneededtohandlethemassivetorquecapabilitiesoftheQC4vplatform.Thankfullythenewdrivewasbuilttotakethatonandthensome.TheM8driveandhydraulictransmissionaredesignedtohandlethe1650shightorqueandpowerlevelsaswellasenduretreacherousoffshoredutycycles.AtthesametimethetransmissiondesignedspecificallyforSmartCraftDTSdeliverssmoothandconsistentshifts.Thesurface-piercingM8gearcaseinspiredbythelegendarydry-sumpSixdriveistwoinchesshortertocomplementthelowerengineprofile.LoweringenginemountinginaboatresultsinalowerEXTREME1650MERCURYRACEENGINEBYDAVEHAGENANDMIKECARUSO engineprofessionalWWW.AERA.ORGEP17centerofgravityforimprovedboathandlingandoverallperformanceitalsoprovidesmoreflexibilityinboathatchstyling.TheM8drivefeaturestherace-inspiredtwinpiniongearshaftdesign.FirstpatentedbyMercuryforoutboardracingbackinthe1950stheinnovativedesignsplitsthetorqueloadforahigherpowercapacitywhilemaintainingaslimsurfacepiercinggearcaseshapeformaximumefficiency.Theforgedlowergearsdesignedtohandlethehighertorqueofthe1650enginearelargerandevenmorerobustthanthoseusedintheworldchampionSixdrive.LiketheNXT1orNXT6theM8isdry-sumpedformaximumefficiencyandpoweroutput.POWERTOTHEWATERThemassivetorqueandpoweroutputofthenewengineistransferredtothewaterviaMercuryRacingsProFinish56-bladeCNCsterndrivepropellers.Thenewpropsaredesignedwithstaminaforthe1650smassivetorqueandsurfacepiercingimpact.InAugustofthisyeartheMercuryRacingpoweredMissGEICOpicturedonpage18participatedintheOffshorePowerboatAssociationracesinPortHuronOhioandLongBeachNY.TheirboatimpressedthefanswithconvincingwinsintheExtremebracketraceswhichhadaspeedcapof135mph.Thatruleputsaspotlightondrivingskillandaccelerationandtheirquicktimesinandoutoftheturnswerethedecidingfactorinthisbracketrace.The1650sranflawlessly.Theyrespondandpulllikenoother.TheyareablasttodrivesaidMissGEICOdriverMarcGranet.The1650isclose-cooledformoreuniformtemperaturedistributionoptimalrunningqualityandlongerlife.Closedcoolingcombinedwithaballbearingsupportedcompressorshaftenhances1650turbochargerperformanceanddurabilityaswell.OffshoreracerswillappreciateMercuryRacingsproprietarypulse-separatedexhausttuningwhichkeepstheturbosspooledupvirtuallyeliminatingthrottlelagandlow-endtorquedeficit.1650RACEKEYFEATURESPowerboatracingenginebasedonMercuryRacingsexclusivequadcamfourvalveQC4vengineplatformEngine9.0Ldisplacement90degreeDOHCV-8Racefuelcalibrationrequires112AKISunocoorequivalentracefuelLargerturbochargersforenhancedpowerandtorqueAluminumblockandheadsforreducedweightDurableNiComcoatedaluminumcylinderboresNiComcoatingimprovesheattransferanddurabilityQuadcamfourvalveQC4vdesignoptimizespowerandtorquethroughouttheengineoperatingRPMrangeIntakeandexhaustportflowissignificantlyimprovedoverconventional2-valveheadsMercuryRacingrevolutionizedtherecreationalsportboatindustrywiththereleaseofthequadcamsfourvalveQC4v1100and1350sterndriveenginepackages.NowthenewQC4v1650RaceEngineissettoagainraisethebarandcapturecheckeredflagsinthesportofoffshorepowerboatracing.M8Sterndrivefeaturestherace-inspiredtwinpiniongearshaftdesign. 18OCT-DEC2013engineprofessionalEXTREME1650MERCURYRACEENGINEBYDAVEHAGENANDMIKECARUSOOverheadcamdesignextendstheoperatingrpmrangeElectronicturbo-compressormanagementdeliversabroadtorqueunderalloperatingconditionsNewclosedcooledturbochargersfeatureaballbearingsupportedshaftforenhanceddurabilityAnenhancedcompressorwheeldesignprovidesgreaterairflowforenhancedpowerandtorqueandimprovedsoundqualityIntegralexhaustsystemdesignedanddevelopedspecificallyforQC4vPulseseparatedexhausttuningfromMercuryRacingsexpertiseinhighperformance2-strokeenginesimproveslowRPMturbochargerresponseCorrosionEngineandturbochargercentersectionsareclosedcooledforenhancedcorrosionprotectionandenginedurabilityThechargecoolerismadeofamilitaryspecificationalloyforexcellentcorrosionresistanceADVANCEDELECTRONICSAPropulsionControlModulePCMmicroprocessorwithracespecificfuelcalibrationrunsonrealtime.Theenginesabilitytoprovideaconsistenthorsepowerinanyconditionorlocaleeliminatesthehassleofre-proppingtheboattomatchconditions.ThePCMalsoenablesindividualcylindercontrol.Thisabilitytooptimizefuelandsparktimingindependentlyforeachcylinderenhancesenginerunningqualityperformancefueleconomyanddurability.Theuseofeightindependentignitioncoilsonepercylinderhelpseliminatesparkplugfouling.DigitalThrottleandShiftSingle-turnSmartStartAutomaticthrottlesynchronizationShadowmodewheretwoleverscontrolthreeorfourenginesEngineGuardianreal-timeself-protectionenginefaultdiagnosticsandmessagingSequentialfuelandsparkThe2013MissGeico1650MercuryRacingEngineparticipatedintheOffshorePowerboatAssociationracesinPortHuronOhioandLongBeachNY.ThisboatimpressedthefanswithconvincingwinsintheExtremebracketraceswhichhadaspeedcapof135mph.Thatruleputsaspotlightondrivingskillandaccelerationandtheirquicktimesinandoutoftheturnswerethedecidingfactorinthisbracketrace. SPECIALIZINGINREPLACEMENTPARTSFORBENDIXCARRIERCATERPILLARCUMMINSDETROITDIESELHINOISUZUMIDLANDNAVISTARTHERMO-KINGTRANE...yourFriendlyalternativeDieselenginepartsESCOINDUSTRIESINC.TOLLFREE1-800-372-6872FAX951-782-2136SALESESCOUSA.COMWWW.ESCOUSA.COMALLOTHERCOMPANYBRANDPRODUCTANDSERVICENAMESAREUSEDHEREINFORIDENTIFICATIONPURPOSESONLYANDMAYBETHETRADEMARKSSERVICEMARKSORTRADENAMESOFTHEIRRESPECTIVEOWNERS.THEREISNOAFFILIATIONORSPONSORSHIPBETWEENTHESECOMPANIESANDESCOUNLESSEXPRESSLYSTATED.CARRIERBENDIXREPLASPECIALIZINGINTERPILLARCARRIERBENDIXARTSFORCEMENTREPLASPECIALIZINGINTHERMONMIDLANDISUZUHINODETROITDIESELCUMMINS-KINGRMIDLANDISUZUHINODETROITDIESELCUMMINSTERPILLARTRANE-KINGTHERMOiend...ourTRANE-KINGyalternativeDieselenginepartsyalternative...yourFDieselenginepartsyalternativeED.XPRETHESECOMPBETWEENSPONSORSHIPTHEREISNOTHEIRRESPECTIVEOWNERS.OFVICEMARKSORTRADEMARKSSERTHEBEBRANDPROANYOTHERCOMPALLANDESCOUNLESSANIESTHESECOMPINRAFFILITHEREISNOTRADENAMESVICEMARKSORANDYTIONPURPOSESONLVICENAMESANDSERBRANDPRODUCT PREDICTIVEENGINEERINGEXTREMETESTINGTodaysnewhighoutputturbo-chargedenginescreateunprecedentedheatandstress.ButnewFel-Prohightemperaturealloymaterialsarebeingdesignedtohandlethoseextremesandtomeetthesealingneedsofprofessionaltechniciansbothtodayandtomorrow.HIGHTEMPERATUREALLOYHTA20OCT-DEC2013engineprofessionalAERATechnicalSpecialistDaveHagenpicturedabovelefthasover41yearsofexperienceinourindustry.AERATechnicalSpecialistMikeCarusopicturedaboverighthasover50yearsofenginerebuildingandhigh-performanceexperience.FormoreinformationcalltheAERATechHotline888-324-2372.Providesexcellentfueleconomyandrunquality105ampchargingsystem50moreoutputcomparedtocompetitivemodelsamplepowersupplyfortodaysadvancedmarineelectronicsPROPULSIONSYSTEMAllnewhydraulictransmissiontohandlethe1650smassivetorqueM8sterndrivepackedwithheavy-dutycomponentsisdesignedspecificallytohandlethe1650shighertorqueDelivers35morecapacitythanthelegendarySixdriveTwoinchesshorterresultinginanoveralllowercenterofgravityforimprovedhandlingandoverallboatperformanceFeaturestwinpiniongearshaftdesignfirstpatentedbyMercuryforoutboardracingbackinthe1950sInnovativedesignsplitsthetorqueloadforahighpowercapacitywhilemaintainingaslimgearhousingshapeforhydrodynamicefficiencyDry-sumpedformaximumpower-outputAnactiveanodeenhancescorrosionresistancebyadjustingitscurrenttotheprotectionneedNewProFinish5and6-bladeCNCsterndrivepropellersaredesignedwithstaminaforthe1650smassivetorqueandsurfacepiercingimpact1650RACESPECIFICATIONSSEPTEMBER2013RatedPoweratTransmission1650Hp1230kWFullThrottleRPM6500-6800DisplacementCIDLiter5529.0Boreinmm4.57116Strokeinmm4.21107CompressionRatio7.81CylinderArrangementV-8Alternatorampwatt1051481ControllerPCMFuelSystemSequentialFuelInjectionFuelRequirements112AKIOctaneSunocoRaceFuelorequivalentTransmissionMercuryRacingDry-SumpHydraulicDriveUnitDry-SumpM8GearRatioApplicationdependentContactMercuryRacingforadditionalinformationLengthinmm26.69678FromBackofBlockWidthinmm34864Heightinmm29737FromCrankshaftCenterlineWeightlbskg1720782WarrantyNoneThisproductishighlyspecializedandproducedinlimitedquantitiesforsalewithoutwarrantytoqualifiedpowerboatracingprofessionals.I engineprofessionalWWW.AERA.ORGEP21 22OCT-DEC2013engineprofessionalDashsizesor-ANsizesarecommonlybelievedtohaveoriginatedinmilitaryapplicationsonaircraftshipstanksetc.inordertocreatedurableandreli-ablehydraulicfuelandcoolantplumb-ing.Thetoughbraidedreinforcedhosecoupledwiththread-onconnectionsthatwerereliableincombatconditionsledearlyracerstobuymilitarysurplushosehoseendsandfittingsintheyearsfollow-ingWWIIandtheKoreanwar.Therac-ingcommunityquicklylatchedontothisstyleofplumbingresultingincommonuseintodaysperformanceandracingmarkets.Theterm-ANacommonabbreviationforArmyNavyspecifica-tionstickswithustothisday.Thatswhythereinforcedhosehoseendassem-bliesweseetodayarereferredtoas-ANassemblies.Sowerefertothesehoseshoseendsandfittingssizeswiththewordorsym-boldashorbythetermANorbytheterm-AN.Itallmeansthesamething.ForexampleImplumbingmyfuelsys-temwithdash6hoseorIuseddash8ANhoseformycarburetorfeed.Wheninwrittenformthedashsymbol-ortheworddashmightbeused.-ANARMYNAVYhosesizingisbasedonsingleanddouble-digitidentifi-cationnumbers.Commonsizesforper-formanceautomotiveapplicationsinclude-3-4-6-8-10-12-16and-20thelargerthenumberthelargerthehosediameter.-3and-4sizesaretypicallyusedforbrakelineapplicationssmalloillinessomesmallfuellineapplicationspressuregaugesandvacuumlines.-6sizeistypicallyapplicableforfuelandoilplumbing.-ANHOSEAND-ANHARDWAREAbasicunderstandingof-ANplumbingTEXTANDPHOTOSBYMIKEMAVRIGIAN-ANplumbinghoseadaptersandhoseendsprovideexceptionallyreliablefluidconnections. engineprofessionalWWW.AERA.ORGEP23-8sizeistypicallyusedforfuelcoolantandoilplumbing.-10sizeistypicallyusedforoilfuelorheaterhoseplumbing.-12sizeistypicallyusedforcoolantlargefueldeliveryordry-sumpoil.-16sizeistypicallyusedforcoolantdry-sumpoilorlargefueldelivery.-20sizeistypicallyusedforcoolantradiatorhose.WhatdotheseANdashnumbersreal-lyrepresentActuallythereisalogicalreasonforthesenumberswhichother-wisemightseemlikemade-upcodes.Thedashnumberreferstothehoseinsidediameterinincrementsof116ofaninch.Forexamplea-10sizetranslatesto101658insidediameter.Thisisaneasywaytounderstanddashsizes.Justthinkintermsof116increments.A-6meansthattheinsidediameteris616or38.A-8sizeis816orinsidediameter.Justrememberthattheformatisbasedon116.Nottomakethingsconfusingbutthose116incrementsarenominalnumbersthatindicatetheO.D.ofthehoseendsinternalmetaltubethistubeslipsintothehose.InrealitymostANhosemakersactuallymaketheirhosesabitonthetight-tolerancesidetothetuneofabout132smallerthanthetheoreti-calnominaldiametersizewhichaidsinhosesealingontothehoseendstube.Soa-6hosewhichtheoreticallyshouldhaveaninsidediameterof61638or1232morethanlikelyfeaturesaninsidediameterof1132.Neverthelessusingthe116theoryasyourguidewillhelpyoutoeasilyvisualizewhattheinsidediameterwillbe.Forexamplea-6hosewillprovideabouta38I.D.anda-8hosewillprovideaboutaI.D.Ifyouvedecidedthatyourfuellineshouldfeatureainsidediameteryouknowthata-8ANsizewillbethecorrectchoice.ANTHREADSIZEThethreadsizeoftheANhoseendanditsmatingfittingareasfollowsThestandardoftheANhoseworldatleastforautomotiveperform-anceapplicationshastraditionallyinvolvedaredandblueanodizedfinish.Whilealuminumfittingswereoncetradi-tionallysolidblueandsometimesredtwo-piecehoseendsweregenerallyblueandred.Howeverwiththeintroductionofblackwhichhasbecomeincreasinglypopularandbrightfinishesyoucantreallydependonthecolortoidentifystyles.Colorshadesaswellasfinishglosswillvaryamongmakers.Soifits-ANHOSESIZINGCHARTACTUALI.D.SIZENOMINALI.D.OFTHEHOSE331618414732638113281271610589161234111616178201-141-18NOTETheabovesizesarebasedonexamplesofRussellhose.Diametersmayvaryamonghosemanufacturersandamonghosematerials.Operatingpressureratingswillvarydependingonthespecifictypeofhoseconstruction.ANSIZETHREADSIZE338-24UNJ4716-20UNJ6916-18UNJ8-16UNJ1078-14UNJ121116-12UNJ161516-12UNJ20158-12UNJTraditionalredblueanodizedhoseendsremainpopulartoday.Angleconfigurationsareavailableforanyrouting.SilhouetteviewofANmalethreadsrangingfrom3to20.ArtcourtesyEarls. importanttoyouthateverythinglooksmatcheditsbesttostickwithonepartic-ularmanufacturershoseendsandfit-tings.Rememberanodizingisnotacoating.Itsactuallyacontrolledoxi-dationprocessthatisusedtoprotectthefinishofanalloytoallowtheuseofacolordyeandortohardenthealloysur-face.Adullnon-glossappearanceisactu-allyquitenormal.Ifahigherglossisdesiredmanufacturerscanpolishthealu-minumbeforehandandtheycanevenuseaglossclearanodizingoftencalledabrightdip.Thepointistolookatthevariousmakersofferingsandifappear-anceiscriticaldecidewhatcolorandfin-ishyouprefer.Thenstickwiththatonemanufacturerslineofplumbinghard-ware.Otherwiseifyoumixitupyoullhavedifferentshadesofbluesandredsandglossandflatfinishesunderthehood.Ifitsaracecarfunctionismostimportant.Butifitsashowcarorstreetroditlllookbestifallpiecesmatch.ExamplesoftodaysmanufacturersincludeAeroquipXRPFragolaRussellandEarlstonamebutafew.HOSEENDSHoseendsattachdirectlytothehoseandprovideahighpressureseal.Thehoseendfeaturesatwo-piecearrangementconsistingofasocketthisslipsovertheendofthehoseandfeaturesafemalethreadedopeningandamalefemalecomponent.Themalefemalepiecefea-turesamalethreadednipplethatthreadsintothehoseendsocket.Thefemaleexposedendisthenreadytothreadontoamalefittingatthedesiredinstalla-tionlocation.Thesecomponentsarecalledhoseendsbecausetheycomprisetheendofthehose.NoteWhilethisisthemostcommonconfigurationnotallassembledhoseendsfeaturefemalethreads.Somemakersofferspecialmalethreadedendsthatfitintofemalefittings.Hoseendsnotonlyallowhosecon-nectionandsealingbutbecausehoseendsareavailableinvariousshapestheselectionofthehoseendshapewillallowyoutoobtaininstalledanglesnecessaryforclearanceandpreferredrouting.Hoseendsareavailableinstraight30-degree45-degree90-degree120-degree150-degreeandeven180-degreeshapes.Withregardtoangledhoseendsthesearealsoofferedintwobasicprofilesincludingstandardprofileandlowprofile.Standardprofilehoseendsfeatureatubeneckwhilelowprofilehoseendsfeatureaforgedormachinedneckthatshortensthehoseendsdistancefromthefittingconnectiontothebend.Lowprofilever-sionsaregoodchoiceswhereinstallationspaceisatapremium.NOTEDependingonthesizeofthe-ANhoseendassemblieswithpipethreadconnectionsareavailableinafullrangeofNPTsizesfrom18NPTallthewayupto12NPTwithNPTalsoavail-ablefromsomemakers.Generallyhoseendsthatfeaturefemaledash-sizeconnectionsaredesignedtoacceptthesamehosedashsizeateachendforinstanceahoseendmaybelabeled-6femaleto-6hosewhichmeansthata-6hosewillconnecttothetubesleeveendandthefemalethreadedconnectionwillacceptamale-thread-6fitting.Howeversomemakersoffersiz-ingdifferentials.Forexamplea-6femaletoa-8hosehose-endmightbeavailabletosuitaspecialtyneed.Howeverthemostcommonapproachforhoseendsisadesignthataccommodatesthesamedashsizeateachend.HOSESWereallaccustomedtoseeingbraidedstainlesssteelhosewithblueandredhoseendsoncustomcarsandracecars.Howevergreatstrideshavebeenmadebythevarioushosemakersresultinginawidearrayofchoiceswithvariousbene-24OCT-DEC2013engineprofessional-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANExamplesofANhoseendsizesfromleft-6-8-10-12-16and-20.Exampleofa90-degreetube-stylehoseend.Theswivelnutallowseasyclockpositioning.A90-degreeforgedbodyhoseend.Forgedstylesoftenprovideadditionalclearancefortightspaces.InadditiontohoseendsthatfeaturefemalethreadsforattachmenttofittingshoseendsarealsoavailablewithmalethreadsineitherstraightANthreadshownhereaswellasNPTthreads.FittingsadaptersareofferedinawidevarietyofanglesandthreadconfigurationsincludingmaleANflarewithmaleNPTshownmaleANflarewithmaleANstraightthreadandmaleANflarewithfemaleANthreadinbothsolidandswivelstyles.Ifyoucanimaginetheconfigurationchancesareitexists. EVERYTHINGTOBOOSTYOURBUSINESSISHERE.THEONLYPARTMISSINGISYOU.EXHIBITDAYSTUESDAYNOVEMBER5FRIDAYNOVEMBER82013EDUCATIONDAYSMONDAYNOVEMBER4FRIDAYNOVEMBER82013LASVEGASCONVENTIONCENTERLASVEGASNVRegisternowatwww.SEMAshow.comEPRengineprofessionalWWW.AERA.ORGEP25 26OCT-DEC2013engineprofessional-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANfits.Therescertainlynothingwrongwithstainlessbraidedhose.Itworksgreatandlooksgreat.Theonlydownsideofstain-lessbraidedhoseisitsweightanditsabrasiveoutersurface.Whilethedurablestainlessbraiddoesawonderfuljobinprotectingthehoseitselfthissurfacecanscratchorevenfile-throughanadjacentsurfaceifthehoserubsagainstanythingforalongperiod.Whereweightsavingsareneededandorabrasiondamageneedstobeavoidedtheindustrynowoffersaselectionofoptionalhosedesignsthatarelighterandthatwontabradenearbysurfacesbutstillprovidethestrongreinforcementandprotectionforthehoseitself.Onetypeisntbetterthananoth-eritssimplyamatterofselectingthetypethatbestsuitsaparticularapplica-tionorpreference.Asanalternativetostainlessbraidedhoselighter-weighthighperformancehoseisofferedwithKevlarouterwovenbraidornylonbraidedsheathingandspecialelastomerichosethatfeaturesnoouterbraidedcover.Syntheticrubberhosefeaturinginteriorbraidedfabricsheathforstrengthisavailablewithmaximumpressureratingsinthe250psirangeandcanbeassembledusinghosenipplesandbeadedtubing.Hoseswithatoughabrasion-resistantouternylonsheathingbondedtoatextileinnerbraidandsyntheticrubberlinercanbeassem-bledusingtraditional-ANhoseendsorcrimphoseendswithmaximumpressureratingsinthe1400psirange.Ultra-lightKevlar-outer-sheathedhosesareavailablethatweighabout50-60lighterthanstainlesssteelbraidedhoseswithmaxi-mumpressureratingsinthe1100-1200psirangebutmayrequireonlytheuseofdedicatedcrimphoseendsrequiringtheuseofahosecrimpingmachineforassembly.Awiderangeofchoicesareavailabletodaynotonlyintermsofweightflexibilityandmaterialsbutincolorsaswell.FITTINGSADAPTERSThefittingalsocalledanadapterallowstheconnectionofthehoseendtothecomponent.Insomecasesthefittingwillbeprovidedaspartofthecomponentforexampleanengineoilcoolermightalreadyfeaturewelded-on-10fittingssoa-10hoseendwillthreaddirectlyontothecooler.Inothercasesyoullneedaseparatefittingtofinishtheconnection.FittingsareavailablewithANthreadsand37degreeflareseatononeendandanappropriatethreadontheoppositeendtofitthecomponent.Forexampleletssaythatyouneedtoplumba-10hoseassemblytoyourwaterpump-to-heaterrouting.Thewaterpumpmayfea-tureaNPTfemalethreadedhole.InordertocompletetheconnectionyoullneedanANfittingthatfeaturesamaleNPTatoneendanda-10maleattheoppositeendtoattachtoyourhoseend.Fittingsareavailableinawidevari-etyofboththreadsizecombinationstoaccommodateanyreasonablypracticalconnectionbetweenvariousANhose PERFORMANCEENGINEBEARINGS endsandNPTthreads.Fittingsarealsoavailableinstraightthreadasopposedtotaperedpipethreadforlocationsthatfeaturestraight-threadholes.IftheANfittingfeaturesstraightthreadforthecomponentconnectionasealingO-ringwilllikelyberequired.Fittingslikehoseendsarealsoavail-ableinvariousshapesincludingstraight45-degreeand90-degreetofurtheraccommodateplumbingroutingandclearanceissues.Withthecombinationofhoseflexandhoseendandfittingshapesitispossibletoachieveextremelyneatandtidyplumbingroutingthatwouldpleaseeventhemostdemandingappear-ance-consciousbuilder.Metric-threadadaptersarealsoavail-abletoaccommodatealldomesticandimportOEvehicleapplicationsfortheuseofAN37-degree-seatplumbingcon-nections.The-ANthreadsarethesameasalwaysbuttheoppositeendinsteadoffeaturingNPTor-ANstraightthreadfeaturesmetricthreadsizeinstead.ANadaptersformetricapplicationsareavailableinallcommonANtometricsizesincludingAN-4to8mmx1.5AN-4to10mmx1.25AN-4to10mmx1.5AN-4to12mmx1.5AN-4to14mmx1.5AN-6to10mmx1.25AN-6to10mmx1.5AN-6to12mmx1.5AN-6to14mmx1.5AN-6to16mmx1.5AN-8to12mmx1.5AN-8to14mmx1.5AN-8to16mmx1.5AN-8to18mmx1.5AN-10to14mmx1.5AN-10to16mmx1.5AN-10to18mmx1.5AN-10to20mmx1.5AN-12to14mmx1.5AN-12to16mmx1.5AN-12to18mmx1.5AN-12to20mmx1.5AN-12to30mmx1.5AN-16to16mmx1.5AN-16to18mmx1.5AN-16to20mmx1.5AN-16to30mmx1.5NoteAsfarashoseendandfittingmaterialsareconcernedbothsteelandaluminumareavailable.Forpurposesofweightsavingandappearancemostpeo-plefavoraluminumasyoualreadyknowhosehardwaremakerscommonlyofferaluminum-ANhoseendsandfit-tingsinblueandredanodizedcolors.Howeverforbrakesystemconnectionssteelhoseendsandfittingsarepreferredtoavoidthepotentialoffatiguecracks.BAREALUMINUMADAPTERSForthosewhowishtohavetheir-ANadapterscustom-anodizedinothercolorsbareun-anodizedaluminumadaptersareavailablefromselectmanufacturersnotallmakersofferbareun-anodizedhardware.Ifyouwantun-anodizedhoseendsyouneedtocheckwiththevariousmakers.Dependingonexistingstockorbackordersituationsyoumightbeabletoplaceacustomorderoryoumightgetluckyandbeabletosnatchwhatyouneedfromexistingstock.Thereareanumberofanodizingshopsinthecountrythatdoexcellentwork.Whilethestan-dardcolorsthatallanodizingshopscarryusuallyincludeblackblueandredthereareothershopswhoofferadozenormorecolorsandyetothershopsthatcanattempttomatchthecoloryouwant.Ifyoupurchasedalready-anodizedhoseendsandadaptersbutwanttochangecolorthiscanbedonebutyouneedtobeawareofafewthings.Iftheitemhasalreadybeenanodizedandsinceanodizingisessentiallyanoxidationprocessthesurfaceisnowetched.Whentheoriginalcolorisstrippedoffchemi-callytheresultingsurfacewillberatherdull.Ifyoulikeaflatlookyoureinbusiness.Ifyouwantaglosssurfaceyouhavetwochoiceseachpiecemustbepol-ishedbeforeanodizingoryoucanrequestaclearglossbrightdipfinishoverthecoloranoptionthatnotallanodizingshopsoffer.Fromastandpointofappearanceonlybeawarethatoneofthebigvariableslieswiththecompositionofthealuminumstock.Dependingonthehardnessandalloymakeupsomealu-minumpieceswillprovideaglossierfin-ishthanothers.Alsothesamecoloranodizingwillappearlighterordarkerwhenappliedtodifferentgradesofalu-minum.Ifyouwantallofthecustom-anodizedpiecestomatchbesurethatyouobtainallofthepiecesfromthesamemanufacturerSEALSCRUSHWASHERSFORSTRAIGHTTHREADWithNPTthreadssimplyapplyTeflonsealingtapeorcompound.Howeverwhenusingan-ANadapterthatfeaturesstraightthreadatoneendyouneedasealingwasher.Dependingontheapplica-tionsyoullneedeitheranO-ringoracrushwasher.O-ringsareavailableinbothBunaNsyntheticrubberandinViton.Bunaiscompatiblewithmost28OCT-DEC2013engineprofessional-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANWheneveryouredealingwithafittingthatfeaturesamalestraightANthreadasseenhereyoumustuseanO-ringforsealingatthestraightthreadside.Whileblueandredanodizedcolorshavebeenthenormfordecadesinthepastfewyearsblackaswellasbrightsilverchromefinisheshavebecomeincreasinglypopular. engineprofessionalWWW.AERA.ORGEP29Anexampleofblackhardwarecoupledwithbraidedstainlesshose.TheownerofthisenginefeltthatusingblueorredwouldnotcomplimenttheChevyorangebackground.Dontseeanoff-the-shelfcoloryoulikeYoucanalwayshaveyouraluminumhoseendsfittingsortubenutsanodizedinthecolorofyourchoice.Crimp-stylehoseendsofferextremelyhighdurabilityandarequickeasytoassembleprovidingyouhaveahosecrimpingmachine.Nolongerareyoulimitedtostainlessbraid-coveredhose.Avarietyofmaterialsofferinglighterweightandcolorsareavailable.UseofnylonKevlaretc.braidedoutersurfacesalsoeliminatesthepotentialforwearabrasiononnearbysurfacesascomparedtobraidedstainless.Hoseendsthatfeaturequick-connectsareofferedinafullrangeofsizesandshapes.Thequick-connectdisconnectcouplersself-seal.Thisisidealwherefastengineserviceisrequiredinthepits.PhotocourtesyJiffy-Tite. 30OCT-DEC2013engineprofessionalfuelshydraulicfluidsandlubricantsuptoabout275degreesF.Vitonispreferredforsyntheticlubricantsoxygen-bearingfuelsandadditivesandnon-ether-basedbrakefluids.Vitonalsooffersbetterscuffresistancelongerservicelifeandoffersahigheroperatingtemperaturerangeofabout400degreesF.CrushwashersdoexactlythattheycrushundercompressionprovidingtheneededsealbetweentwoflatsurfaceswherethereisnogrooverelieftoacceptanO-ring.Crushwashersarecommonlyavailableinaluminumandcopper.Banjofittingsforexampleasusedonbrakelineconnectionstocalipersforexamplerequiretwocrushwashersonebetweenthebanjofittingandthecaliperandonebetweenthebanjofittingandbanjobolthead.CrushwashersMUSTmatchtheinsidediameteroftheadapter.Whetheryouredealingwithaluminumorcopperitishighlyrecommendedtoneverre-useoldcrushwashers.Alwaysreplacewithnewsinceoncetheyrecrushedtheydontspringbacktotheiroriginalthicknessandthefingerprintwillhavemirroredtheparentsurfaceoftheorigi-nalinstallationandmightnotsealagainstadifferentsurface.Crushwashersaregenerallyavailableinholediametersincluding38-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANStat-O-SealspicturedaboveleftfeatureasoftaluminumcrushwasherthatfeaturesaninternalO-ring.Thesearewonderfulcrushwasherversionsthatoftensealproblemareasthatatraditionalcopperoraluminumcrushwashercanthandle.DowtysealspicturedaboverightaresimilartoStat-O-Sealsbutfeatureaslightlysmalleroutsidediameter.ANcupsealscansaveadamagedANhoseend-to-fittingconnectionwheretheANmaleandorfemale37-degreeflareseatsareslightlydamaged. THELEADERINVALVESEATGRINDINGOrder50ormoreRegisValveSeatWheelsmaybeassortedtake10off.CALL1-800-527-7604www.regismanufacturing.comYellowMagnumValveSeatWheelsforSiouxandKwik-Waygrindandfinishheavy-dutyorhardseatsinjustonestepRegisHeavy-dutyUniversalValveSeatWheelDressingStandCalltodaytorequestourFREEcatalogSioux-StyleValveSeatWheelAirDriverKwik-Way-stylealsoavailableREGISMFG.1500CorinthStDallasTX75215800-527-7604214-421-5171Fax800-535-8414214-565-1704RegisoffersallthepopularsizesofValveSeatWheelsinGeneralPurposeStelliteNickel-ChromeRubyandFinalFinishforBlackDeckerKwik-WayandSioux.Wealsocarrydriversstoneholderspilotscoolantseverythingyouneedtogrindseats.engineprofessionalWWW.AERA.ORGEP31 32OCT-DEC2013engineprofessional10mm12mm716and916.Anotherandbetterapproachtoseal-ingbanjoassembliesarealuminumwash-erswithbuilt-inrubberO-rings.Thisapproachoffersthebestofbothworldsthestrengthandcrushofalu-minumplusanO-ringthatexpandstoprovideasuperiorseal.Thistypeofseal-ingwasherisavailableintwobasicfor-matsoneisofAmericandesignandtheotherwasborninEngland.TheAmericandesigncalledtheStat-O-SealfeaturesasyntheticrubberO-ringcap-turedmechanicallylockedinsidetheI.D.ofanaluminumwasher.Thisisagreatchoicetosealanythingthatnormal-lywoulduseanaluminumorcoppercrushwasher.TheEnglish-originversioniscalledtheDowtysealwhichissimilartotheStat-O-SealbuttheO.D.issmallerandthewasheristhicker.EitherworkswellbuttheStat-O-Sealismorereadilyavail-able.Whilewereonthesubjectofsealingfluidheressomethingmanypeoplearentawareof.Ifyouhaveadamaged-AN37-degreesealingsurfacehoseendofadapterthatmayhavebeencausedbygallingwhenassembleddirtyetc.youcanmakeaquickandeasyfield-fixwith-outtheneedtoreplacethehoseendoradapter.Aluminumconicalsealsareavailableinall-ANsizes.Thisissimplyasmallshallowconicalcupthatmatch-esmaleandfemaleseatangles.Simplypushtheconicalsealoverthemaleconeandreassemblethehoseendtotheadapterinthenormalmanner.Theuseofthesecupsisanalternativetoreplacingthedamagedmaleorfemale37-degreeflarecomponent.ASSEMBLYOF-ANHOSEASSEMBLIESCUTTINGSTAINLESSBRAIDEDHOSEWhenyoubuyalengthof-ANstainlesssteelbraidedhoseandplantocutpiecestodesiredlengthandmakeyourownassembliesyoufirstneedtoknowhowtoproperlycutthehose.Yesyoucanuseahacksawbutfranklythatmethodstinks.Itsdifficulttoobtainasquarecutyouneedtouseaspecialhardenedbladeandchancesareveryhighthatyoullendupwithfrayedwireendsthatyoullthenneedtosnipoffwithwirecuttersbythewaysnippingthishardstainlesswirebraidisntaseasyasitmayseem.Ifyousecurethehoseinavisetomakeyourcutyoullhaveaten-dencytosmashthehoseoutofroundwhichwillonlyaggravatetheproblem.Thebestmethodistouseanabrasivechopsaw.Firstwraptheareatobecutwithelectricaltapeoraqualitybodyshopmaskingtapewrapthehosetight-ly.Markyourintendedcutonthetapecarefullycinchthehoseinthesawsvisewithoutdistortingitandlettheabrasivewheelslicethrough.Dontapplyabunchofpressureonthesawarm.Lighttomoderatepressureworksbest.Oncethecutismaderemovethetapeandthoroughlyrinsethehoseoutusingcompressedairtoremoveallwireandrubberparticles.ThisisimportantMakesurethehoseiscleaninside.Naturallyyoumustalwaysweareyeprotectionwhencuttinghosewhentrimmingstain-lessbraidorwhenblowinghoseclean.-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANIfyouplantouse-ANhoseassembliesinyourshopaselectionofaluminum-ANwrenchesareanabsolutemust.Usinganaluminum-ANwrenchpreventsgougingandmarringoftheanodizedaluminumsurface. engineprofessionalWWW.AERA.ORGEP33Aboveisanexampleofnitrousinjectiontubescustom-bentforatidyappearance.Picturedleftacarbhasbeenplumbedusingsectionsofstraight38tubingconnectedusing-6tubenutsandsleeves. HANDYASSEMBLYTOOLWhileImonthesubjectheresaverycoolspecialtytoolthateasesthepainofhoseassembly.IjustcameacrossthistoolrecentlyandIlikeit.ItscalledtheKoulToolaptlynamed.Whileyoudontabsolutelyneedthistoolifyouwanttosaveyourfingertipsfromneedlepunc-turesfromfrayedstainlesssteelwireIdhighlyrecommendit.Thetoolisessentiallyaguidethatallowsyoutofeedthehoseontothehoseendscollarwhileencapsulatingthesharptipsofthewirebraid.Thetoolisofferedinkitformtocoverallpopularhosesizes.KitPN468coverssizes-4-6and-8whileKitPN1016covershosesizes-10-12and-16.Hereshowitworkschoosethecor-rectsizetoolforthehoseendtobeinstalled.Thetoolismadeoftwopiecesthatclam-shelltogether.Placethehoseendcollarinonesideofthetoolencloseitwiththematingsidesecurethetoolinaviselubethefunnelentranceandinstallthehoseusingatwistingmotion.Thetoolsfunnelentranceguidesthehoseneatlyintothecollarwithnomussorfuss.Infactwhilethehoseendcapisstillintheclamshellwiththehoseinsertedyoucanleavethetoolintheviseandinstalltheremainderofthehoseendthreadingitintothecollarwhilethecol-larisheldstationary.Thekitsincludeseveraladapterssincethevarioushoseendandfittingmakersoftenproducetheirownuniquelengths.Thekitinstructionsadviseyouregardingtheneedforadapterspacers.Forinstancethekits1adapterisrequiredforAeroquip-16while-16FragolaGoodridgeEarlsandXRPhoseendsrequirethekits2adapter.Thehoseendmustfitinsidethetooltightlywithnoend-play.Theadapterssimplyserveasspacerstopreventthehoseendfromwalkinginsidethetool.PROTECTTHEHOSEENDSANDFITTINGSWheneveryouredealingwithaluminumhoseendsandfittingsbeawareoftwoprecautionsaluminumissofterthansteelsoyoursteeltoolscangougeorburrtheseitems.Alsoifyourecon-cernedaboutappearancestreetrodcus-tomapplicationetc.youcertainlydontwanttoburnish-offtheattractiveanodizedfinish.Insteadoftapingawrenchortryingtojamapieceofclothbetweenthefittingandawrenchmaketheinvestmentandbuyaselectionofalu-minum-ANwrenches.Thealuminumwrenchesunlesstheyredirtyandgrittywontdamageyourprettyhoseendsorfittings.-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANThisdual-quadsetupwasplumbedusing38aluminumfueltubingand-6tubenutssleeves.Aluminumtubingiseasytobendandformusingahand-heldtubingbender.34OCT-DEC2013engineprofessional engineprofessionalWWW.AERA.ORGEP35Dontforgettocreatetheflarebeforeslippingthetubesleeveandtubenutontothetubing.Youllneedaflaringtoolcapableofprovidinga37degreeflare.Thehoseandcollarcanbesecuredinanaluminum-jawfixturetoreducethechanceofmarringthehoseendfinish.Useanairguntoblowthehosecleanbothbeforeandafterrinsing.Thetapeprovidesahandyreferenceincasethehosepullsoutfromthehoseendduringinstallation.Installthehosetoapointjustbelowtheendofthefemalethreads.Manycapnutsaremarkedwithnotchesonthehextoindicatedesiredhosedepth.KoulToolsoffersaveryhandyassemblyaidfor-ANhose-to-hoseendconnections.Thetoolprovidesaguidedslip-ininsertionofthehoseintothehoseend.Withthenippleendofthehoseendassemblylightlylubedinsertintothecollarnutinsertingthenippleintothehoseandcarefullyengagingthethreads.Ahoseendisplacedintoonehalfofthetoolhousing.Theoppositesideofthehousingisthensnappedintoplaceencapsulatingthehoseend.Notethetaperedentryportforthehose.Tightenthehoseendonlywithanaluminum-ANwrench.Withthetoolsecuredinavisethehoseisinsertedbyhandwithoutthehassleoffightinganysmallbraidedmetalburrs.Thehousingalsoprotectsthefinishofthehoseendduringassembly.Beforecuttingstainlessbraidedhosetightlywrapthecutareawithtape.Anabrasivechopsawdoesanexcellentjobofcuttingstainlessbraidedhose.Besuretocleanthehoseaftercutting. 36OCT-DEC2013engineprofessional-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANAlsobeawarethatananodizedcom-ponentsfinishcanbedamagedbyaggres-sivesolvents.Anodizingisntreallyacoating.Ratheritsachemicalprocesssimilartooxidationthathardensthesur-faceandwhererequiredprovidesadie-coloredappearance.Youcandamagethecolorationbyusingsomebrakecleanersolventsorthinners.Howeversomeanodizeditemsfeatureaprotectiveclearanodizingtreatmentoverthecolor-dyedtreatmentthathelpstoprotecttheappearance.Regardlessdonttakechances.Useonlyamildcleanerandneveruseanycleanerthatcontainsabra-sivessuchasbuffingcompound.SLIP-ONBARBEDNIPPLE-ANIfyouopttouse-ANhoseendswithbarbednipplesandtheproperreinforcedhosedesignedforthesehoseendsinthe-orythetaskiseasy.Simplyinsertthebarbednippletubeintothehoseuntiltheendofthehoseseatsintotheshallowstop-collar.Howeverthisisanythingbuteasyduetothetightinterferencefitofthenippleinthehose.LubethenipplewithWD40orlithiumgreaseandpushthehoseontothenipple.Youllneedyourstrengthforthis.Ivefoundthatithelpstofirstdiptheendofthehoseintoveryhotwatertoslightlysoftenandexpandthehose.Oncethehoseisfullyinserteditsnotcomingoff.QUICK-DISCONNECTSQuick-connectdisconnectfittingsareavailablethatallowyoutoquicklywithnotoolsdisconnectorconnectfluidhoseassembliesandwithnofluidloss.Jiffy-Titeprobablythemostpopularofthisgenreofferstheseself-sealingconnectorsthataresuitableforfueloilandwaterapplications.Thecouplerfeaturesaspring-loadedvalvethatshutsoffwhenthecouplerisdisconnectedandopenswhenconnected.Thisisperfectforracecarswhereenginesareservicedorchangedonaregularbasissincethisquick-connectfeaturesavestime.Simplyslidethecouplercollarbacktoreleasetheconnection.Youcanpopthecouplerslooseandyankanenginewithoutspillingfluids.Eventhoughthesecouplersareeasytodisconnectandconnectbyhandoncecoupledtheconnectionissecurewithnoworriesaboutaccidentaldiscon-nectionorleakage.Theseself-sealingfittingsareavailableinavarietyofthreadstylesincluding-ANNPTpipethreadreusablehoseendsandbarbtypehoseends.EveryimaginableconfigurationisalsoavailableThisviewshowsthehoseinsertedintothehoseend.Withthehosesecuredinthehoseendthenipplesectionofthehoseendassemblyisinsertedandthreadedintothehoseendfemalethreads.Slip-onpush-onhoseendsofferanalternativetothetraditionaltwo-piecehoseendassembly.Theseslip-onconnectionsareextremelytight.Theinterferencefitonthenipplebarbseliminatestheneedtoaddadditionalclamping.Itsbesttoheat-softenthehoseinhotwaterpriortoassembly. 2013ElginIndustries.Allrightsreserved.ElginRanksAmongFastestGrowingSuppliersFEEDYOURENGINESWITHELGINSWORLD-CLASSCAMSHAFTANDVALVETECHNOLOGIESAskaboutourBLACKICESuper-CryogenicTemperingTechnologyElginCamshaftsMusclecarcamswithoriginalgrindsFullHemiLS1coverageRollercamsforFordGMenginesElginValvesStockStandard.015oversizePerformance-Forged21-4Nmaterialwithhardwafertip-Straightundercutdesigns-Standard.100lengths-ChromestemsFEEOURENGINYESWHELGISWOLD-SSengineprofessionalWWW.AERA.ORGEP37 38OCT-DEC2013engineprofessional-ANHOSEAND-ANHARDWAREBYMIKEMAVRIGIANmalemalemalefemalefemalefemaleetc..TUBE-PLUMBINGWITH-ANTUBENUTSANDTUBESLEEVESIfhardlinesarepreferredasopposedtoflexiblehosebutyouwanttobeabletoconnectusingAN37-degreeseatingseal-ingyoullusetubenutsandtubeflaresonmetaltubing.Thehardlinemetaltubemustbeflaredusinga37-degreeflaringtool.Atubesleeveslipsonimme-diatelybehindtheflare.Thistubesleevefeaturesaconcaveseatthatmatestothebacksideofthetubeflare.Behindthetubesleeveisatubenut.Thisdrawsthetubesleeveandtheflareonthetubetothemale37-degreeANfittingoradapter.Whenmakingtubeassembliesfirstslipthetubenutovertheun-flaredtubethenbythetubesleeve.Thetubenutthreadedportmustfacetheendofthetubethatwillbeflared.ThetubesleevessmallerO.D.shoulderfacesthetubenutwiththelarger-O.D.sleeveshoulderfac-ingtheendofthetubethatwillbeflared.Oncethetubenutandsleeveareinpositiononthetubethenthetubeisflared.Dontforgettoinstallthetubenutandsleeveontothetubebeforeflaringthisisacommonoopsthatmanypeoplemake.AsfarassizingisconcernedtheANdashsizereferstotheoutsidediameterofthetubing.ANDASHSIZENOMINALEQUIVALENT331641463881210581234161Hardtubingequippedwiththeappropriatesizetubenutandsleevewillallowtubingconnectionto-3-4-6-8-10-12or-16maleANfittingsadapters.Thishardtubingplumbingmaybeusedforanyplumbingapplicationwhereflexi-bilityisnotrequired.Examplesareplumbingfuelandnitrousoxidefromtheengine-mounteddistributionblocktothenitrousoxideinjectorsorplumbingafuellinefromanengine-mountedfuelpumptothecarburetor.Ifanymovementisanticipatedbetweenthetwopointsuseaflexiblehoseplumbingsysteminstead.Forexampleneverrunahardlinefromachassis-mountedlocationtotheengineasenginerockwillrequireplumbingflexi-bility.IINTRODUCINGTheExclusiveGOODSONValveSpringTester1-800-533-8010www.goodson.comtwitter.comGoodsonToolsfacebook.comGoodsonToolsAndSuppliesThankyouGoodsonToolsSuppliesthanksyouforyourcontinuedsupportandpatronage.Wepromisetoearnyourfuturebusinesswiththeseservices.Same-DayShippingonordersplacedby5pmcentralDeliveryin3daysorlessinthecontinentalUSCustomerServiceRepsavailableM-F7am-530pmcentralIRON-CLADSatisfactionGuaranteeMasterMachinistsonstafftoassistyouwithtechnicalproblemsWorldwideShippingSpanish-speakingsalesandservicerepsonstaffSecureOnlineOrderingSeethisandmanyotherNEWproductsinthe2014GoodsonCatalog.Reserveyourstoday5dia.Ashcroftqualityanalogpressuregaugewith600lb.capacityIntegralverticalheightscalethatmoves180lefttorightOrderNo.VST-60GJobber879.99Platformhandlesspringsupto2diax4.5OALOver-centercamactionholdsspringatthedesiredheightRubberprotectivebootkeepsthemechanismdebris-freeMikeMavrigianhaswrittenthousandsoftechnicalarticlesoverthepast30yearsforavarietyofautomotivepublications.InadditionMikehaswrittenmanybooksforHPBooks.ContacthimatBirchwoodAutomotiveGroupCrestonOH.Call330435-6347ore-mailmikebirchwoodautomotive.com.Websitewww.birchwoodautomotive.com TOLLFREE800.648.7970CheckoutthefullselectionofSilv-O-LiteandKBHighPerformancePistonsatwww.uempistons.comCallusoremailusatsalesuempistons.comforapersonalresponseabouthowUEMpistonscanmakeyourbuildssuccessful.ReinforcedtoplandsCoatedskirtsFloatingwristpinswhereapplicableApplicationspecificaluminumalloysDiamondfinishedskirtsPinholeaccurateto-.0001Morethan485OEreplacementpistons.AsNorthAmericaslargestpistonmanufacturerUEMhasyourpiston.OurprocessesandequipmentfeaturethelatesttechnologyforbothOEreplacementandhigh-performancepistonsforeverytypeofengineyouarebuilding.Wehavebeenmanufacturingaftermarketpistonsforautomotivelighttruckpopularimportandheavydutyapplicationssince1922.390HypereutecticalloyFullymachinedcrownsandvalvereliefsDrilledoildrainbacksFullfloatingwristpinsTriplewoundspirallocksOver190differentoversizepartnumbersReflectivealloyallows2powerincreaseApplicationsavailablewith564thand116thringpacks.VastassortmentofcompressionratiosavailableindishflattopanddomestylesQuenchdometechnologyminimizesdeteriorationZerodeckquenchdesignsLightweightwristpinsavailableinmostapplicationsAllpartnumbersavailableinkitswithringsKBHighPerformancePistonsSilv-O-LiteOEReplacementPistonsBOTHICONSERIESFEATUREOver100applicationsontheshelfOver360differentpartnumberoversizesAvailableinkitswithringsICONFHRForgedHeadReliefPISTONSPremium4032alloySecondlandaccumulatorgroovesToplandminigroovetechnologyDiamondfinishedskirtsTriplewoundspirallocksSpacerringsincludedinshortcompressionheightsthatintersectthewristpinboreICONPREMIUMFORGEDPISTONSPremiumHighductility2618alloyNitrousTurbo-ChargedandSuper-ChargedAppsDualforcedpinoilingonmostapplicationsLateralgasportingonhighercompressionratiosFullymachinedwithdeepvalvepocketsSecondlandaccumulatorgroovesToplandminigroovetechnologyDiamondfinishedskirtsTriplewoundspirallocksSpacerringsincludedinshortcompressionheightsthatintersectthewristpinboreengineprofessionalWWW.AERA.ORGEP39 40OCT-DEC2013engineprofessionalManythingshavechangedintheautomotiveindustryovertheyears.Componentsthatwereconsideredessentialhavebeenreplacedwithnewtechnologies.Thecarburetorsuccumbedtothefuelinjectorbreakerpointsfirsttoelectronicignitionandeventuallyasystemthathaseliminatedthedistributorandthesimplethrottlecablegavewaytodrive-by-wiretechnology.Butlittlethoughthasbeengiventotheheattransferfromthewaterjacketofthecylinderheadtotheliquidcoolant.Thisiswhatisrequiredtokeepanenginecoolanddetonationfreeespeciallyinahighperformanceapplicationorextremeuse.ThatisuntilEvansCoolingSystemscompletelyrethoughtthechemistryofcoolinganengine.Beforethisadvancedconceptinenginecoolantthatemploysnowatercanbeunderstoodareviewofcoolingsystembasicsisinorder.LETITBOILALMOSTItisgoingtobehardformanytoacceptthatenginecoolantonthevergeofboilingisagoodandproperthing.Thecaveatbeingitneedstooccurinthecylinderheadandnotintheradiator.Thedreadedengineboil-overthatstrandsyouonthesideoftheroadwiththehoodopenandacloudofsteamemanatingfromtheradiatoriswhatusuallycomestomind.Thatkindofboilingisnotgood.Whenboil-overoftheradiatoroccursitisrootedinthecoolantbecomingsuperheatedandtheradiatorsinabilitytotransferenoughBTUofheatknownasrejectionintotheair.Ifthisoccursthenthecoolantstartstoboilandexpandjustasapotofwaterwouldonakitchenstove.Itisimperativetounderstandthatthejoboftheliquidistocooltheengineandthefunctionoftheradiatoristocooltheliquid.Astheliquidpassesthroughtheradiatoritstemperaturedropssothatitcanthenbeaneffectiveheatabsorptionmediumwhenitispumpedbackthroughtheengine.Theliquidstimeintheradiatorcanbeconsideredrestandrelaxationtimeasasoldierwouldreceiveinbetweencombatassignments.Ifitisnotprovidedtheopportunitytodropintemperatureduringitsresidenceintheradiatoritwillpossesstoomuchheattobeeffective.Theliquidwillkeepabsorbingheatfromtheengineuntilitcantakenomore.Atthattimeitboilsandchangesphasesfromaliquidtoagaseousform.Thechemicalcompositionoftheliquidalongwiththeoperatingpressureofthecoolingsystemallimpactthetemperature.Thephasechangeoccursbutcannotstopit.Whenthecoolantboilsandbecomesavaporitisineffectiveinpullingheatfromthecylinderhead.TheintroductionoftheradiatorpressurecapbyGeneralMotorsinthe1930salongwiththeadoptionofglycolbasedcoolantsweremajoradvancementsinraisingtheboilingtemperature.AsanasideforeveryonepoundofpressurethatisaddedtoacoolingsystemthroughapressurecaptheboilingpointincreasesthreedegreesF.Environmentalfactorsimpacttheboilingpointofthecoolantalso.AltitudehasamajorinfluenceonloweringtheLIARLIARYourtemperaturegaugeisnottellingthetruthBYRAYT.BOHACZ engineprofessionalWWW.AERA.ORGEP41Attendeesareeligibleforover30000inproductgiveawaysfromAETCsponsors.HaroldBettesLauraShehanVinceRomanBillMcNightBruceBaldwinStephenGolyaLeeCarducciJonSamsDanJeselIndustryPanelBenStraderBrianKurnCecilStevensGregWestKeithJonesChrisPaulsenOzzieHutchinsDaneKalinowskiSPEAKERSINCLUDETheONEeventwherethelatestinperformancetechnologyisfreelysharedbytheindustryskeythinkers.SponsorsTitlePartnerInPresentingPlatinumGoldSilverMakeplansnowtoattendthecantmisseventof2013.Thisistheonlyconferencethatbringstogethertheleadingexpertsfromalldisciplinesofhighperformanceenginedesigntosharethelatesttechnologytrendsandapplicationtechniques.Missthisoneandyoullspendalifetimetryingtogaintheknowledgethatyouwillreceiveatthe24thAnnualAETCinthethreedaysleadinguptothePRITradeShow.1.866.893.2382WWW.AETCONLINE.COM.24THANNUALAETCAdvancedEngineeringTechnologyConference...ANDMOREGetTheLatestConferenceNews9241EPjTheLatestAdvancementsDevelopmentsInEnginePerformanceTechnology boilingpointofaliquidsincethereislessatmosphericpressureonit.Themisunderstandingofthepurposeoftheliquidcoolantisrootedinthefactthattheindustrymonitorsthecoolanttemperaturealoneandnotinconjunctionwiththemetalsurfacetemperatureofthecombustionchamberinthecylinderhead.Itcanbethoughtofasamarinerreceivingdirectionsinlatitudewithoutlongitude.Thepropermethodtodetermineiftheengineisinthermaldistressistocomparetheliquidtemperaturetothemetalsurfacetemperatureofthecylinderhead.Onlythenwouldthepicturebeclear.Ifthemetalsurfacetemperatureisclimbingandtheliquidreadingisnotkeepingupthentheengineisonthevergeofmetaloverheatingthoughthecoolantmaybefarfromboiling.Astheliquidstemperatureincreasesitsstorageabilityorinotherwordsitspotentialtoabsorbmoreheatisdiminished.Whenthisoccurstheliquidtemperatureasreadonacoolantgaugemayappeartobestablealbeitatanelevatedtemperaturebutthemetalsurfacetemperatureofthecombustionchamberandaroundtheexhaustvalveskyrockets.Thiscanleadtodetonationpingandenginefailurefromacrackedcylinderhead.Enginesthatemployanaluminumcylinderheadareextremelysensitivetothissincethesteelvalveseatsarepressedintotheheadasaninsert.Numerousorprolongedexcursionstoextrememetaltemperaturesalongwiththermalcyclingcancausetheseattofallout.Withrareexceptionthisismetwithtotaldestructionoftheengineasthepistoncollideswiththevalveandthesteelseat.Inalmosteverycasetheengineneveroverheatedaccordingtotheliquidtemperaturebutthemetalsurfacesdid.Thusthemosteffectiveliquidcoolantisonethathastheabilitytoabsorbahighamountofheatbeforeboilingwhichwillresultinthecoolestmetaltemperaturesinthecylinderhead.Whentheliquidcanabstainfromboilingandcontinuetoabsorbheattherewillbemorethermaltransferfromthecylinderhead.Whendiscussingacoolingsystemitmustbenotedthatthoughthecoolantisalsoemployedtoremoveheatfromtheengineblockandcylinderwallsitsmostchallengingassignmentistocontrolthetemperatureofthecombustionchamberandexhaustvalvearea.DIFFERENTLEVELSOFBOILINGTheloadandthustheheatrejectionintotheliquidcoolantofanenginearenotlinear.Itisdependentonmanyfactors.Givenaspecificenginetheheatrejectionrequiredwilldependontheoperatingstateofthevehicle.Acarthatisusedforlightloaddrivingevenifitisagreatdistancewillnotputmuchheatintothecoolant.Thisisduetotheenginenotbeingrequiredtoproducemuchpowerforthedrivingstate.Theamountoffuelconsumedandthevolumetricefficiencyofthecylinderborearelow.Ifthesamevehicleisnowrequiredtoclimbasteephillorpullatrailerthentheloadontheliquidcoolantincreasesdramatically.ThisisthereasonthatsincethedaysoftheearlyautomobilecarcompanieshaveperformedhotweathertestingintheAmericanwestwhereacombinationofhighambienttemperatureandextremeelevationcanbefoundatthesametime.Turbulentflowthroughthecoolingsystemisnecessaryforthemosteffectivethermaltransfer.Thisactionwillcauseachurningandallowthecoolanttoabsorbmoreheatfromthecomponentsitcomesincontactwith.Inlikefashionitisimperativethatthecoolingsystemisdevoidofanyairbubblesandisasolidstreamofliquid.Airisaverypoorheattransferagentwhencomparedtoaliquid.Ifthecoolingsystemisairboundthentheareasthatdonothaveliquidcontactingthemveryquicklybecomesuperheatedandwillresultinextremethermalstress.Theliquidcoolantgoesthroughanumberofdefinedboilingstagesasitabsorbsheatandpriortobecomingsteam.Theserangefromnucleateboilingtocrisisboiling.Whentheliquidisjustonthevergeofenteringthenucleatestageiswhenthemostheattransferoccurs.Whencrisisboilingoccurstheliquidforallintentsandpurposesdoeslittletocoolthecylinderheadandthemetalsurfacetemperaturerisesrapidly.Thekeytoproperheattransferistoallowthecoolanttojustenterthenucleatestagewhentheengineisundersevereorheavyload.Thenhavethesystempressuremovetheboilingcoolantawayfromthesitetakingtheheatalongwithitandre-condensingbacktoaliquidasitispushedaway.Thiscycleofheatingnucleateboilingreleasefromthesiteandre-condensinggoesoncontinuallyinthewaterjacketofthecylinderheadandisresponsiblefortheconsumptionofthechemicaladditivepackagethatisincludedintraditionalenginecoolant.Thisiswhyanti-freezewearsoutandneedstobechanged.Itsabilitytostayliquidatlowtemperatureaslongasadditionalwaterisnotaddedisnotalteredbuttheadditivepackageisdepleted.Productsthataredesignedasanenginecoolantincludeanti-corrosioninhibitorsalongwithelementstomakeitmoreslippery.Thisisrepresentedusingametricofdymescentimeter.Itisameasureofthesurfacetensionofthecoolant.Thelowerthesurfacetensiontheliquidhastheeasieritwillreleasefromthecastingofthewaterjacketinthecylinderwhennucleateboilingoccurs.Itcanthenre-condenseandremovethenecessaryheat.AliquidthatlikestoclingmayhavetheabilitytoLIARLIARBYRAYT.BOHACZHeattransfervianucleateboilingisresponsibleforreducingthemetalsurfacetemperatureofthecombustionchamber.42OCT-DEC2013engineprofessional engineprofessionalWWW.AERA.ORGEP43ALERTDontLetYourEnginesFLAT-LINEByUsingAnythingButGenuineMellingOilPumps.MellingwarnsallenginerebuilderstoavoidRiskyOilPumpsfoundinsomeenginekits.TheoilpumpistheHeartoftheengine.DontgambleonaHeartAttack.Withmorethan60yearsofprovenqualityanddurabilityMellingurgesyouandyourcustomerstodemandaNEWHeartGenuineMellingOilPumps2620SaradanDriveJacksonMichigan49204800-635-5464TEL517-787-5304FAXVisitusonlineatwww.melling.com 44OCT-DEC2013engineprofessionalLIARLIARBYRAYT.BOHACZabsorbheatbutwillnegatethatbenefitbyrefusingtoleavethenucleateboilingsite.Itwillthenentercrisisboilingandbecomeworthlessasacoolant.Formanyyearsitwasbelievedthatwateristhebestenginecoolantsinceithasaspecificheatratingofonebutitisapoorchoice.Evenifyoudonotconsiderthecorrosionitcausesthelowboilingpointevenwhenusedwitharadiatorcapandthehighsurfacetensionmeansthatitwillnotdoaneffectivejobofremovingheatfromthecylinderheadwhencomparedtoanapplicationspecificenginecoolantnomatterwhatthedashboardgaugestates.ADVANCEDCHEMISTRYWhileotherareasofenginetechnologyhaveevolvedenginecoolantthoughchangedslightlyrepresentedbythevariouscolorformulationsseentodaybasicallystayedthesameamixtureofethyleneglycolandwaterina5050solution.Thereisnodenyingthattraditionalcoolantworkedtherearenotcarsoverheatedallovertheroadbutabetterchemistrywasneededforenginestobecomemoreefficientandtoaddressenvironmentalconcerns.Itcanbelookedatitinthismannertheoldbias-plytireheldairandgotthevehicledowntheroadbutitcannotbecomparedtotheperformancewearandoverallimprovementamodernradialbringstoavehicle.JustthinkoftheEvansNPG-Ccoolantasamoderntireandtraditionalanti-freezeasabias-plydesign.TheEvansNPG-Cgetsitnamefrombeinganon-aqueousglycolthathasnowatermixedwithit.Asidebenefitoftheeliminationofthewaterfromthechemistrymeansthatcorrosioninthecoolingsystemandengineiscompletelyeliminatedalongwithcavitationandtherearenoadditivesthatbecomeconsumed.TheEvansNPG-Cisalifetimecoolant.Therealbenefitofthemodernchemistryisthatitdoesnotboiluntil375degreesFvirtuallyeliminatinganychanceofoverheatingintheradiator.Thishighboilingpointisresponsibleforadrasticdropinthemetalsurfacetemperatureofthecombustionchamberinthecylinderheadovertraditionalcoolant.Sinceitwillrefrainfromboilingmoreheattransferoccurs.Oncethecoolantdoesenterthenucleatestagethefactthatithasamuchlowersurfacetensionasmeasuredindynescentimeteritismoreslipperymeansitreleasesfromthewaterjacketwithlesssystempressureandallowsfreshcoolanttocomeincontactwiththeregion.DuetotheuniquechemistrythesystemoperatingpressureislowersincetheEvansNPG-Cdoesnotexpandatthesamerateasconventionalcoolantsnordoesiteverfreeze.AlloftheseattributesoftheEvansNPG-Callowforamoreaggressivefuelmixtureandignitioncurveorboostpressuresinceheat-induceddetonationwillbeeliminatedinaperformanceuse.WhentheEvansNPG-Cisemployedinapassengercarorheavy-dutyapplicationitwillprovideincreasedlongevityoftheengineanditscomponentstheabilitytouseloweroctanefuelandreducedmaintenancecostsinceitwilllastthelifetimeofthevehicle.ToconvertfromtraditionalcoolanttotheEvansNPG-CallthatisrequiredisthecompleteremovaloftheoldcoolantandrefilledwiththeEvansproduct.TheEvanswebsitegoesovertheprocedureingreatdetailwww.evanscooling.com.IRayT.Bohaczsinterestshavealwaysrevolvedaroundmechanicalapparatusbutheadmitshistrueloveisengines.ItmatterslittleifitisaDetroitDiesel-poweredirrigationpumpinthemiddleofacornfieldornitro-burningHemi.Hisfirstbylineappearedin1995andhassincepublishedover1200in-depthtechnicalarticlespertainingtoengines.Hehasalsoauthoredthreebooksonenginesystems.HeisamemberofSAEAmericanSocietyofMaterialsandtheInternationalMotorPressAssociation.AreyouanengineguyWeareContactusbecausewehavetheanswersforengines.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372.JointodayGotopage98foramembershipapplication. BYSTEVESCHOEBENIntheearly90swewereweldingmanyofthoseever-popularcrackedheads2.6LMits2.3Lquadsand1.8LGMs.Youcanrelate.Therepairweldingofthosecrackedcastingseventuallydried-upwiththeexceptionofsomehigh-endGermanapplications.ThiswasduetoourexcellentrelationshipwiththeChineseandtheirabilitytoofferNEWreplacementcylinderheadsformuchlessthanthecostofrepairingin-house.Themajorityoftheweldingleftoverwasisforerosionrepairsanditisnoeasytaskobtainingapitfreeweld.SoweldingisnotwhatitwascrackeduptobeNowitsthePITSByPITSImeanthosenastylittleimperfectionsthatarerevealedaftermillingaheadthathasbeenpreviouslywelded.InthisarticleIwouldliketoaddresshowweattacktheissueofEROSIONparticularlyonthegasketfacesofthecylinderheadPITFREEMostoftheequipmentneededtorepairerosionmanyshopsalreadypossesshottankovenweldermilletc.Forafewthousanddollarsandalittlepracticeweldingyoucanhaveanexcellentadd-onservicetooffercustomers.YoucontrolQUALITYin-houseprovidequickerSERVICEifyouwerefarming-outandportrayamorecompleteIMAGE.MostimportantyoumakeacoupleBUCKSAlthoughIamNOTaweldingexpertIknewourshopneededtoprovidethisserviceandgetgoodatit.Inthepastyouneededtobeaveryskilledweldertogetthejobdone.Nowwithtechnologyandadvancementsinweldingequipmentitsmucheasier.Wefire-upthewelderalmosteverydayaddressingsmallthumbnailsizeareasoferosiontomajorsurgery.HereIwilltakeyouthroughacoupleofcontrastingjobswecompletedandourmethodoferosionrepair.SeeFigures12Thefirststepisobvious.Uponinspectinganareaoferosionyouneedtodetermineifthecastingneedsanyweldingatall.Willthecastingcleanupwitha.004-.005cutIfsojustmillit.Ifnotsuretakea.001ticklepassinthemillandyouwillknow.IfAluminumWeldingandErosionRepairNotwhatitwascrackeduptobenowitsthePITS46OCT-DEC2013engineprofessional weldingisneededandyouproceedwiththerepairbeawarethereisalwayswhatIcallashadedareaaroundtheouterperimeteroftheweld.Thatareausuallytakesanadditional.002cutpasttheweldtocompletelycleanuptheheadsurface.Thisissomethingtoconsiderwhendecidingtoweldornottoweld.PREPARATIONPreparationisthemostimportantsteptoobtainpit-freewelds.Aluminumisverysusceptibletocontaminantsthatcancauseproblemswhenwelding.HotTankdegreasewellextractALLoilsfromcasting.GlassBeadcleanusingfreshglassbeadsEVERYTIMEIfyoudontusenewglassbeadsyouwillimpregnatethesurfacewithimpuritiesanddirt.Anotheroptionnotusedbyusisstainlesssteelshotblasting.Shopsthatweldinquantityusethismethod.Cleantheerosionandsurroundingareausingavirginstainlesssteelbrushjustenoughtobrightenupthearea.Usedbrushescarrycontaminantssowekeepstainlessbrushesexclusivelyforthistaskseparatefromothers.Thesebrushescanbethesmalltoothbrushstyleorthecrimpedwireendtypicallyusedinanairdrillatlowspeeds.Thiskeepsthebristlesfromcominglooseandwoundingyou.SeeFigures34Herewediegrindawaytheerosionusingaball-stylesingle-cutrotaryfile.Weusevariousdiameterfilesdependingonthesituation.Grindjustdeepenoughtogetbeyondanypittingandintovirginaluminumcreatingauniformrecessedareaforthefillerrod.Wedonotusetheaidofanylubricantorwaxeswhicharecontaminantstokeepthecarbidefilefromloading.SeeFigures56WELDINGEQUIPMENTNOTEIamNOTendorsinganyonespecificproducthereratherprovidingalistofequipmentsuppliesweusefortheweldingprocess.TheTIGWelderWeuseaMillerDynasty300serieswithinvertertechnologyminimumsizeIrecommend.Weldingaluminumcylinderheadsismorecomplicatedthannormalaluminumweldingbecauseoftheirvariouscompositions.Thisnewtechnologyofweldersenabledustofine-tunethecleaningandpenetrationsettingsthusobtainingacleanerweld.Workingwiththesesettingshasenablesustorepairsomeancientdirtycastings.Torch-HeadWeuseaWeldcraftWP-225whichisflexibleandinterchangeablewithotherprofiletorchheads.WiththisIusea8gasnozzleand18thdiameter2ceriatedtungstenorangetip.Thelargecupprovidesgoodgascoverage.Wegrindthetungstentoapointthenslightlybluntitbackusingadedicatedsingle-purposegrinder.Theslightbluntingbackofthetungstenprovidesbetterarcstability.engineprofessionalWWW.AERA.ORGEP47 ALUMINUMWELDINGBYSTEVESCHOEBENGasArgonisourgasofchoice.EarlieryearsweusedaMillerSynchrowaveandexperimentedwithheliumandargontheresultsvaried.Argonislessexpensivereadilyavailable.WeldingRodWeusea4043Aluminumrod332diameter.SeeFigures78WELDINGPROCESSPreheatingThisallowstheuseoflessamperagewhenweldingthusdrawingfewerimpuritiesintotheweld.Wetypicallypreheatacastingintheovenfor30-45minutesat375-400degrees.Forverysmallsinglelocationerosionareaswepreheatusinganoxyacetylenetorchjustenoughtotakethechilloutinsteadofusingtheoven.NOTEIfperformingextensive48OCT-DEC2013engineprofessional engineprofessionalWWW.AERA.ORGEP49 ALUMINUMWELDINGBYSTEVESCHOEBEN50OCT-DEC2013engineprofessionalweldingyoumayneedtoplacetheheadBACKintheovenbetweenwelds.AlsoifyouarereplacingguidesbesureandremovethemBEFOREtheweldingprocessandinstallthemwhentheweldingiscompleted.SeeFigure9WeldingPracticemakesperfect.ThetwomostimportantsettingsonthewelderaretheACfrequencyandbalance.Insimpletermsthefrequencycontrolspenetrationoftheweldandthebalancecontrolsthecleaningcycle.Anincreaseordecreaseinfrequencynarrowsorwidensthearcconeandpenetrationprofile.Thebalanceadjustmentsimplyincreasesordecreasestheamountofcleaning.Therearemanyfactorsthatgointodeterminingyoursettings.HereIcanonlyprovideabaselineofthesettingsweusewithourMillerTIGwelderfrequency175andbalance65-70.Theadjustablebalancefeatureisbeneficialwhenweldingdirtycastingsasithelpsreducetheamountofimpuritieswedrawfromthecastingitselfintotheweld.Ifyouareinterestedinmorespecificsfeelfreetocontactme.SeeFigure10THEFINISHPeeningAftertheweldingiscompletedandthecastingiscooledwecarefullypeentheweldwithoutstrikingthehead.Ifyouneedtrainingwheelsgrabasmallpieceofsheetsteeltofollowyouaroundtheweldasyoupeenprotectingthecastingface.Thebenefitsofpeeningarestressreliefandwork-hardeningcondensingofthealuminumweld.Thishelpsalleviatepitting.ThisisalsoimportantwhenrepairweldinganywhereontheFire-Ringareasbecauseyouneedtheweldtobeasdurableastheheaditself.Asyoucanseewearetryingtomimicthefinishofapoundedspoonfishinglure.NOTEweuseasmall4oz.hammerapplyingmultiplemediumhardblowstopeentheweld.SeeFigures111213 engineprofessionalWWW.AERA.ORGEP51 52OCT-DEC2013engineprofessionalALUMINUMWELDINGBYSTEVESCHOEBENMillingweuseCBNbecauseweliketheabilitytobeveryaggressivewhencuttingweldsdowntothebasematerialquickly.ForourfinishedcutweuseasmallamountofPAMcookingspraytoeliminateanypeeling.Foravirtuallynon-detectablelookandthoseveryspecialjobsweperformourfinishcutonourothermillwhichisPCDdedicated.TheoutcomeisamazingandinvisibletothecustomerSeeFigures1415Inconclusionthesmallererosionrepairarticleexampletookapproximately20minutesofadditionalwork.Thisresultedinalittleextrajobprofitalongwithasatisfiedcustomeraswesavedthehead.Asmentionedearlieryouprobablyhavemostoftheequipmentneedtoattackanerosionrepair.Withpracticeyoucanofferthisservicetoyourcustomersandnotturnthisbusinessaway.HappyWeldingISteveSchoebenistheownerofHeadWerksInc.anautomotivemachineshopservingMinneapolisandsurroundingareassince1991.HeadWerksspecializesincylinderheadrepairindustrialandlightdieseltomotorcyclesantiquesracingandEuropeanautos.Formoreinformationcall952884-6306oremailinfoheadwerks.com. PERFORMANCESTARTSHEREFor90yearsSunnenhaskeptcompanywiththetopnamesinthebusiness.FromraceteamstoproductionrebuilderstoOEMstoringmanufacturersandevenoiltestinglabsworldwideSunnenisthenametheytrust.Theyknowhoningisouronlybusinessandwhenyouonlydoonethingyouhavetodoitwell.SinceintroducingthelegendaryCylinderKingin1964wehavesoldnearly8000cylinderhonesworldwideandhavecontinuedtoadvancehoningtechnologywithsuchinnovationsasdiamondhoningrotaryfeedsystemstwo-stagehoneheadsadvancedPCcontrolstrueverticalstrokingmultiplespindlesandautomatedblockrolloverfixtures.Todayweofferfourdifferentcylinderhoningmachineswithfeaturestofitanyhoningrequirementsorbudget.NomatterwhatyourcylinderhoningneedsSunnenhasyoucovered.2013SunnenSt.LouisMOUSAA13-1Testedbytime.Trustedbythebest.SV-10Theindustrystandardforperformanceenginebuildingprovideseverythingyouneedforconsistentboresizeandsurfacefinishwithconventionalordiamondabrasives.SV-20Verticalstrokerotaryfeedandtwo-stagediamondhoningmakethistheNEWchoiceformid-volumeenginebuildersperformanceshopsandraceteams.SV-2410SV-2510Theultimateinproductioncylinderhoningwithautomaticstepandrepeatautomatedrolloverfixtureandallaxesservodriven.Standardorcustombuiltforyourneeds.PutSunnentothetestandyouwillseewhythebestchooseSunnen.Formoreinformationvisitsunnen.comorcontactyourlocalSunnenrepresentativeat1-800-325-3670.VisitusatSEMABooth10180andPRIBooth5101.ASunnenExclusive.WedesignandmanufacturethecompletehoningsolutionmachinestoolingfixtureboregagesandabrasivesatourSt.Louisfacility...norepackagingorimportingwhenyoubuyfromSunnenengineprofessionalWWW.AERA.ORGEP53 54OCT-DEC2013engineprofessionalTheU.S.EnvironmentalProtectionAgencyEPAhasadoptedrequirementsthatapplytotheprocessofmaintainingorrebuildingengines.Theserequirementsgenerallydescribehowtoavoidviolatingtheprohibitionagainsttamperingwithacertifiedengineitthereforeappliesbroadlytoalltypesofcertifiedenginesandvehicles.Separateprovisionsapplyforrebuildingandremanufacturinglocomotiveenginesandsomemarinedieselengines.WhatisthegeneralprinciplebehindEPAsrebuildingrequirementsAssomeonewhomaintainsorrebuildsenginesyoumustgenerallyrestoretheenginetoitsoriginalconfiguration.Thiskeepstheenginerunningthewaythemanufactureroriginallydesignedittooperatebothforcontrollingemissionsandforachievingthebestoverallperformance.Thisaddsanassurancethateachenginewillcontinuetocontrolemissionsconsistentwiththemanufacturersoriginaldesignthroughoutitslifetime.WhatdoesEPAconsiderrebuildingRebuildingreferstoapartialorcompleterebuildofanengineorenginesystem.Thisincludesamajoroverhaulinwhichyoureplacetheenginespistonsorpowerassembliesormakeotherchangesthatsignificantlyincreasetheservicelifeoftheengine.Italsoincludesreplacementorrebuildingofanenginesturbochargeraftercoolersystemoritsfuelinjectionelectroniccontrolsystemifitincreasestheservicelifeoftheengine.Fortheseprovisionsrebuildingmayormaynotinvolveremovingtheenginefromthetruckequipmentorvessel.Usuallyrebuildingdoesnotincludefollowingthemanufacturersmaintenanceinstructionsorotherroutinemaintenanceforthesesimplerserviceitemsyoustillneedtoavoidmakingchangesthatmightincreaseemissionsbutyoudontneedtokeeprecords.HowdoImeettherebuildingrequirementsYoumusthaveareasonabletechnicalbasisforknowingthatyouarerebuildingtheenginetoitsoriginalcertifiedconfigurationforalltherelevanttolerancescalibrationsandspecificationsthatmightaffectemissions.Youmayusenewusedorrebuiltpartsbutyoushouldhaveareasonabletechnicalbasisforknowingthatthepartsperformthesamefunctionastheoriginalparts.Youshouldfollowtheoriginalenginemanufacturersinstructionsifyouchangeanyparameterordesignelement.Alsobesuretocheckcleanadjustrepairorreplaceallcriticalemission-relatedcomponentsasneededaccordingtotheoriginalmanufacturersrecommendedpractice.Thisincludesanyinstalledcatalyticconvertersorotheraftertreatmentdevices.WhatisareasonabletechnicalbasisYouhaveareasonablebasisifyoudotwomainthings.Firstyoumustinstallpartsnewusedorrebuiltsoapersonfamiliarwiththeenginesdesignandfunctionwouldreasonablybelievethattheenginewiththosepartswillcontrolemissionstothesamedegreeaswiththeoriginalparts.Forexampleitwouldbereasonabletobelievethatpartsperformingthesamefunctionastheoriginalpartsandtothesamedegreewouldcontrolemissionstothesamedegreeastheoriginalparts.Secondadjustparametersorchangedesignelementsonlyaccordingtotheoriginalenginemanufacturersinstructions.Orifyoudifferfromtheseinstructionsyoumusthavedataorsomeothertechnicalbasistoshowyoushouldnotexpectin-useemissionstoincreaseforanypollutant.WhataboutdiagnosticcodesintheenginescomputersDonteraseorresetemission-relatedcodesorsignalswithoutdiagnosingandrespondingappropriatelytothediagnosticcodes.Clearallcodesfromdiagnosticsystemsonlywhenyoureturntherebuiltenginetoservice.Dontdisableadiagnosticsignalwithoutaddressingtheproblem.Thisdoesntapplytoanengineifithasnoonboardcomputer.MayImakeanychangestoimprovetheengineYes.Youmaymakechangesifyouhavedataorsomeothertechnicalbasistoshowthatemissionswillnotincrease.Alsoyoumayusedifferentthanoriginalpartsormakeotheradjustmentsiftheymaketheengineoperatelikeoneoftheenginemanufacturersnewercertifiedmodels.DoestherebuiltengineneedtomeetemissionstandardsThereisanexpectationthattheenginewillcontinuetomeettheemissionstandardsthatappliedwhenitwasnewaslongasitisrestoredtoitsoriginalconfiguration.Rebuildersdonotneedtoperformemissiontestingtodemonstratethatrebuiltenginesmeetemissionstandards.Inthecaseoflocomotivesandsomemarinedieselenginesadditionalrequirementsapplywhenenginesareremanufactured.Undertheregulationsremanufacturingisatypeofrebuildingthatgenerallyinvolvesreplacingallofanenginescylinderlinerswhetherduringasinglemaintenanceeventorcumulativelywithinafive-yearperiod.MaytherebuiltenginegointoanyvehicleequipmentorvesselNosomerestrictionsapply.Rebuiltenginesshouldreturntothesametypeofservicehighwaynon-roadormarine.AlsotheenginemaynotgointotrucksequipmentorvesselsthatwereHowtomaintainorrebuildenginescertifiedtoEPAstandardsBYTHEU.S.ENVIRONMENTALPROTECTIONAGENCYEPA engineprofessionalWWW.AERA.ORGEP55originallypoweredbyenginescertifiedtoamorestringentstandard.Contactusatcomplianceinfoepa.govifthisisnotclearfromtheenginesemissioncontrolinformationlabel.WhatrecordsdoIneedtokeepRecordkeepingrequirementsapplyforrebuildingheavy-dutyhighwayenginesandanytypesofenginesorvehiclesthataresubjectto40CFRPart1068.Howevertheregulationswaivetherecordkeepingrequirementforallnon-roadspark-ignitionengineswithtotalcylinderdisplacementbelow225cc.Keepthefollowingrecordsforatleasttwoyearsthehoursofoperationormileageorotherindicationofageattimeofrebuildtheworkperformedontheengineemission-relatedcontrolcomponentsyouworkedonincludingalistingofpartsandcomponentsyouusedengineparameteradjustmentsemission-relatedcodesorsignalsyourespondedtoandresetYoumaykeeprecordsbasedonenginefamiliesratherthanindividualenginesifthatsthewayyoudobusiness.Keeptherecordsinanyformatthatallowsustoreviewthemifweask.Ifyouareabackyardmechanicworkingonyourownengineswedontrequireyoutokeepanyrecords.WhatrecordsarenotrequiredYoudontneedtokeepinformationthatisnotreasonablyavailablethroughnormalbusinesspractices.Wedontexpectyoutohaveinformationthatyoucantreasonablyaccess.Alsoyoudontneedtokeepanyrecordsofwhatothercompaniesdo.SeethefollowingregulationsforamoredetaileddescriptionNon-roadenginesandvehicles40CFR1068.120Heavy-dutyhighwayengines40CFR86.004-40Youcanaccessdocumentsrelatedtoemissionstandardsfornon-roadandhighwayenginesonEPAsOfficeofTransportationandAirQualityOTAQwebsitewww.epa.govotaq.IContacttheOTAQlibraryfordocumentinformationatU.S.EnvironmentalProtectionAgencyOfficeofTransportationandAirQualityLibrary2000TraverwoodDriveAnnArborMichigan48105734214-4311214-4434EmailGroup_AALibraryepa.gov 56OCT-DEC2013engineprofessionalTheAdvancedEngineTechnologyConferenceAETCwillbeholdingits24thannualconferenceattheIndianaConventionCenterMondaythroughWednesdayDecember9-11threedayspriortothePerformanceRacingIndustryPRItradeshow.Thisyearsversionoftheconferencewillonceagainprovideenginebuildersmanufacturersdesignengineersbusinessownersracerandmediamemberswithagreatopportunitytolearnfromthebestandmostcreativemindsintheaftermarketperformancebusiness.Theever-expandinggroupofspeakerswillpresentseminarsonawidevarietyoftopicsspeakwithattendeesone-on-oneandsharepersonalinsighttohelpconferenceattendeeslearnawealthofinformationinthreeshortdays.SpeakerswhowillspeakingatthisyearsconferenceareHaroldBettesPowerTechnologyConsultantLeeCarducciArrowRacingEnginesCecilStevensIllusionsEngineDevelopmentBillMcKnightMahleLauraShehanHolleyPerformanceProductsJonSamsHolleyPerformanceProductsKeithJonesTotalSealPistonRingsDanJeselJeselValvetrainInnovationVinceRomanBurnsStainlessLLCBenStraderEFIUniversityChrisPaulsenCRRacingInc.GregWestFel-ProGasketsRonRotunnoFel-ProGasketsStephenGolyaPerformanceMotorsportsDaneKalinowskiJEPistonsBrianKurnFourStrokeDesignOzzieHutchinsRoushYatesEnginesBruceBaldwinOliverRacingProductsAttheAETCconferenceyouwillgetafirsthandlookatsomeofthelatesttechnologicaladvancesintheautomotiveindustry.Therewillbeanewproductdisplayareaset-uptoallowattendeesahands-onopportunitytoreviewthenewperformanceproducts.Duringtheconferencethereisalwaysatimetomeetanddiscussyourissueswithspeakersleadersoftheindustryandotherfellowattendees.Therelaxedatmosphereandcamaraderieoftheattendeeswillhelpyoubuildvaluablerelationshipsthatbenefityoulongaftertheconferenceisover.Everypersonwhoattendsleaveswithsomesortofprizeorgiftcertificatedonatedbythegeneroussponsorsoftheconference.Thisisoneeventthatbringstogethertheleadingexpertsfromalldisciplinesofhighperformanceenginedesigntosharethelatesttechnologytrendsandapplicationtechniques.Ifyoucanmakethetimetoattendthisconferenceyouwillnotbedisappointed.Thisisoneyouwillnotwanttomiss.Formoreinformationortoregistertoattendgotowww.aetconline.com.IAERATechnicalSpecialistSteveFoxhasover25yearsexperienceintheenginebuildingindustrywith10ofthoseyearsspentworkinginthemachineshop.SteveisanASE-certifiedMasterMachinistaswellasalongtimememberofthedragracingcircuit.AETCConferencehelddayspriortoPRIShowBYSTEVEFOXTheAdvancedEngineTechnologyConferenceAETCwillbeheldattheIndianaConventionCenterMonday-WednesdayDecember9-11threedayspriortothePerformanceRacingIndustryPRITradeShowinIndianapolis.Formoreinformationortoregistergotowww.aetconline.com. engineprofessionalWWW.AERA.ORGEP57 58OCT-DEC2013engineprofessionalValvespringsareoneofthemostcriticalandmostoverlookedcomponentsinyourengine.Properselectionofthevalvespringbeginswithidentifyingtheapplicationandselectingallofthevalvetraincomponentstoachievetheenginebuildersgoals.Thespringisselectedtocomplementthesystemandmustbematchedwiththeentirevalvetraininorderfortheenginetoreachitsfullpotential.Itdoesabsolutelynogoodtoinstallacamthatwillrpmto8000ifyoudonothavethecorrectsprings.Improperselectionofthewrongvalvespringisoneofthemostcommoncausesofenginefailure.Othercommoncausesaretheincorrectinstallationandimproperhandlingofthevalvesprings.SelectingaValveSpringWhenselectingavalvespringuseonlythevalvespringsthatwillgivethecorrectspringpressurewiththevalvebothontheseatandatmaximumlift.Theoutsidediameteroftherecommendedvalvespringmayrequirethatthespringpocketoftheheadbemachinedtoabiggersize.Oneoftheeasiestandsometimesmostcostlymistakesmadeinracingenginesisnotpositivelylocatingthespring.Avalvespringthatdancesaroundonthecylinderheadorretainercausesharmfulharmonicsandexcessivewear.Aspringthatisforcedontoaretainerislikelytofailatthatcoil.ThatiswhythereissuchalargeselectionofsteelandtitaniumretainershardenedsteelspringseatcupsandI.D.locatorstobettermatchoursprings.Aspringthatiscontainedproperlyattheretainerandthecylinderheadwillofferthelongestpossibleservicelife.ProperSpringHandlingHandlethevalvespringswithcare.Neverplaceinavisegrabwithpliersorhitthemwithahammer.Thiswilldamagethesurfaceofthespringwhichwillcauseaspringtofail.Whenseparatingdoubleortriplespringsuseonlyadurableplasticobjectthatcannotharmtheshot-peenedsurfaceofthespring.Neveruseatoolorhardmetalobjectlikeascrewdriver.Mostvalvespringsareshippedwitharustpreventativecoatingthatshouldremainonthespringthroughoutengineassembly.Donotcleanspringswithacidicorevaporativecleaners.Thiscausesrapiddryingandpromotestheformationofrustonthesurfacewhichcancausecatastrophicfailures.Evenaslightamountofcorrosioncangrowtobeaproblem.WheninstallingspringsuseaValveTrainAssemblySpraytoeaseassemblyandimprovethelifeofthevalvespring.CheckingLoadsValvespringmanufacturershavematchedeachsetofspringsforloadconsistencyduringproduction.Avarianceofor-10isacceptablefornewvalvesprings.Whencheckingthespringloadsonaloadtestermeasureandnotethethicknessoftheretainerwheretheouterspringsits.Assembletheretaineronthespringandplaceonthebaseofthespringchecker.Compressthespringtothedesiredinstalledheight.Thisisthemeasurementbetweenthetopofthespringonthebottomsideoftheretainerwheretheouterspringsitsandthebottomofthespringonthebase.NOTESincetheretainerisinstalledinthespringwhencheckingthespringloadsmakecertainthatthethicknessoftheretainerisnotincludedwhencalculatingtheinstalledheightandisaccountedforwhencompressingthespring.Thespringloadcheckerwillshowtobehigherwiththespringinstalledatthecorrectheight.InstallationBeforeinstallingthespringonthecylinderheadschecktheinstalledspringheightasshowninDiagramAonthefollowingpage.Thisisthedistancefromthebottomoftheretainertothesurfacewherethespringrestsonthehead.Thevalvesretainersandvalvelockswillbeusedinthisstep.FirstinstallthevalveinTheTruthAboutValveSpringsBYSTEVEFOXANDCOMPCAMS engineprofessionalWWW.AERA.ORGEP59 theguidetheninstalltheretainerandvalvelocks.Pulltheretainertightlyagainstthevalvelockswhileholdingthevalveassemblysteady.Measurethedistancebetweenthespringseatandtheoutsidestepoftheretainerusingyourheightmicrometerorasnapgaugeandapairofcalipers.RepeatthisprocedureforallthevalvesandrecordyourInformation.Afteryouhavemeasuredallthevalvesfindtheshortestheight.Thiswillbecomethespringsinstalledheightonyourheads.Ifyourcombinationincludesadualortriplespringassemblyitwillbenecessarytoallowfortheinnerstepsoftheretainer.Onceyouhavedeterminedtheshortestinstalledheightitwillbenecessarytouseshimstoobtainthisvalvespringinstalledheight.020isacceptableontheremainingvalves.BeforeremovingtheretainersmeasurethedistancefromthebottomoftheretainertothetopofthevalvesealasshowninDiagramA.Thisdistancemustbegreaterthantheliftofthevalve.Ifthedistanceisnotgreaterthanvalvelifttheguidemustbemachined.Thisisaverycommoncauseofearlycamshaftfailure.Oncethevalvespringshavebeeninstalleditisimportanttocheckforcoilbind.Thismeansthatwhenthevalveisfullyopentheremustbeaminimumof.060clearancebetweenthecoilsofboththeinnerandoutersprings.Ifthisclearancedoesnotexistyoumustchangeeithertheretainerorthevalvetogainmoreinstalledheightorchangetoaspringthatwillhandlemoreliftormachinethespringseatforextradepth.Alwayscheckforclearancebetweentheretainerandtheinsidefaceoftherockerarm.Thiswillbemostevidentwhilethevalveisontheseat.Rockerarmsaredesignedtoclearspecificspringdiameterssoyoushouldchecktoseethatyouhavetheproperrockerarmretainercombination.Thissituationcanalsobetheresultofimproperrockergeometryandmaybecorrectedwithdifferentlengthpushrodsoradifferentlengthvalve.BreakingInaValveSpringItisimportantfornewspringstotakeaheat-set.Neverabuseorruntheengineathighrpmwhenthespringsarenew.Uponinitialstart-uplimitrpmto1500to200060OCT-DEC2013engineprofessionalDiagramAInstalledValveSpringHeightTHETRUTHABOUTVALVESPRINGSBYSTEVEFOXANDCOMPCAMSFindenginespecsfastandeasyPRO-SISSAENGINESPECIFICATIONSOFTWAREGIVESYOUACCESSTONEARLY7000ENGINESPECIFICATIONSWITHJUSTACLICKOFYOURMOUSEPLUSYOUCANADDYOUROWNCUSTOMENGINEINFORMATIONTOTHEPRO-SISSADATABASE.SOBYTHETIMEITTAKESYOUTOFINDTHEMANUALWITHPRO-SISSAYOUVEALREADYFOUNDYOURSPECSANDAREBACKTOWORK...THATSAMONEY-MAKINGDIFFERENCEWWW.AERA.ORGPRO-SISTOLL-FREE888-326-2372815-526-7600500COVENTRYLANESTE180CRYSTALLAKEIL60014twitter.comaeraepfacebook.comaeraep engineprofessionalWWW.AERA.ORGEP61 62OCT-DEC2013engineprofessionaluntilthetemperaturehasreachedoperatinglevels.Shutofftheengineandallowthespringstocooltoroomtemperature.Thisusuallywilleliminateearlybreakageandprolongspringlife.Afterthespringhasbeenbroken-initiscommonforittoloseaslightamountofpressure.Oncethisinitialpressurelossoccursthespringpressureshouldremainconstantunlesstheengineisabusedandthespringbecomesoverstressed.Thenthespringsmusteitherbereplacedorshimmedtothecorrectpressure.ISpecialthankstoCompCamsfortheircontributionstothisarticle.FormoreinformationpleasecontactCOMPCams3406DemocratRdMemphisTN38118.Call901-795-2400TollFree800-999-0853orgotowww.compcams.com.DiagramBBreakinginaValveSpringTHETRUTHABOUTVALVESPRINGSBYSTEVEFOXANDCOMPCAMSSM1000ForOnly21250TheBestSurfacerOnThePlanetPrecisionsurfacingthatyoucanrelyontolastmanygenerations.Bercohas90plusyearsofmanufacturingqualitymachinesthatlastalifetimeJointhethousandsofshopsthathaveexperiencedthequalityofBercobutnowatanaffordableprice. OnecalltotheAERAtechlineandmyproblemwassolved.Tomaintainanedgeintheenginebuildingindustryyouneedresourcesyoucandependon.AERAisaspecializednetworkofprofessionalenginebuildersrebuildersproductionengineremanufacturersandinstallerswiththeexpertiseandconnectionstogetyoutheinformationyouneedwhenyouneedit.WithanAERAmembershipherearejustafewofthebenefitsyoullreceiveIToll-freetechnicalsupportISpecializedenginespecificationsoftwareIEngineProfessionalmagazineIRegionalTechSkillsConferencesIAutomotiveMachiningOnlineTrainingProgramIAvoiceinWashingtonD.C.IAERAcarriesavarietyofhigh-qualityshopsuppliesuniqueitemswhichhavebeenselectedandproducedbasedoninputfrommembersnewandimprovedtemperaturerecorderlabelstagsbagsandmoreISpecialdiscountsfromanumberofpartnercompaniestohelpAERAmembersreducecostsoncreditcardprocessingcomputerhardwareandsuppliesinsuranceshippingutilitieswasteremovalandavarietyofotherservices.IDetailsonallmemberbenefitscanbefoundatwww.aera.orgmember-servicesmember-benefitsEvenifjustoneAERAtechbulletinhelpspreventanenginecomebackyourmembershipiswellworthitsdues.Wereheretohelpyoumakeyourbusinessthebestitcanbe.JointodayCompletethemembershipapplicationonpage98andreturntoAERA.FormoreinformationcallAERAtoll-free888-326-2372orvisitwww.aera.org.AERAEngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600fax888-329-2372815-526-7601www.aera.orgemailinfoaera.orgtwitter.comaeraepfacebook.comaeraepengineprofessionalWWW.AERA.ORGEP63 64OCT-DEC2013engineprofessionalMakingonehorsepowerpercubicinchisnothingtosneezeatbutitsnot1957anymore.Chancesarethatthenethorsepowerratingofyourwifesminivancomesprettydarnclosetomatchingthegrosshorsepowerofthe57CorvettesvauntedFueliesmall-block.Obviouslyenginebuildershavelearnedathingortwoaboutrampingupefficiencyandspecificoutputovertheyearswithtodayspremiereracingenginesexceedingajaw-droppingtwohorsepowerpercubicinch.Theproblemforgrassrootsenginebuildersisthathittingthetwo-hp-per-cubemarkisreservedexclusivelyforthemega-dollarrealmofNHRAProStockandNASCARSprintCupandthefinegentlemenworkinginthoseshopsarentgoingtorevealtheirhorsepowersecretsanytimesoon.FortunatelywevefoundthenextbestthingintheSchoolofAutomotiveMachinistsSB2.2small-block.Thisbeastlycombinationkicksoutanincredible853hpfromjust402cubicinchesandsinceSAMwww.samracing.comisinthebusinessofeducatingtomorrowsenginebuildersitsinstructorsweremorethanhappytoexplainhowitsdone.Championship-WinningPerformanceTheimpressiveoutputofSAMs402wasenoughtowintheXtremeStreetDivisionatthe2012AmsoilEngineMastersChallenge.ForthoseunfamiliarwiththiseventthinkofitastheSuperBowlofenginebuildingcompetitions.OveradecadeagoPopularHotRoddingmagazineinvitedenginebuildersfromaroundthecountrytocompeteinaput-up-or-shut-updynocompetition.SincethentheEngineMastersChallengehasgrowndramaticallywitheveryonefromsmall-scalemachineshopstoNHRAProStockenginebuilderstoDIYersgoingheadtoheadeachOctoberforfatpaychecksandbraggingrights.Althoughtherulesstipulatingwhichpartscanandcantbeusedhavechangedovertheyearstheuniquescoringsystemhasalwaysemphasizedoptimizingaveragehorsepowerandtorqueoverabroadrpmrange.Sincelow-andmid-rangetorqueoutputoftencomesattheexpenseofhigh-rpmhorsepowerbuildinganenginecombinationthatperformswellundertheEMCscoringsystemischallengingtosaytheleast.Inadragracingapplicationhigh-rpmhorsepowerisfarmoreimportantthanlow-endtorqueSAMDirectorofEducationJudsonMassingillexplains.The2012EMCscoringsystemaveragesenginehorsepowerfrom4000-to8000rpm.Thatmeansthatthepoweranenginemakesat4000rpmisjustasimportantasthehorsepoweritmakesatitspeak.Unlikeinaraceengineyouhavetodesignthepartscombinationtogiveupsometop-endpowerinordertoincreaselow-andmid-rangetorque.FurthercomplicatingmatterstheEMCscoringsystemalsodividesengineoutputbydisplacementtooffsetthepotentialadvantagesofbuildingalargecubicinchcombination.InotherwordssimplychoosingwhichengineplatformtobuildrequirespainstakingresearchbutultimatelySAMdecidedthattheSB2.2wasthebesttoolforthejob.ThepowerisinthecylinderheadsandthegoalistoEMCChampionDissectingtheSchoolofAutomotiveMachinists853hp402CIDSB2.2small-blockBYSTEPHENKIMPHOTOSCOURTESYOFPOPULARHOTRODDINGMAGAZINE engineprofessionalWWW.AERA.ORGEP65moveasmuchairaspossiblethroughassmallofaportaspossible.Youhavetomakethecross-sectionalareaoftheportsmalltokeeptheairvelocityupatlowrpmwhilemakingsurethatitdoesntbecometoorestrictiveathighrpmJudsonsays.ComparedtoalltheothercylinderheadsouttheretheSB2.2headsareaboutasgoodasitgetswhenitcomestoairflowinrelationtocross-sectionalarea.TheportdesignwecameupwithforthisEMCmotorflowed400cfmat0.900-inchlifethroughaconservativelysizedport.Ifaconventional23-degreesmall-blockChevyheadhadasimilarcross-sectionalareaasanSB2.2headitwouldflow70cfmless.AllinYourHeadTheastoundingadvantageinairflowandportvelocityoftheSB2.2cylinderheadsbegsthequestionWhatmakesthemsogreatSavvyhotroddersalreadyknowthattheSB2.2headsweredesignedbyGMspecificallyforNASCARcompetitionandtheywereneverofferedinaproductionengine.WhatslessknownisthatwhiletheywillboltuptoastandardChevyblocktheyshareverylittleincommonwithaconventional23-degreehead.Lotsofpeopleknowthatan18-degreecylinderheadisbetterthana23-degreeheadandthereareseveraladvantagesofflatteningoutthevalveangle.AsyoustandthevalvesmoreuprightyoualsomakethecombustionchamberssmallerJudsonexplains.Thiscreatesamoreefficientchamberthatalsoallowsincreasingthecompressionratiowithamuchlighterflat-toppiston.Thecatchisthatifyoustandthevalvesupbutkeeptheportentranceinthesamelocationyoullendupwithasharpertransitionattheshort-turnradiuscompromisingairflowathighvalvelift.ToForhigh-rpmbighorsepowerapplicationsGMPerformancePartsBowtieblockboastsseveralhighlydesirablefeaturesincludingextrathickbulkheadsfour-boltcapsonallfivemainsandprioritymainoiling.TheBowtieblockscommodiouscrankcaseswallowsuptheLunati3.750-inchcrankwithroomtospare.SAMdoesntsubscribetothetheorythatlong-rodmotorsincreaselow-endtorque.Neverthelessitoptedfor6.125-inchLunatirodssincelongerrodspushthewristpinclosertothepistoncrowntherebyreducingpistoncompressionheightandweight.ThecustomDiamondpistonswerematchedwithahardsteeltopringaNapiersecondringanda2mmoilringwithjust7-10poundsoftension.TheBowtieblocksthickcylinderwallscanbeboredaslargeas4.155inchesbutSAMdeterminedthata4.128-inchborewasidealfortheEngineMastersChallenge.ForquickerandmoreconsistentcylinderwallfinishSAMprefersdiamondhoningitsraceblocks.TheteamendedupwithanRAvalueof6andanRZvalueof50.WhenorderingthepistonsSAMdigitizedtheSB2.2headswithitsin-houseco-ordinatemeasuringmachineandsentthedataovertoDiamond.Theresultisapistoncrownthatperfectlyfollowsthecombustionchambercontours.Valvetrainstabilityisalwaysaconcernwhenturning8000rpm.SinceenhancingvalvetrainstiffnessisfarmoreimportantthanreducingmassonthepushrodsideoftherockerarmsthanonthevalvesideoftherockersSAMoptedforthickSmithBrotherspushrodsandheavydutyJesel0.937-inchkeywaylifters.TheTDshaft-mountrockersmultiplylobeliftata2.11ratioontheintakevalveandata2.01ratioontheexhaustvalve. 66OCT-DEC2013engineprofessionalEMCCHAMPIONBYSTEPHENKIMcounterthistheSB2.2headshaveanintakeportentrancethatsraisedsubstantiallyovera23-degreehead.Thisstraightensouttheshort-turnradiusandprovidesamoredirectpathintothecylindersfortheincomingair.AlthoughtheSB2.2sflat11-degreevalveangleandraisedportscontributegreatlytoitsairflowpotentialthatsnottheentirestory.Traditionalsmall-blockChevyheadsareplaguedbypushrodpinchwhichhasalwayslimitedhowaggressivelyenginebuilderscanpushportdesignbeforerunningoutofroomatthepushrodpassages.Acommonaftermarkettrickismovingtheintakepushrodsovertothesidebyusingoffsetlifterswhichfreesupadditionalspacearoundtheintakeports.IndeedtheSB2.2castingsemployasimilaroffsetstrategybuttheyalsotakethingstoawholenewlevelbycompletelyalteringthestandardsmall-blockChevyvalveplacement.InanSB2.2headtheintakeandexhaustvalvelocationsontheoutboardcylindersarereversed.Soinsteadofhavingintakeportsthataredirectlyadjacenttoeachotherasinaconventionalsmall-blockChevyheadtheSB2.2sintakeportsarespreadveryfarapart.Thisofferstremendousflexibilitywhendesigningtheintakeports.Furthermoretheintakevalvesarealsocantedfourdegreestohelpde-shroudincomingair.BothonpaperandonthedynotheseattributesmadetheSB2.2castingstheultimateweaponfortheAmsoilEngineMastersChallenge.IttakesaseriousinductionpackagetokeeppacewithahealthysetofcylinderheadsliketheSB2.2castingsandgettingthejobdoneonSAMs402areanEdelbrock2862high-riseintakemanifoldandaBookRacing4500-seriescarburetor.ConsideringthatSAMhadtheoptionofrunningatunnelramwithdualfour-barrelcarbswhichispreciselywhatmostcompetitorsintheXtremeStreetdivisionelectedtorunthe402scomparativelypedestriancastsingle-planeintakesetupissomewhatalarming.Whatsevenmorealarminghoweverishowwellitperformed.NASCARhasmandatedcastsingle-planeintakemanifoldsfordecadessothereisatremendousamountofRDthatsgoneintotheEdelbrockmanifoldthatmakesitworkverywellwiththeSB2.2headsJudsonsays.Alloftheportsarepointedtowardthecenterofthemanifoldtooptimizethesingle-carbconfiguration.Wetestedatunnelramwithdualquadsandwhileitdidmakemuchbetterpeakhorsepowerithurttheaveragehorsepowernumberstoomuchtowarrantkeepingit.Short-BlockFormulaAsthemanresponsibleforteachingstudentslife-longlessonsinenginebuildingathisvocationalinstitutiontheSchoolofAutomotiveMachinistsJudsonMassingillbringsfivedecadesofracingsavvyintotheclassroom.BasedonlessonslearnedbuildingeverythingfromNHRASuperStocktocircletracktoroadracetopowerboattostreetenginesovertheyearsheteachesstudentsthatcylinderheadairflowisfarmoreimportantthanshort-blockdesign.EvensoEMCsemphasisonaveragehorsepoweroutputmeantthatasignificantamountofeffortwentintodesigningthebottom-endonSAMs402.Thecylinderheadsmakethepowerandtheshort-blocksimplyholdseverythingtogetherbutalotoftimewentintodesigningtheshort-blocktobesttakeadvantageoftherules.Inthepastwhenhorsepowerwasaveragedbetween2500and6500rpmwewentwithunder-squareboreandstrokedimensionstohelpboostthelow-endtorqueJudsonrecalls.Sincetherpmrangein2012forourclasswasraisedto4000-8000rpmwefeltthatwecouldgetawaywithanover-squarecombinationandendedupwitha4.128-inchboreanda3.750-inchstroke.ThelargerborehelpsthecylinderheadsMovingthepushrodsovertothesidereducespushrodpinchattheintakeportsbutitalsorequiresmovingthepushrodsovertothesideatthelifters.Usingoffsetliftersisacommonsolutionbutthedrawbackisundesirablepushrodangularity.ToavoidthisSAMoffsetboredandsleevedthelifterboresinstead.Theresultarepushrodsthatareorientedcompletelyvertical.AnotheralternativeisstartingoutwithaSB2-specBowtieblockwhichcomeswithoffsetboresstraightfromGM.TohelpdirectoilwayfromthecrankSAMinstalleddrainbackplugsintheliftervalley.Comparedtoaconventional23-degreesmall-blockChevycylinderheadthelocationoftheintakeandexhaustvalveshavebeenreversedontheoutboardcylinders1278oftheSB2.2head.Thiseffectivelyspreadstheintakeportsapartofferingmuchmorespaceandflexibilityforheadporters.Thecantedintakevalvesmoveawayfromthecylinderwallsastheyopenwhichincreasesairflowandimproveswetflowcharacteristics.MinimizingvalvetrainmassareDelWest2.181.60-inchtitaniumvalveslocksandretainers.TheManleyspringscheckinat250poundsofseatpressureand600poundsofpressureoverthenose. FortheultimateinprecisionSAMsSB2.2utilizesabelt-drivenMSDdistributoraswellasanMSDcranktrigger.AnATISuperDamperkeepscrankshaftharmonicsincheckwhileaMeziereelectricwaterpumpcoolseverythingdownwithoutimpartinganyparasiticpowerloss.Inanefforttoboostmid-rangeoutputSAMboltedasetofSpecialtyMetalCraftstepped2-to-2.125inchTri-Yheaderstothe402.WhileTri-Yheaderstypicallyincreaselow-andmid-rangetorqueattheexpenseofhigh-rpmhorsepowerSAMfoundthattheSMCheadersdidntgiveupanytop-endpowercomparedtootherheadersthatittested.WithvalveseatsthatareclearlyvisibleattheintakeportentrancetheSB2.2headsmeanbusiness.ByraisingtheintakeportsashighaspossiblewithoutwipingoutthevalvetrainGMcreatedanextremelyefficientportintheSB2.2heads.AftertinkeringwithvariousrunnervolumesSAMendedupwithintakeportsthatflow400cfmat0.900-inchliftthroughaveryconservativecross-sectionalarea.Purpose-builtforNASCARcompetitiontheEdelbrockSB2.2intakemanifoldflowsgreatrightoutofthebox.AlthoughSAMdidntperformanymajormassageworkonthemitdidspendmanyhourssmoothingoutthetransitionsfromtheplenumtotherunners.Since4500-seriescarburetorswerebannedinNASCARnaturallytheEdelbrockintakefeaturesa4150-seriesplenumopening.SAMbuiltacustomspacertoadaptthe4500-styleBookRacingcarburetortothe4150-styleintake.SAMmassagedthespaceradaptertirelesslytocreateasmoothtransitionintotheplenum.JustlikeontheintakesidetheSB2.2castingsfeatureraisedexhaustportsbutthevalveangleisevenflatterat8degrees.Theresultis280cfmofflowat0.900-inchlift.WithabilletbaseplateandmeteringblockstheBookRacing4500-stylecarburetorisaworkofart.Itboatsmassive2.40-inchthrottleopeningsandhasbeenworkedovertodelivermuchmoreconsistentfuelflowthananout-of-the-boxcarburetor.InadditiontothecarbadapterSAMalsoinstalledaone-inchHVHcarbspacer.Theincreasedplenumwasworthafewextraponiesuptopandthespaceralsoisolatesthecarburetorfromengineheat.engineprofessionalWWW.AERA.ORGEP67 68OCT-DEC2013engineprofessionalEMCCHAMPIONBYSTEPHENKIMbreathebyunshroudingthevalvesbutwedidntopenuptheboreanylargerthanweneededto.Sincetherulesrequirerunningtheenginethroughdualthree-inchmufflersmakingtheenginetoobigwouldhaveseriouslyhurthigh-rpmpower.Assuchwewentwitha3.750-inchstrokesinceourdisplacementtargetwasroughly400cubicinches.Enduringtherigorsof853horsepowerand8000rpmrequiresaseriouslystoutshort-blocksoSAMoptedforaGMBowtieblockasthefoundationofthebuild.Atestamenttohowfaraftermarketrotatingassemblieshavecomeinrecentyearsthe402utilizesanoff-the-shelfLunati4340forgedsteelcrankshaftand6.125-inchconnectingrods.CustomDiamondpistonsperfectlymatchthecontoursofthecombustionchambersandafterlotsoftrialanderrorSAMsettledupona15.01compressionratiototakeadvantageoftheclassmandatedVPQ16racefuel.Westartedouta15.51compressionbuthadtotakeoutnearly10degreesofignitionadvancebelowpeaktorquetokeepitoutofdetonation.Loweringthecompressiondownto15.01gaveusamuchbroadertuningwindowsaysJudson.Ofcourseallthefineingredientsthatwentintothecylinderheadsandshort-blockwouldhavegonetowasteunlessthecamshaftspecswerespoton.DrawinguponwhattheylearnedinpastEngineMastersChallengestheSAMteamdesignedacustom250260-at-.050CompCamssolidrollercamshaftwith0.8920.850-inchlift.Thegoalwastokeepthedurationfiguresrelativelyshortandthelobeseparationangle106degreestighttooptimizemid-rangeoutputwhilepackinginasmuchliftaspossibletotakefulladvantageofthecylinderheadshigh-liftairflowpotential.Evenwithbeefy0.937-inchdiameterJeselliftersrunningbig-blocklevelsofliftinasmall-blockforcedtheteamtogetcreative.Withashort-durationcamyourelimitedOntheUniversityofNorthwesternOhiosDTSdynoSAMs402finishedFirstinbothqualifyingandinthefinals.Ithadtofendoffsomestiffcompetitionfromseveralchampionship-winningProStockenginebuildersbutultimatelySAMsSB2.2prevailed.DYNORESULTSSAMCHEVYSB2.2RPMHPTQ400040453042004445554400475567460052660048005706245000608638520064264854006696505600696653580072865960007586646200784664640080466066008186516800830641700084663472008536227400850604760084658478008385648000831546402SB2.2ENGINESPECSBore4.128inchStroke3.750inchDisplacement402cubicinchesCompressionratio15.01CamshaftCompCamssolidrollerCamduration250260degreesat0.050Valvelift0.8920.850-inchTimingsetJeselbelt-driveLiftersJesel0.937inchPushrodsSmithBrotherscustomRockerratio2.102.00Lobeseparation106degreesInstalledcenterline102degreesTopring0.043inchTopringgap0.018inchSecondring0.0325inchSecondringgap0.030inchOilring2mmPistonsDiamondcustomBlockGMBowtieCrankshaftLunatiforgedsteelRodsLunati6.125inchsteelMainjournaldiameter2.75inchMainbearingclearance0.0025inchRodjournaldiameter2.10inchRodbearingclearance0.0025inchBearingsCleviteH-seriesCylinderheadsGMSB2.2Chambervolume50ccIntakevalvediameterDelWesttitanium2.18inchExhaustvalvediameterDelWesttitanium1.60inchValvespringsManleySpringretainerslocksDelWesttitaniumIntakeportflow400cfmat0.900-inchliftExhaustportflow280cfmat0.900-inchliftHeadgasketFel-Pro1143Quenchclearance0.041inchIntakemanifoldEdelbrock2862CarburetorBookRacing4500IgnitionMSDDamperATIWaterpumpMeziereOilpanWilliamscustomOilpumpSchumannOilAmsoil5W-20FuelVPQ16 engineprofessionalWWW.AERA.ORGEP69inhowsteepyoucanmakethecamlobeprofiles.Sinceyoucantgetmuchliftthroughthecamandlifterswehadtogowith2.11ratiorockersontheintakesideand2.01rockersontheexhaustsideJudsonexplains.DynoTimeAfterpostingthehighestscoreduringqualifyingalleyeswereonSAMs402duringthefinals.Withthetimingdialedinat29degreestheSB2.2didntdisappointstrainingtheDTSdynowith853hpat7200rpmandanequallyastounding664lb-ftoftorqueat6000rpm.Thatworksouttoanimpressive2.12hppercubicinchbutyoucouldmakeacompellingcasethattheenginestorqueoutputof1.65lb-ftpercubicinchisevenmoreimpressive.ToputthingsintoperspectiveconsiderthattheCorvetteZR1sLS9small-blockproduces1.60lb-ftpercubicinchandthatswiththehelpofa2.3Lsuperchargercrammingairintothecylinderheads.TheonlynaturallyaspiratedenginethatcanmatchthatkindoftorquepercubicinchisaProStockenginesaysJudson.IntheClassroomBraggingrightsprideandpursemoneyarethereasonswhymanyenginebuilderscompeteintheAmsoilEngineMastersChallenge.FortheSchoolofAutomotiveMachinistshowevertheprocessofgoinghead-to-headwithProStockchampionenginebuildersprovidesanunparalleledlearningopportunityforitsstudents.FromstarttofinishourstudentsareinvolvedinthedesignassemblyanddynotestingofourEngineMasterscombinations.EngineslikethisSB2.2showsthemwhatittakesintherealworldtobuildahardcoreracemotorthatmustcompeteandperformataveryhighlevelJudsonexplains.Whenstudentsenterourprogramtheydontknowanythingaboutmovingalifterboretostraightenoutthepushrodangleloweringthecompressionratioahalf-pointtobroadenthetuningwindoworadvancingthecamfourdegreestoincreaselow-endtorque.Aftereachchangewemakeonthedynoweprinttheresultshandthemoutintheclassroomandexplainhowandwhyanenginereactedthewayitdidtoeachchange.Wealsodiscusswhatchangesweregoingtomakenexttimetoreachourperformancetargets.Itsvaluableexperiencelikethisthathelpspreparethemtobuildcompetitiveraceenginesintherealworld.IFormoreinformationabouttheSchoolofAutomotiveMachinistspleasecall713683-3817orvisitthewebsitewww.samracing.com.The2012AmsoilEngineMastersChallengemarkedteamSAMsseventhattemptatwinningthechampionship.Whilethecrewhascomeclosetowinningbefore2012wastheyearwhereitfinallytookhomethechampionship.FromlefttorightareSAMInstructorChrisBennettstudentPrestonMosherInstructorShawnHopperDirectorofEducationJudsonMassingillandExecutiveDirectorLindaMassingill.Congratstoeveryoneinvolvedforajobwelldone. 70OCT-DEC2013engineprofessionalThenextgenerationNissanTitanwillmakeuseofa5.0-literV-8turbodieselCumminstheJapanesecompanyannouncedatthestartofitsNissan360industryshowcase.Itisexpectedtobeofferedasearlyasmid-2014asa2015model.Nissandeclinedtoconfirmwhenitsnext-generationTitanwillgointoproductionbutprototypesareundergoingengineeringtestsonpublicroadswiththeCumminsdiesel.Thenew5.0-literV8engineisratedatmorethan300horsepowerwithtorqueofaround550pounds-feetthecompanysaid.AnotherversionoftheenginewillalsobemarketedbyCumminstoothercommercialtruckmakers.DodgeTrucksatonetimewasnegotiatingtobuildaversionofitsfull-sizeRampickupforNissantoreplacetheJapaneseautomakersslow-sellingTitanpickup.ThatdealfellthroughduringChryslers2009bankruptcyandsubsequentacquisitionbyItalysFiatSpA.EarlierthisyearFredDiazwhowasleadingChryslersRamTruckbrandjumpedshipforNissanNorthAmericawherehenowheadsU.S.salesandmarketingfortheNissanbrand.ThecurrentTitanwentintoproductioninlate2003inCantonMississippi.Annualsalesinrecentyearshavebeenjustover20000.IncomparisonthesegmentleaderFordsfull-sizeFSeriessold645000lastyear.Nissanhassaidtheadditionofmorebodystylesandengineoptionsonthenext-generationTitanshouldhelpboostthetrucksappeal.ThenewenginewillbebuiltnearCumminsheadquartersinColumbusIndianainafactorythatdatestothe1920s.CumminsfirstannouncedplansfortheV8dieselin2006butdelayeddevelopmentduringtheindustry-widedownturnin2008-2009.2014shouldbeinterestingasNissanwillhaveahead-to-headmatchwithChryslersrecentlyannouncedRam1500EcoDiesel.The2014Ram1500EcoDieselwasannouncedearlierthissummerandisslatedtogoonsalelatethisyearorearlynextyear.DescribedbyChryslerastheindustrysfirstlight-dutyV6dieselpickuptheRam1500EcoDieselfeaturesa3.0-literV6turbochargeddieselfromItalysVMMotorialongtimesuppliertoChryslerandanaffiliateoftheU.S.automakerscorporateparentFiatSpA.Cumminsalong-timeU.S.supplierofdieselenginestocarmakersaroundtheworldcontinuestomakedieselenginesforChryslersheavy-dutyRampickups.IthasbeenaChryslerdieselenginesuppliersince1988.NeitherFordnorGeneralMotorscurrentlyofferadieselengineoptionforlight-dutypickupsandseemtobeplayingawaitandseeapproach.ItwouldhoweverbequiteeasyforGMtolaunchitspreviouslydesigned4.5LDuramaxDieselinthetonpickuplines.The4.5-literV-8isfullydevelopedandreadysaidMarkCieslakGMsfull-sizetruckchiefengineer.Ifwedecidedtoofferitwecouldlaunchitinaheartbeat.FordmeanwhilehasmadethestatementFordMotorCo.hasnoplansforalight-dutydieselaspokesmansaidaddingthatFordsEcoBoostV6engineisalessexpensiveoptiontosavefuelandwillbeourdieselfighter.I2015NissanTitanwillfeaturenewCumminsTurboDieselV8EngineBYDAVEHAGEN 72OCT-DEC2013engineprofessionalThroughthePRO-SISSAprogramAERAoffersitsmembersafeaturecalledShopFA.SomeofyoumayhaveseenitintheprogramandwonderedwhatitwaswellIamabouttotellyou.ShopFAisaShopFinancialAnalyzerthatallowsyoutoinputsomeofyourfinancialinformationandmanipulatethenumberstoseehowitaffectsyourbottomline.ThisbusinesstoolwasintroducedtomembersofAERAacoupleofyearsagotohelpwithbusinessandalsotoassistinseeingifthebusinessisprofitable.Inusingthisprogramyouwillbeabletoseeifanyareasintheshoparenon-profitableandhowyoucanchangeacertainnumberorshopratetohelpinmakingyourbusinessprofitable.Eachtabcontainsareasthatyoucaninputinformationandchangeasneeded.Thechartaboveshowswhatareasareineachtab.OnceyouhavefilledinthenecessaryinformationyoucanhittheCalculatebuttonandseeyourresults.Afterreviewingtheresultsyoucanthengobackandmanipulatetheinformation.Forexampleletssayyouwanttoincreaseyourshoplaborrateby3.00.OnceyouhavechangedthelaborrateclickCalculateagainandseewhathappenswhenyouraisedtheshoplaborrateby3.00.AERATechnicalSpecialistSteveFoxhasover25yearsexperienceintheenginebuildingindustrywith10ofthoseyearsspentworkinginthemachineshop.SteveisanASE-certifiedMasterMachinistaswellasalongtimememberofthedragracingcircuit.ThescreenshotaboveshowsoneofthefeaturesofPRO-SISSAcalledShopFAShopFinancialAnalyzer.Thisusefultoolhelpsyoulookatyourshopsperformanceinanewlight.JustenterafewdetailsaboutyourshopsoperationalcostslaborratesandpartsandShopFAwillquicklyidentifyandhelpyoufixareasofnon-profitability.SHOPDATACOSTOFOPERATIONSFRONTOFFICECOSTOfficeShopHoursWeekOutsideLaborSalaryRelatedBenefitsBillableHoursRentMortgageAdvertisingPromotionLaborRateSalaryComputerSoftwareAverageLaborRateHourBillablePayrollTaxesTravelEntertainmentHealthInsuranceSubscriptionsSeminarsTelephoneProfessionalFeesUniformExpenseVehicleExpenseUtilitiesOfficeExpenseShopSuppliesToolsAERAMembershipInsurancePRO-SISDebtServiceonMachineryMisc.Misc.ShopFinancialAnalyzerAsimpleprogramtocheckthebottomlineThisprogramgivesyouanideaofwhattheshopisdoingallowsyoutomanipulatethenumbersandmakechangestoseeifyoucanbecomemoreprofitableincertainareas.IfyouareamemberofAERAusingPRO-SISSAandwouldliketotrytryShopFAjustclickonShopFAinthemenuandyouwillberunningtheprogram.Playwithitandseewhatyoucanchangeintheshoptomakemoremoney.Youjustmightbesurprisedhowalittlechangewillmakeabigdifferenceonyourbottomline.IPRO-SISCORNERBYSTEVEFOX engineprofessionalWWW.AERA.ORGEP73 74OCT-DEC2013engineprofessionalFewproductlaunchesinrecentyearshavegeneratedtheexcitementofCatsentryintothevocationalworktruckbusiness.IthadallthetrappingsofaBigDealabrandnewproductlineinanewmarketandfromamajorenginemanufacturer.PlusithadallthenuancesthatmakesuchstoriesinterestinghowwouldthealliancewithNavistarworktobuildandpowerthetrucksHowwouldCatfareintheon-highwayworldsosoonafterexitingthetruckenginebusinessWasthereroominthevocationaltruckworldforanothermanufacturerThuswithalltheappropriatepompandcircumstanceCaterpillarrolledouttheall-newmodelCT660worktruckatConExpo-ConAgg2011inLasVegas.Thenewtruckwasintroducedasatruckordaycabtractorwithsetbackfrontaxleand116and122in.bumpertobackofcabdimensions.TransmissionoptionsincludedmanualautomatedmanualandfullautomaticthelatterCaterpillarsCX31.ThetrucksweretobebuiltbyNavistarinGarlandTexas.InitialmodelsweredueinOctober2011rampinguptofullproductionlastyear.ThetruckprogramwouldfinditscorporatehomeintheNC2GlobalLLCjointventurenowasubsidiaryofNavistarcreatedbyCaterpillarandNavistarin2008.TheConExpo-ConAggannouncementsaidtheCT660wouldeventuallyhavethreeengineoptionsan11LdieseltheCT11withoutputsfrom330to390hpthe13LCT13withratingsfrom410to475hpandbythefirstquarterof2012a15LdieselthemodelCT15rated435to550hp.NotlongafterthesmokehadclearedfromtheLasVegasproductlaunchCatsroadbackintotheon-highwayworldtookafewunexpectedturnsandsomedetourspoppedup.InOctober2012NavistarannouncedaspartofitsefforttoreducecostsandoptimizeitsmanufacturingfootprintthatitwasclosingtheGarlandtruckplant.WorktruckmanufacturingendedupinMarch2013atNavistarsEscobedoAssemblyPlantinEscobedoMexico.Butthebiggestchangescameontheengineside.Navistarsenginetechnologywoeshavebeenwelldocumentedincludingdroppingitsownplanned15LdieselandsourcingthatenginerangefromCummins.FortheCatworktrucklinethatmeanttherewouldbeno15Ldieselsooncertainlynotbythethefirstquarterof2012.Thuscomingupontwo-and-ahalfyearssincetheintroductiontheCT660truckhasasingleenginetheNavistarbuiltCT13a12.4Lasixcylinderinlinedieselwithfourvalvespercylinderanddualseriesintercooledandaftercooledturbochargers.Theratingsforthe13Ladvertisedenginehavechangedto365to475hpat1700rpmandpeaktorquesisnow1250to1700lb.ft.1000rpm.CathasexpandedtheCT13engineratingstoincludethemostpopularCT11engineratingsandhavediscontinuedtheproductionoftheCT11.Clearlyweunderstandhowcriticala15LengineistoourcustomerssaidGeorgeTaylordirectorofCaterpillarsGlobalOn-HighwayTruckGroup.ThebestIcantellyouisthatwereintheprocessofmakingthefinaldecisionsaroundthatandplantomakeanannouncementonwhatweregoingtodo.Ifwecoulddoittomorrowwewould.Itssuchaprevalentpowertrain.WhenyoulookattheClass8heavy-dutytruckmarket15Lenginesprobablyrepresent40to50ofthissegmentthatweserve.Soitsacriticalplatform.ButwehavetohaveaverygoodcoherentstrategyaroundourenginesA15LEngineForCatsWorkTruckLineBYMIKEOSENGACaterpillarC13DieselEngine 76OCT-DEC2013engineprofessionalA15LENGINEFORCATSWORKTRUCKLINEBYMIKEOSENGAgoingforwardandwereworkingtogetthattakencareofTaylorsaid.Changesinthetruckenginemarkethavesomewhatmitigatednotcurrentlyhavinga15Lengineoption.Ithinklastyearwasthefirstyearinourindustrythat13Lenginesoutsold15LenginesTaylorsaid.CombinedwithourCX31automatictransmissionyouhavetolookattheweightsavingsyoupotentiallygetwitha13Lyoulookattheautomatictransmissionaddressinghowtomanagethepoweritselfandthenthefueleconomyour13Lenginewithourautomaticisdeliveringbetterfueleconomythansomeofthecompetitiveofferings.DaveSchmitzCatsvocationaltruckproductmanageraddedwerehearingsomeverypositivefeedbackaboutthe475hpratingwiththeCX31andthetypeofpullingcapabilitiesthatyouhavewiththathesaid.Wereevengoingintoterritoriesthathadusedthetraditional15L18-speedandnowtheyreusingthe13LCX31withthe475hprating.Of engineprofessionalWWW.AERA.ORGEP77coursethatwillnotreplaceallthe15Lapplicationsbutwerestartingtoimpedeinthetraditional15Lmarkets.OverallTaylorsaidtheprogressfortheworktruckprogramhasbeensteadyandaboutasexpectedwithsalesintoconstructionequipmentloadandhaulminingoilandgaspavingandheavyhaulusesinmanycasesparallelingCatsequipmentprofileamajorpointwhenthetruckswereintroduced.Dustabatementapplicationshavebeenespeciallystrong.WevehadsteadygrowthTaylorsaid.Onethingformelookingatthisyearversuslastyearisthatthesecondhalfoflastyearwasprettystrongandwhilethefirsthalfofthisyearhasbeenprettyweakfromanoveralltruckmarketpointofviewithasntaffectedusatall.Wearenowatapointwherewearegettingrepeatcustomers.AcoupleofnewbitsofnewsaboutthevocationtruckprogramisthattheexpectedsecondmodelinthelinetheCT680set-forwardtruckisexpectedtobeintroducedbyConExpo-ConAgginMarch2014.Iwonderwhatengineitwillhave.BeyondtheCT660andCT680TaylorsaidWehaveotherthingsthatwerelookingat.Werecommittedtocontinuetoexpandthatproductlinetomeettheneedsofcustomersinspecificsegments.AlsoTaylorsaidthevisionforthetrucklinehasalwaysbeentobeaglobalsupplier.ThetruckswereinitiallyintroducedintheU.S.andMexicoandmorerecentlyinPuertoRicoandMexico.InterestinglytheexpansionintoothermarketsmightinvolvetheuseofCaterpillardieselengines.WearelookingathowwemightleverageourexistingenginebasepossiblyforlesserregulatedemissionscountriesTaylorsaid.WhynotifyouhaveaCatenginethatmeetstheemissionsregulationsinaLatinAmericancountryforexampleWemightlooktoleveragetheproductonamoreglobalbasis.Wehavesomeprogramsnowwherewereaggressivelylookingatdoingthat.CustomeracceptanceofthenewCT660seemstobehighasfarasfromatruckusagepointbutsomeexpresseddisappointmentwithlackofproposedengineoptions.AtthispointintimeonlytimewilltellbutitdoesntlookgoodforthepreviouslyproposedCT15atleastinitscurrentrendering.IMikeOsengaisthePresidentofDieselGasTurbinePublicationsandPublisherofDieselProgressDieselProgressInternational.Formoreinformationpleasecall262-754-4127orvisitwww.dieselprogress.com.EditorsNoteWewouldliketothankMikeOsengaofDieselProgressforhiscontributionstothisarticleandsupportthroughoutthelasttwentyplusyears. 78OCT-DEC2013engineprofessionalCONFERENCERECAPBYSTEVEFOXAERAandPERAteameduptohostaregionalconferenceatAERManufacturinginCarrolltonTexasduringthemonthofSeptember.Attendancetotheconferencewasoutstandingandeveryonewasveryhappythattheyattended.AERManufacturingopenedtheirdoorstoAERAmemberstocomeinandseethefacilityaswellastheircarmuseumwheretheconferencewasheld.ThedaybeganwithapresentationbyDavidCookofFlame-SprayIndustries.HehelpedeveryoneunderstandthatthermalsprayisaversatiletooltoaidintheremanufacturingofmanydifferentenginecomponentsfocusingonthespecialthermalsprayprocesscalledPTWAPlasmaTransferredWireArc.Thisprocesshasbeendevelopedtocoattheinternalsurfacesofboresandisbecomingveryvaluablefortheremanufacturingofmanycomponents.ThispresentationbroughtonmanygreatquestionsbytheattendeesandDavidwashappytoanswerthem.ThesecondpresentationwasgivenbyAERAPresidentPaulHauglieandAERATechnicalSpecialistSteveFox.PaulbeganthepresentationbygivingthegroupsomebackgroundhistoryaboutAERAandwhatAERAprovidestoitsmembership.PaulthenhandedthemicrophoneovertoStevewhocontinuedthepresentationonAERAsenginespecificationsoftwarePRO-SIS.Presentationswrappedupbeforelunch.ThelastonewasgivenbyKeithJonesofTotalSealPistonRings.Keithtalkedaboutthechangesyouseebetweenmodernraceengineapplicationscomparedtothoseofthepastregardingpistonringmaterialsanddesigns.Heonceagaingaveagreatpresentationwhichleftmanyoftheattendeesaskinghimquestionsoncehewasfinished.AfterthemorningpresentationsandagreatBBQlunchprovidedtothegroupAERtookeveryoneonatouroftheirremanufacturingfacility.ThiswasagreatopportunitytoseehowAERdoestheirremanufacturingprocess.Thetourconsistedofthedisassemblyprocessthemachiningprocessandassemblyoftheengines.WeappreciateAERforopeningupandlettingAERAmembersseetheirfacility.IfyouhaveneverattendedanAERATechSkillsConferenceyoushouldEveryoneowesittothemselvesandtheirbusinesstogainknowledgeandnetworkwithotherpeoplewithinthesameindustry.AERAunderstandsthattravelingtonationaltradeshowstogainthisknowledgeandnetworkingopportunitiesisveryexpensive.ThereforeAERAhasdecidedtohelpbyteamingupwitharegionalhosttooffertheseopportunitiesindifferentregionsofourcountryandhopefullyclosertoyourshop.AlongwiththeoutlinedtechnicalprogramsAERAinvitesleadingmanufacturersofenginebuildingandrebuildingtoolssuppliesservicespartsandmachinerytoalsoattendtheconferences.Thesesuppliershavetable-topdisplaysthatareaccessiblealldaylong.Meetingthesesuppliersinarelaxedatmosphereisagreatwaytobeginlifelongrelationshipsthatwillhelpyouprosper.WelookforwardtoseeingyouataconferencesoonLookforthemostrecentconferencescheduleupdatesandinformationontheAERAwebsiteatwww.aera.orgconferences-events.IAERAandPERAhostTechSkillsConferenceatAERManufacturingInSeptemberAERAandPERAhostedaTechSkillsRegionalConferenceatAERManufacturinginCarolltonTexas. IsYourCarburetedHotRodReallySafeRunningEthanolBlendedPumpGasONLYIFYOUREUSINGCARBDEFENDERTheProblemEthanolCorrosionInCarburetedHotRodsTheSolutionDrivenCarbDefenderFuelAdditiveSimplypour-inabottleofCarbDefenderwitheachfill-upespeciallybeforeextendedstorageperiods.CarbDefenderisproudlymadeintheUSAandsoldinconvenient6-packcartons70041.Donttakeourwordaboutthisgrowingproblem.ScanthisQRcodetoreadarecentFoxNews.comarticle.1.866.611.1820DRIVENRACINGOIL.COMEthanolCorrosionCanQuicklyDestroyYourCarburetorEthanolKillsCarbsengineprofessionalWWW.AERA.ORGEP79 80OCT-DEC2013engineprofessionalTECHSIDEBYLAKESPEEDJR.LiketheysayItsthethingsyoudontseethatyouvegottowatchoutfor.RememberwhentheZincZDDPwasreducedinthemotoroilsandalltheproblemsitcausedWelltheadditionofEthanolisthesamestoryonlyinreverse.AfewyearsagowhenethanolbeganbeingblendedwithgasolineweweretoldhowitsgoodfortheenvironmenthowithelpsreduceourdependenceonforeignoilandhowitwillbenefittheAmericanfarmer.AfterallintheU.S.theethanoliscreatedfromcorn.Butethanolalsohassomeveryseriousdrawbacksthatwerentmentionedatthetime.Namelyethanolishygroscopicwhichisjustafancytermmeaningthatitattractswater.Ethanolactuallypullsmoisturefromtheair.Havingwaterinyourfuelsystemisbadenoughonitsownsincewaterisprettyusefulatputtingoutfiresinsteadofhelpingcombustionbutitgetsworse.Thewaterandethanolcocktailareactuallycorrosivetomanymetalsandharmscomponentslikefuelpumps.ThatswhymanyautomanufacturersnowbuildandmarketcarsandtrucksasFlexFuelvehicles.ThatdoesntjustmeanthattheycanburnE15andE85ethanolblendedfuelspracticallyanyfuelinjectedvehiclewithO2sensorscandothatitmeansthatthemanufacturerhastakenextrastepstoprotectthefuelsystemcomponentsfromthefuelitselfSoisethanolreallythatdamagingYesMostofthegasolineusedintheUnitedStatesisdeliveredtoterminalsthroughpipelines.Becauseethanolissocorrosivethepipelinecompanieswontallowitintotheirpipelinessotheethanolisntblendedintothefueluntillater.Thepipelinecompaniessimplydontwanttheethanoleatingawaytheirpipesfromtheinsideout.ThinkingaboutyourcarburetoryetThesamecorrosivedamagescanhappeninyourhotrodracecarmotorcycleorboatifyouuseE10orhigherfuel.Thewaterandethanolcorrodebothaluminumandzinctwooftheprimarycomponentsinthealloyusedtomakecarburetors.Evidenceofthiscorrosioncanbeseenbythewhitescalydepositsthecorrosionleavesbehind.Thosedepositscreatetheperfecttrifectaofbadlossofperformancefuelmileageandreliability.Tomakethingsworsethedamagetakingplacehappensunseeninsidethefuelsystemhiddenfromyou.Andtherateofcorrosioncanalsovarydependingonafewfactors.Thebigoneishowmuchethanolisinyourfuel.ObviouslyE8585percentethanolfuelwillcorrodeyourfuelRememberZincandMotorOilGetreadyforEthanolandGasolineModernfuelblendscontainingethanolareeatingcarburetorsfromtheinsideout.Corrosivedamagecausedbyethanol. engineprofessionalWWW.AERA.ORGEP81LakeSpeedJr.fromDrivenRacingOilisthesonofLakeSpeedSr.whoracedinNASCARfrom1980to1998.Formoreinformationcallat704239-4401ore-maillspeeddrivenracingoil.com.Findmoretechnicaldataatwww.drivenracingoil.com.systemfasterthanE1010percentethanolbutneitherisgood.WhenNASCARwenttoE15theimpacttothecarburetorswasimmediate.Thesecondmajorfactorishowlongthecarisallowedtosit.Believeitornotethanolisntasdamagingtoadailydriverasitistoacarthatisonlydrivenoccasionallyandallowedtositforlongperiods.ThatiswhyboatswhichsitinstoragemostoftheyearwerethefirsttoseetheeffectsofincreasedEthanolinthefuel.Itsthatprolongedcontactthatcanreallydothedamage.Knowingallthisitseasytoseethatclassicshotrodsandotheroldercarsthatarenormallyonlydrivenonweekendsandniceweatheraresusceptibletotheperilsofethanol.ThatenginethatrangreatlastSummerthatwontidlerightthisSpringSoundsimilartoyourlawnmowerthatdoesnotwanttostarteachspringMaybeitisthefuelandtheeffectsoftheethanolinthefuel.Sinceethanolbeganshowingupinfuelsamultitudeofquickfixeshavepoppedupclaimingtomagiccuresforalltheproblemsethanolcreates.Allyouhavetodoismakeatriptoyourclosestautopartsstoretoseetheincrediblevarietyofproductsnowonthemarket.Almosteverysingleonehoweverclaimstoworkbychangingthefueleitherbysomehowremovingwaterorbydispersingthewater.Theproblemwiththatisbychangingthefueltodealwiththewateryoudontknowwhatthepropertiesofthefuelarenow.Thefuelsvaporpressuremayhavechangedtheoctanemayhavechangedandallofthisaffectsthewaythecarburetormixesthefuelandthewaythefuelburns.Thisisnotabigdealforyouraverageweedwackerorlawnmowerbutitcanharmahighlytunedmorepowerfulengine.Anyadditivethatchangesthechemistryofthefuelcanaffectthepropertune-upfortheengineinwaysthatareverydifficultorevenimpossibletopredict.TheanswerforhighperformanceenginesthatrunonethanolE10pumpgasuptoE85orOxygenatedRaceFuelsisaspecializedcorrosioninhibitorfueladditive.Lookforsomethingthatdoesnotclaimtochangethefueloreffectthewaterdirectly.Ifyoucantavoidethanoldefendyourcarburetorfromthecorrosiveeffectsoftheethanol.Nobodylikesspendingaweekendrebuildingacarburetorinsteadofhavingfunwithyourcarmotorcycleorboat.BacktotheZincconnectionnotonlydoestheadditionofEthanoltothefuelhurtengineslikethereductionofZinchurtflattappetenginesbutwhentheEthanolcorrodesyourcarburetorguesswhatthatwhitestuffisthatgetsleftbehindZincOxideI 82OCT-DEC2013engineprofessional engineprofessionalWWW.AERA.ORGEP83 84OCT-DEC2013engineprofessionalAbouttheProgramEachprogramisanonlineself-pacedcoursewithuptooneyeartocomplete.GaryLewisbookAutomotiveMachiningEngineRepairwillbeincludedwiththe150registrationfee.Everythingatechnicianwillneediscontainedintheprogramwithvideoclipsandsupplementalreadingsatkeylocationswithintheprogram.Thebookwillbeusedasasyllabuswhennotonline.Eachchapterwillbefollowedbyamultiplechoicetest.TherewillbeafinalexamforeachcertificationCylinderHeadandorEngineMachinist.AERAoffersacomprehensiveonlinetrainingprogramnotjustatestleadingtodiploma-qualitycertificatesinCylinderHeadsandEngineMachinist.Technicianswhosuccessfullyearneithercertificatewillholdproofthattheyhaveaprofessionalunderstandingofautomotivemachiningfundamentalsmeasuringtoolsshopsafetyfastenersenginetheoryenginediagnosisenginedisassemblycomponentcleaninginspectioncrackdetectionandrepaircomponentreconditioningandcylinderheadandblockresurfacing.Theinformationinthisprogramispresentedfromtheviewofenginemachineshopoperations.Basicproceduresareselectedfromthosewithwideindustryacceptanceandrepresentwell-balancedandcompetentstateoftheartpractice.GaryLewisInstructorandAuthorFormoreinformationcallAERAat815-526-7600ext.202oremailkarenaera.org.CylinderHeadandMachinistCertificateProgram engineprofessionalWWW.AERA.ORGEP85AERAONLINETRAININGREGISTRATIONFORMNAMECOMPANYNAMEAERAIDNUMBERCOMPANYADDRESSCITYSTATEZIPPHONEE-MAILADDRESSREQUIREDSIGNEDBYFEES150perpersonINCLUDESGaryLewisbookI2-4PEOPLEfromthesameshop.................................................................125perpersonI5-9PEOPLEfromthesameshop.................................................................100perpersonI10PEOPLEfromthesameshop..................................................................75perpersonEachpersonregisteredwillreceiveaGaryLewisbook.PleaselistadditionalnamesbelowTOTALAMOUNTENCLOSEDICHECKPLEASEMAKEPAYABLETOAERA.CREDITCARDIVISAIMASTERCARDIDISCOVERIAMERICANEXPRESSCARDNUMBEREXPIRATIONMMYY3-DIGITCSSCARDHOLDERNAMECARDHOLDERSIGNATUREIfpayingbycreditcardpleasefaxcompletedregistrationformtoAERAtoll-freefax888-329-2372OrmailyourcompletedformwithpaymenttoAERA500CoventryLaneSuite180CrystalLakeIL60014.CallAERAtoll-freeifyouhaveanyquestions888-326-2372ordirectat815-526-7600. 86OCT-DEC2013engineprofessionalTB2623FlatTappetCamshaftBreak-inProcedureTheAERATechnicalCommitteeoffersthefollowinginformationonthebreak-inprocedureforenginesthatareutilizingflattappets.ThisinformationisacknowledgedbyAERAandsuppliedbytheCraneCamCompany.NOTEREADCAREFULLYANDCOMPLETELYBEFOREINSTALLATION.WARNINGNEWLIFTERSMUSTBEINSTALLEDWITHYOURNEWCAMSHAFT.PRIORTOINSTALLATION1.Checkthecompatibilityofthecamshaftwiththeremainderofthevalvetraincomponentsvalvespringsrockersetc.2.Onracetypehighloadspringapplicationsuselighterloadspringsorremovetheinnerspringdualspringapplicationjustforbreak-in.DuetotheEPAsmandateforzincremovalfrommostmotoroilsproperflattappetcamshaftbreak-inprocedureismorecriticalthaneverbefore.Thisistrueforbothhydraulicandmechanicalflattappetcamshafts.Asapointofinterestthemostcriticaltimeinthelifeofaflattappetcamshaftisthefirst20minutesofbreak-induringwhichthebottomsofthetappetsmate-inwiththecamlobes.Therearesomeoilswithadditivepackagesthatarebetterforcamshaftbreak-in.TherearemanyaftermarketoilsuppliesthathaveincreasedlevelsofZincandPhosphateforenginebreak-inpurposes.ItisimportanttonotehoweverdonotuseAPIratedSLorSMoils.CAUTIONWedonotrecommendtheuseofsyntheticoilsforbreak-in.Priortoinstallingthecamshaftandliftersitisrecommendedthatthecrankcasebedrainedandfilledwithnewcleanoilaslistedabove.Theoilfiltershouldalsobechangedatthistime.Properflattappetcamshaftbreak-instartswiththecaminstallationandincludesthefollowingsteps1.Beforeinstallingthecamshaftandlifterswashthemthoroughlyincleanmineralspiritstoremovetherustpreventativethatisplacedonthecambeforeshipping.NOTEAsaruleofthumbalwaysthoroughlycleananypartbeforeinstallingitinanengine.Neverassumethatthepartsarecleanedbeforepackaging.Duringshippingpackagingmaterialcanrubintothecomponentsurfaceandmustberemoved2.DONOTpump-uphydraulicliftersbeforeuse.Thiscancausethelifterstoholdavalveopenduringenginecrankingwhichwillcauselowcompression.Thelowcompressionwilldelayenginestart-upandisverydetrimentaltopropercamshaftbreak-in.3.Withthesuppliedmolypastelubecoatthebottomofthelifterscamlobesanddistributorgear.UseCraneCamsassemblylubePart99008-1orequivalentonallothersurfacesandcomponents.4.Setyourvalvelashorlifterpreload.Trytominimizethenumberoftimesthatyourotatetheengineasthiscandisplacethemolypastefromthelobesandlifters.techLetusstraightenyourlogisticsout.IfyouneedalogisticspartnerwhocansteeryourshippingbusinessintherightdirectionyouneedFreightquote.com.Weofferavastarrayofproductsandservicesspecificallydesignedtogiveyouanoptimalshippingexperience.Dontgetlostinamazeoflogistics.VisitFreightquote.comorcallusat800.323.5441today. engineprofessionalWWW.AERA.ORGEP875.Ifpossibleprimetheoilingsystem.Whenprimingrotatetheengineatleastonecompleterevolutiontoassureoilgetstoallvalvetraincomponents.Valvecoversshouldbeofftoassurethatallrockersareoiling.6.Presettheignitiontimingtostarttheengineatafastidle.Itisimportantthatthestaticignitiontimingisascloseaspossibleandiftheenginehasacarburetoritshouldbefilledwithfuel.Theengineneedstostartquicklywithoutexcessivecrankingtoinsureimmediatelubricationtothecamlobes.7.Starttheengineandimmediatelybringto3000rpm.Timingshouldbeadjustedascloselyaspossibletoreduceexcessiveheatorloadduringbreak-in.Gettheenginerunningfairlysmoothlyandvarytheenginespeedfrom1500-3000RPMinaslowtomoderateaccelerationdecelerationcycle.Duringthistimebesuretocheckforanyleaksandcheckoutanyunusualnoises.Ifsomethingdoesntsoundrightshuttheengineoffandcheckoutthesourceofthenoise.Uponrestartresumethehighidlespeedcycling.Continuethevaryingbreak-inspeedfor20-30minutes.Thisisnecessarytoprovideproperlifterrotationtoproperlymateeachliftertoitslobe.Shouldtheengineneedtobeshutdownforanyreasonuponre-startitshouldbeimmediatelybroughtbackto3000rpmandthebreak-incontinuedforatotalruntimeof2030minutes.8.Lettheenginecoolandthendrainthecrankcaseandproperlydisposeoftheoilandoilfilter.Refillthecrankcasewithpremiumpetroleum-basedoilnotsyntheticoil.Atthispointtheinitialbreak-iniscomplete.Youcandrivethevehicleinyournormalmanner.Werecommendchangingtheoilandfilterafter500miles.Youmightwanttoputanother5000milesonthecambeforeswitchingtoasyntheticifthatisyourpreference.ADDITIONALINFORMATIONSPRINGPRESSURESForextendedcamshaftlifeflat-tappetcamsshouldnotberunwithmorethantherecommendedopenvalvespringpressure.Racingapplicationswilloftenneedtorunmorespringpressureattheexpenseofreducedcamshaftlife.Inordertobreak-inacamshaftwithhighopenpressurestheinnerspringsshouldberemovedtoreducebreak-inload.Theinnerspringscanthenbereinstalledafterinitialbreak-iniscomplete.LIFTERROTATIONFlattappetcamsbothhydraulicandmechanicalhavethelobesgroundonaslighttaperandthelifterappearstositoffsetfromthelobecenterline.Thiswillinducearotationofthelifteronthelobe.Thisrotationdrawsoiltothematingsurfacebetweenthelifterandthelobe.Ifitispossibletoviewthepushrodsduringbreak-intheyshouldbespinningasanindicationthatthelifterisspinning.Ifyoudontseeapushrodspinningimmediatelystoptheengineandfindthecause.Neveruseoldflattappetliftersonanewcam.Onflattappetcamsthelobesandlifterbottomsmatetogetherandiftheliftersareremovedfromtheenginetheymustgobackonthesamelobefromwhichtheywereremoved.CraneCamsrecommendstheuseofhighqualitytappetstopreventprematurecamorlifterwear.Cranetappetsareofthehighestquality.BigBlockChevroletshaveanoil-primingidiosyncrasy.WhenprimingaBigBlockChevywithadrillmotorandprimingtoolitisoftennecessarytoprimeforasmuchas20minuteswhilerotatingtheenginetogetoiltoalloftheliftersandrockers.Itisadvisabletoprimetheseengineswiththevalvecoversremovedsoyoucanchecktoseeoilcomingoutofalloftherockerarmsbeforefiringtheengine.ThislaststepisadvisableonallenginesbutparticularlyonBigBlockChevrolets.TB2624AlternativeCamBearingFor1997-2013Cummins15.0LISXorQSXDieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardinganalternativecambearingfor1997-2013Cummins15.0LISXandQSXdieselengines.Manyinstancesofbearingfailureandspunbearingshavebeenreportedonthisengine.TherecentlyavailableoversizeoutsidediameterODbearingscanbeusedforsalvageoperationswhencamboresarewornordistorted.ThisengineutilizesaDOHCdesigncylinderheadwithonecamshaftrunningthevalvesandonethefuelinjectors.Thecamshaftbearingsaredifferentbetweenthetwocams.Theoversizebearingscanbeusedatanysingleormultiplelocations.Dependingonspecificlocationtherearetwodifferentbearingsusedfortheinjectorcamshaftwhilethevalvecamshaftusessevenofthesamepartnumber.Theamountoftheoversizeis.030.75MMor.0401.00MMwhichallowsforsignificantsalvageuse.Usethechartbelowtodeterminethebearingsrequiredtousetoreplaceorforsalvageofthecambores.HousingBorePartNo.QtyBearingSizeSmallCam2.7555-2.756540264237STD2.7955-2.7965MCB71047.040OversizeLargeCam3.5425-3.543536805804STD36805813STD3.5725-3.57353680580OS4.030Oversize3680581OS3.030Oversize3.5825-3.5835MCB71054.040OversizeMCB71063.040OversizeAERAisunawareofanyothersourcesthanIPDandInterstateMcBeefortheseoversizecambearings.TB2625RevisedMainBearingBoltTorquefor1985-2000Cummins14.0LN14DieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationonarevisedmainbearingbolttorqueprocedureon1985-2000Cummins14.0LN14dieselengines.ThisservicepartstopicintroducesachangeinthemaincapcapscrewsandtorquevaluesforN14engines.Thischangewasputintoeffecttoreducemaincapblockfretting.Dependingonenginebuilddatetherearetwodifferentprocedures.TheyareasfollowsProcedure1forenginesbuiltuptoJanuary51998andpriortoengineserialnumber11875596usethisprocedurethatincludesuseofthegrade8capscrewPartNo.208346. NOTEThispreviouslypublishedprocedureremainsunchanged.NOTEUsethetorqueprocedureintheN14ShopManualBulletin3810487totightentheN14maincapsinenginesthatweremadepriortoJanuary51998itisTightenthemainbearingcapscrewstothefollowingtorquevalues1.InSequenceTightento122Nm90ft-lb.2.InSequenceTightento230Nm170ft-lb.3.InSequenceTightento346Nm255ft-lb.4.Loosenallboltscompletely.5.Repeatsteps1through3.TB2625Figure1.MainBearingBoltTorqueSequenceProcedure2forenginesbuiltonorafterJanuary51998beginningwithengineserialnumberfirst11875596usethisnewerprocedurethatincludesaNEWgrade12.9capscrewPartNo.3411337.1.InSequenceTightento68Nm50ft-lb.2.InSequenceTightento136Nm100ft-lb.3.InSequenceTightento190Nm140ft-lb.4.Rotatemainbearingcapscrew90degreesinthedirectionoftighteningwhilefollowingtheseinstructionsUsea34-inchdrive1-18-inchsocketthathasbeenetchedwithtwoaxiallines90degreesapart.PlacethesocketoverthemaincapcapscrewheadandmarkthecapwithasilverpencilatthelocationofthesocketaxiallineNo.1.UsinganimpactwrenchrotatethemainbearingcapscrewinthedirectionoftighteninguntilthesocketaxiallineNo.2linesupwiththemarkonthecap90degrees.TB2626CylinderSleeveInstallationOn2007-2013Cummins4.56.7LDieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingcylindersleeveinstallationfor2007-2013Cummins4.56.7Ldieselengines.Thissalvagerepairmayoccurafteronecylinderborebecomesexcessivelyscoredfromabnormalcombustionactivityandtheunavailabilityofadequateoversizepistons.AERAmachineshopsreportsuccessfulsleeveinstallationontheseenginesoverthepastfiveyearseventhoughCumminsdidnotofferaservicesleeveuntilrecently.ThesleevePart4919951isnowavailableforanyoralloftheenginescylinders.Acautionisexpressedtoinstallallsleevesrequiredbeforeboringtofinalsize.Cumminsalsorecommendsablocktorqueplatebeusedforbothsleevingandboringprocesses.PreviouslypublishedinformationbyChryslerCorporationamajoruserofthisenginedesignoriginallydiscouragedcylindersleeveinstallationbecauseoftheenginesSiamesecylinderdesign.Seeminglynowusingablockmountedtorqueplateshouldhelpalleviatethoseconcerns.AftermarketsleevesuppliersreportrecentadditionstotheirproductlinesofferingarepairsleevesuchasCSL1180Xwhichwillaccommodatebothastandardand.020.500MMbore.TB2627RevisedCrankshaftConnectingRodfor2004-2013Cummins8.3LC-SeriesDieselEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingarevisedcrankshaftandconnectingrodfor2004-2013Cummins8.3LC-Seriesdieselengines.ThistechnicalservicebulletinintroducesacommoncrankshaftandconnectingrodtobeusedinallC8.3ISCQSC8.3ISCengineswithCM850andQSC8.3engineswithCM850.ThenewcrankshaftwithincreasedfilletradiiandthenewconnectingrodwithincreasedfilletclearancebeganproductionintheISCengineswithCM850.ThecrankshaftandconnectingrodhasnowbeenmadecommonacrossallC8.3ISCQSC8.3ISCengineswithCM850andQSC8.3engineswithCM850.ThenewconnectingrodPart3971394isbackwardscompatibleandcanbeusedonallC8.3ISCQSC8.3ISCengineswithCM850andQSC8.3engineswithCM850.TheoldconnectingrodPart3901383cannotbeusedwiththenewcrankshaftPart3965006duetotheincreasedfilletradii.TheintroductionofthenewcrankshaftandconnectingrodonallC8.3ISCQSC8.3ISCwithCM850andQSC8.3withCM850enginesbeganwithatConsolidatedDieselCorporationCDCengineserialnumberESN46430358on22-September-2004.ComponentPreviousPartNumberCurrentPartNumberConnectingRod39013833971394Crankshaft39137203965006TB2628ExcessiveOilConsumptionon2010-2011Subaru2.5LSOHCEJ253EnginesTheAERATechnicalCommitteesuppliesthefollowinginformationonexcessiveoilconsumptionon2011Subaru2.5LSOHCEJ253engines.Itappearssomeenginesweredeliveredwithdefectivevalveguideparentboresallowingoiltopassalongsidethevalveguideoutsidediameter.88OCT-DEC2013engineprofessionaltech engineprofessionalWWW.AERA.ORGEP89APPLICABILITY2011LegacyOutback2.5LfortheNorthAmericamarket2011Impreza2.5LfortheNorthAmericamarket2010Forester2.5LfortheNorthAmericamarketVehicleownersmaycomplainofwhitesmokeoutofthetailpipeandexcessiveoilusageontheabovementionedvehicles.Checkvehicleenginenumbersbelowtoseeifthisconditionmaybefoundontheabovelistedvehicles.Thisoilconsumptionmaybetheresultofthe1andor4intakevalveguideinsertionholeimproperlymachinedpermittingoiltoenterthecombustionchamber.Toremedythisconditionthecylinderheadswillneedtobereplacedorrepaired.Pleasereadthisbulletininitsentiretybeforeproceeding.CylinderHeadSerialRange249000-257150EngineSerialRangeLegacyandOutback706500-717084ImprezaandForester241224-3044297NOTEThereisapossibilitythatsomeofthecylinderheadswereinstalledonenginesthatwereinstalledinvehicleswithinthefollowingranges.AffectedVINRangesModelVINRangeLegacyB221209-B222585OutbackB344226-B345935ImprezaSedanB504580-B507148Impreza5DoorB807033-B809007ForesterA914118-A918058REPAIRPROCEDUREINFORMATION1Firstverifyifthevehicleisequippedwithanenginethatmayhavetheaffectedheads.Refertothecylinderheadserialnumberlocationillustrationbelow.Thelevelofcarbondepositsonsparkplugs1andor4willbemuchhigherthan3and2iftheconditionexists.Replacementheadassemblieswillonlybeprovidedforthatcondition.2Removesparkplugsandcomparecylinders.3Removefrontexhaustpipeandinspectexhaustportsforexcessivecarbondeposits.4ForcylinderheadreplacementandtransferofcamandrockerassembliesrefertotheapplicableSubaruservicemanual.CYLINDERHEADRANGEANDSERIALLOCATIONNOTEEachofthecylinderheadkitsincludesacompletecylinderheadassemblyminusthecamsadrockerassemblieswhichwillneedtobetransferredfromtheoldcylinderheadtothenew.NOTEDependinguponwhichcylinderheadkitisorderedeachkitwillincludeonecylinderheadassemblyandthepartslistedbelow.TB2628Figure1Defectivevalveguideparentboresallowoiltopassalongsidethevalveguideoutsidediameter.IMPORTANTThereareonlyverylimitedquantitiesofthesecylinderheadrepairkitsremainingininventory.Oncetheyvebeendepletedorderthenecessaryrepairpartsthroughnormalpartschannels. 90OCT-DEC2013engineprofessionaltechAdditionalPartsRequiredInadditiontothecylinderheadkitthefollowingpartsmustbeorderedfortherepairdependingonvehicleapplication.Pleaserefertothepartscatalogfortheapplicablepartnumbers.Headgasket1orboth2Intakegaskets2CylinderheadsealingwasherSparkplugforcylinder14orbothDependingontheamountofdamagetotheparentvalveguideboreanoversizevalveguiderepairmaybeconsidered.AtthistimeAERAisunawareofaparticularguidenumbertoaccommodatesucharepair.TB2629ExcessiveOilConsumptionon2010-2013GM2.4LEcotechEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingexcessiveoilconsumptionon2010-2013GM2.4LEcotechengines.Toresolveoilconsumptiononsome2010-2013LaCrosseEquinoxTerrainand2011-2013Regalmodelsequippedwiththe2.4LengineRPOsLAFLEAdoesnotrequireenginereplacement.Ifexcessiveoilconsumptionisconfirmedafteranoilconsumptiontestnewpistonsandpistonringsshouldbeinstalled.Thetopcompressionringinthenewkithasamorerobustcoatingonitthatisdesignednottowearasquicklyastheoriginalcoating.Testsindicatethatitwearsabout4-5timeslongerthantheoriginalcoating.Ifthetopcompressionringiswornitwillallowcombustionpressurepastitwhichcausestheoilcontrolringstobelesseffectiveandresultsinexcessiveoilconsumption.On2010-2011vehiclesbuiltbeforeMarch2011thereisastrongcorrelationbetweenleakinghighpressurefuelpumpsdilutingtheoilandcausingtheringwear.Duetothischeckthefuelpumpbalancechainbalancechaintensionerandtimingchainfortheproperpartnumbers.Theupdatedfuelpumphasanenhancedseal.Iftheseupdatedpartshavenotbeeninstalledduringapreviousrepairtheyshouldbereplacedwhenthepistonsandringsarereplaced.Usefieldaction12313ifthebalancechainandorfuelpumpisreplaced.Thepistonsmustbereplacedbecauseastheringsweardownitstartstowidenthepistonringgroves.Theworngrooveswillnotretainthenewringscorrectly.ThezebrastrippingontheboresurfaceFig.1isnotanindicationofacylinderboreabnormalitybutratheratransferoftheringmaterialasitwasworndown.Theboresarestilluniformandthenewringswillseal.Thevalidationofthenewringpackwasdoneonusedblocksthathadzebrastriping.Itsnotnecessarytodoanysurfacetreatmenttothezebrastripedboreswheninstallingthenewpistonsandringsotherthanobviouscleaning.NOTEUseonlyplasticscraperstocleanthesealingsurfacesoftheengine.Abrasivecleaningwheelsandpadswillleavematerialintheengine.Anindicationthatcleaningwheelspadswereusedwillbeanenginethatrunsfor20004000milesafterthepistonringreplacementandthendevelopsanoilpressureconditionorrodmainbearingknockforawornbearings.Whileperformingthisrepairon2010and2011vehiclesbuiltbeforeMarchof2011itshouldbeverifiedthatthehighpressurefuelpumpPN12641847balancechainPN12645237balancechaintensionerPN12649233andtimingchainkitPN12635447havebeeninstalledinthisengineinapreviousrepair.Inquireaboutthesecomponentsandcheckthepartslistedinthepriorrepairs.Ifthesepartshavenotbeeninstalledtheyshouldbereplacedatthetimethatthepistonandringsarereplaced.Iftheyhavebeenreplaceddonotreplacethemagain.Enginesin2012and2013vehiclesdonotneedthebalancechainorfuelpumpinspected.ReplacementPartsPartNumberDescription12646457PISTONKITEngine12659419RINGKITPiston12637166GASKETKITCylinderHead12609291SEALCamshaftZebraStripesConditionscratcheslineswithintheboreAreyouanengineguyWeareContactusbecausewehavetheanswersforengines.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372.JointodayGotopage98foramembershipapplication. engineprofessionalWWW.AERA.ORGEP91TB2630OilFilterCautionfor2011-2012Subaru2.5LFB25EnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardinganoilfiltercautionfor2011-2012Subaru2.5LFB25engines.Pleasebeadvisedthattherehasbeenarunningdesignchangeontheengineoilfilterusedforthe2011ForesterswithnaturallyaspiratedFB25engines.Forthenaturallyaspirated2011and2012Forestermodelsonlytheoilfiltersareinterchangeableandeitheronemaybeused.HoweverthiswillnotbethecasewithotherfutureSubarumodelsusingthesefilterpartnumbers.Designrequirementsoffuturemodelswillnecessitatetheuseofaspecificoilfilterpartnumberforeachapplicationgoingforward.Thereforethesepartswillnotsupersedewithinourpartssystemandwewillbecarryinginventoryofbothparts.Aftermarketoilfiltersmaynotoffertheseconsiderations.NEWOLDPartNumber15208AA16015208AA130ApplicableProductionDatesApril2011-June2010thruApril2011EnginecutoffforApril-089276Sizemm68wx85h80wx75hAmoundofrotationaftertheseal1Turn34TurnrubbercontactsthechaincoverAERATechnicalBulletinsalsoavailableonlineAERAmailsEngineProfessionalmagazinequarterly.ThetechnicalbulletinsinEnglishandSpanishcanbefoundontheAERAwebsiteatwww.aera.orgep.Ifyouhaveanyquestionsorifyouneedtechnicalsupportsendane-mailtoinfoaera.orgorcalltoll-free888326-2372.www.aera.orgepFindenginespecsfastandeasyPRO-SISSAENGINESPECIFICATIONSOFTWAREGIVESYOUACCESSTONEARLY7000ENGINESPECIFICATIONSWITHJUSTACLICKOFYOURMOUSEPLUSYOUCANADDYOUROWNCUSTOMENGINEINFORMATIONTOTHEPRO-SISSADATABASE.SOBYTHETIMEITTAKESYOUTOFINDTHEMANUALWITHPRO-SISSAYOUVEALREADYFOUNDYOURSPECSANDAREBACKTOWORK...THATSAMONEY-MAKINGDIFFERENCEWWW.AERA.ORGPRO-SISTOLL-FREE888-326-2372815-526-7600500COVENTRYLANESTE180CRYSTALLAKEIL60014twitter.comaeraepfacebook.comaeraep NewDura-Bond2014CatalogDura-BondBearingCompanyintroducesitsnew2014enginepartscatalog.Thiscataloghasmanynewappli-cationscompletewithphotoscompetitorsinterchangeconversionreferencechartsandapowdermetalvalveseattechnicalinformationandinstallationinstructionmanual.Formoreinformationpleasecall775883-8998orvisitwww.dura-bondbearing.com.92OCT-DEC2013engineprofessionalIproductnewsGoodsonIntroducesNewAnalogValveSpringTesterGoodsonToolsSuppliesforEngineBuildershasintro-ducedanewAnalogValveSpringTester.Featuresinclude600lb.capacityin10lb.increments5diameterAshcroftqualityanalogpressuregaugespringplatformhandlesspringsupto2diam-eterx4.5overallheightpressassem-blyheightadjustablein12incrementspressinganviladjustablein1incrementsheightismeasurablein116incrementsadjustableverticalscalerotates180degreesforleftorrightreadingandergonomicallydesignedT-Handlegivesfirmcontrol.Formoreinformationcall800533-8010or507452-1830orvisitwww.goodson.com.RHSProActionAssembledSmallBlockFordCylinderHeadsTheSmallBlockWindsorand5.0-literenginesaretwoofthemostpopularenginedesignsinthehistoryofFordtechnol-ogy.AndnowRHShasdevelopedanimpres-siveheadseriestoprovideSmallBlockFordengineswithincreasedairflowandhorsepower-noportingormodi-ficationsareneeded.RHSProActionSmallBlockFordCylinderHeadsincludemorestandardfeaturesthananyFordheadintheindustryincludingpremiumbronzevalveguidesforextendedvalvesealinganddurability.Withahostofrunnerandchambersizestomeetvariousperformanceneedstheseheadsaretrulytheracewinnerschoice.Formoreinformationcall877776-4323orvisitwww.racingheadservice.com.JESELIntroducesNewChryslerHemiBeltDriveDistributorDriveComboThelatestgeneration5.7L6.1L6.4Lsmall-blockChryslerHemiisbuildingasolidreputationindragracingcirclesandhorse-powershootoutsliketheEngineMastersChallenge.Jeselsnewbolt-onHemibeltdriveprovidesracersandenginebuilderswithasolutiontointegratecamshaftanddistributordrivesintoanextremelyaccuratesinglecompactunit.ItincorporatesJeselstraditionalbeltdrivefeaturessuchasabilletaluminumcoverGatesHTDhightorquebelthigh-vacuumTefloncamandcranksealsandcoatedpulleysforwearresistance.Formoreinforma-tionpleasecontactJESELat732901-1800orwww.jesel.com. QuickFuelTechnologyIntroducesNew2-4-PortBilletFuelPressureRegulatorsQuickFuelTechnologyQFThasreleasedtwonewfuelpressureregulatorsthatfeaturehard-coatanodizedbillethousingsandinternalcomponentsthatarecom-patiblewithgasalcoholandE85fuels.Additionalpro-tectionagainstcorrosionanddeteriorationincludeFlourocarbondiaphragmsVitonO-ringsstainlesssteelpinsbrassvalveguidesandhard-coatanodizeddiaphragmplates.The2-portmodelisratedforupto650hpandthe4-portversionisintendedforapplica-tionsproducinginexcessof650hp.Formoreinforma-tiononQFTsrace-winningcarburetorsandfuelsystemcomponentspleasecall270793-0900orvisitwww.quickfueltechnology.com.engineprofessionalWWW.AERA.ORGEP93Regis2013-14CatalogCalltodaytorequestyourFREERegisCatalogfilledwithhundredsoftoolsandsuppliesforenginebuildersandrebuilders.Formoreinformationpleasecall800527-7604orvisitwww.regismanufacturing.com.productnewsIFederal-MogulsAll-NewElectronicCatalogFederal-Mogulswww.FMe-cat.comelectroniccataloghasbeenrelaunchedwithanall-newinterfaceandavarietyofinnovativefeaturesthatmakeitfasterandeasiertouseincludingexpandedcontentforsmart-phonesandtabletcomputers.ThesitecoversallFederal-Mogulproductsineachofsixapplicationcate-goriespassengercarandlighttruckcommercialagri-culturalandindustrialper-formancemarinepower-sportandsmallengine.AmongthetechnicaltoolsavailablethroughthenewsitearerepairtipsandbulletinstorquepartandenginespecificationslookupscalculatorsthatenabletheusertodetermineenginedisplacementhorsepowerandtorqueandcompressionratiobasedontheirpartschoicesandaTrainingCenterfeaturingdozensoffreetechnicalvideosrepresentingeachofthecompanysbrandsandproductlines.Tolearnmoresimplyvisitwww.FMe-cat.comandwatchthebriefvideotutorialsonthehomepage.4-PatternHydraulicRollerCamsfromCOMPCamsCOMPCams4-PatternCamshaftsarehydraulicrollersdesignedtooptimizevalveeventsbasedonrun-nerlengthandfeaturealargeincreaseinbothareaunderthecurveandstabilityathighRPM.ThesearethemostadvancedhydraulicrollercamsCOMPhaseverintroducedforstreettrackSmallBigBlockChevyandSmallBlockFordengines.Thesecamshaftsincludetechnologybreakthroughsthatcollectivelydeliv-ergainsof5-20horsepowerandstabilityupto7500RPMwithoutcompromisingmaintenanceordurability.MajorTechnologyAdvancements4UniqueLobeDesignsOnEachCamNewStrongerSteelBilletCamCoreAll-NewRaceStreetHybridLobeSeries100CNC-GroundWithAdcoleCertificationFormoreinformationpleasecall800999-0853orvisitwww.compcams.com. 94OCT-DEC2013engineprofessionalONTHESAMEPAGEBYMIKECARUSOHowToBuildForMaxPerformanceFord351ClevelandEnginesByGeorgeReidSubjectInformationexplainingthe351-Cenginesgoodpointsplusthe351-Mand400familiesofengines.Thereisinformationonwhataftermarketpartstouseforincreasedlevelsofperformance.Readaboutoilsystemsandhowtomaketheseenginesdeliveralongusefullife.Thebookhasplentyofcylinderheadintakemanifoldvalvetrainandassemblyinformationincluded.InformationChapters1buildingbasics2theblock3rotatingassembly4lubrication5cylinderheadsection6camshaftsvalvetrains7induction8ignition9exhaust10break-inandtuning11powerbuildsandalistofsourcessoyoucanfindanythingyouseeinthebook.SuggestionUnlessyouhaveyearsofworkingwiththe351-Cenginethisbookwillsaveyoutimeandmoneybybringingyouuptothecurrentdaytechnologyappliedtotheseengines.Takeyourtimeandreadandre-read.Thereisplentyofinformationinthisbookjustwaitingforanyonewhowantstolearn.Printedin2013bySADesign252www.cartechbooks.comISBNID978-1-61325-048-8HighPerformanceFastenersandPlumbingByMikeMavrigianSubjectReadingthechapterheadingsbelowandtheinformationcontainedgivesyouanideaofwhatiscoveredinthisbook.Youwillbesurprisedhowmuchyouwilllearn.YouwillfindoutthatMikehasprovidedsomuchmorematerialrelatedtoeachsubject.Thisisvaluableinformationanditwillteachyouthecorrectwayofworkingwitheachofthedifferentitemscovered.InformationChapters1threadedfasteners2chemicalthreadlockerslubricantsandseals3torquefastenerscorrectly4threadrepair5creatingthreadswithtapsanddies6enginestuds7wheelsfasteners8rodends9rivetsandclecos10clamps11pipethreads12fluidpluming13ANhoseandANhardware14howtomakehardlinetubingassembliesplusalistofsourcessoyoucanfindanythingyouseeinthebook.SuggestionMikeMavrigianhasmadeitconvenientforeveryonebyhavingallthisdifferentinformationincludedinonebook.Hemakesiteasyforanyoneintheshoptofindtheinformationneededtostartorfinishajob.Thisbookcouldbeabigtimesaver.Printedin2010byHPBookswww.penguin.comISBNID978-1-55788-559-3BuildingTheChevyLSEngineByMikeMavrigianSubjectGMLSstyleenginescoveredaretheLS1LS6LS2andLS7LS3LS9models.Thereisalsoa625HPLS2buildupwithacompletepartsandpartssupplierslistsoyoucanbuildoneforyourself.InformationChapters1theLSfamilyofengines2OEMAftermarketLSblocks3OEMAftermarketcylinderheads4borestrokecombinations5cylinderblockprep6crankshaftrodspistonsbearings7enginebalancing8cylinderheadreconditioningrebuilding9engineassembly10camshafts11EFIsystems.LStorquevaluesGMLSpartnumbersprojectLS2partnumbersplusalistofsourcessoyoucanfindanythingyouseeinthebook.SuggestionMikeMavrigianworkinghismagicwithwordsandtakingthebestpicturesofanyonedeliversanotherexcellentjob.Everyoneshouldownacopyofthisbook.EvenifyoudontdoGMyoucanstilllearnsometricks.Printedin2010byHPBookswww.penguin.comISBNID978-1-55788-559-3AERATechSpecialistMikeCarusohasover50yearsofenginerebuildingandhigh-performanceexperience.AnASE-certifiedMasterMachinistMikecametoAERAfromFEL-PROshigh-performanceRDandtechlinewhereheworkedfor11years.MikewouldliketohearfromAERAmembersintheshopsWhattypeofbookinformationwouldhelpyoudoyourjobbetterandorfasterContacthimviaemailmikeaera.orgorcall815-526-7609. PEGGYGREENCall507-457-0755or866-457-8975peggybigrivergmail.comRepresentinganumberofqualitylinestobringyouthebestvalueforallyourshopsupplyneeds.HOMEOFREGISNORTH35517SkyviewDriveWinonaMN55987HOMEOFREGISNORTHCallengineprofessionalWWW.AERA.ORGEP95IPDHeavyDutyEngineRepairParts800299-4248310602-5399salesipdparts.comwww.ipdparts.comMORETHAN75YEARSSTRONGOriginalqualityreplacementenginepartsforclassicBritishvehicleswww.gosnays.co.ukemailsalesgosnays.co.ukTel4401708748320MARKETPLACEYOURADHEREBusinessCardAd3.5x21xRate2004xRate170FormoreinformationseetheMARKETPLACEAdFormonthefollowingpage.ToadvertiseinMARKETPLACEyoumustbeanAERAmember.Seepage97inthisissuetolearnmoreaboutallthebenefitsofanAERAmembership.Formoreinformationgoonlinetowww.aera.orgorcalltoll-free888-326-2372. 96OCT-DEC2013engineprofessionalMARKETPLACEAttentionAERAMembersAdvertiseyourbusinesscardwithEngineProfessionalmagazineandcapitalizeonthefastestgrowinghardcoreenginepublicationintheaftermarketMarketplaceBusinessCardAdOrderFormNameCompanyAERAIDAddressCityStateZIPPhoneFaxE-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.ORGEP97AERAEngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600fax888-329-2372815-526-7601www.aera.orgemailinfoaera.orgtwitter.comaeraepfacebook.comaeraep 98OCT-DEC2013engineprofessionalAPPLICATIONFORU.S.ACTIVEMEMBERSHIPELIGIBLITYREQUIREMENTSApplicantshouldbeaproprietorshippartnershiporcorporationthathasadequateautomotiveshopequipmentandperformseitherenginemachiningenginemodificationengineassemblyorengineinstallationandwhoseprincipalbusinessservestheautomotivetrucktractormarinedieselandotherclassesofretailindustrialandcommercialaccountsandnotprimarilysellusedpartswhichtermdoesnotincluderemanufacturedpartsintheirmainplaceofbusiness.1.Pleaseremitasheetofcompanyletterheadcompanybusinesscardorcompanyinvoicewithapplication.2.Ifyourbusinessmeetstheabovecriteriapleasecompletetheformbelow.Pleaseprintlegiblyortype.COMPANYINFORMATIONCompanyNameDatebusinessstartedContactPersononenameonlyBusinessAddressCityStateZipPhoneFaxEmailWebsiteHowmanypersonnelinyourshopincludepart-timepersonnelPleasechecktheappropriatecategoriesforlistingintheAERAMembershipDirectoryIACCustompassengercarandlighttruckenginerebuildingIADDieselheavy-dutyandindustrialenginerebuildingIAFForeignmotorcycleandsmallenginerebuildingIAHHigh-performanceenginerebuildingIALDrivelinerebuildingIAMMarineenginerebuildingIAPProductionenginerebuilding100permonthIAYCylinderheadrebuildingspecialistIAIEngineinstallationIOtherPAYMENTMUSTACCOMPANYAPPLICATIONIENTIREAMOUNTENCLOSEDMONTHLYPAYMENTPLANSAVAILABLEContactAERAfordetails.CREDITCARDIVISAIMasterCardIAmericanExpressIDiscoverICHECKPleasemakecheckpayabletoAERACardholderNamepleaseprintCardNumberExpirationSecurityCodeCardholderSignatureIattestthatmyfirmmeetstheaboverequirementsandgiveAERApermissiontoverifytheinformation.SignatureTitleRECOMMENDEDFORMEMBERSHIPBYSendapplicationandpaymenttoAERA500CoventryLaneSuite180CrystalLakeIL60014.Orfaxyourcompletedapplicationwithpaymentto888-329-2372toll-freeor815-526-7601.Youmayalsoapplyonlineatwww.aera.org.IfyouarealreadyanAERAmemberpleasegivethisapplicationtoafriend.CallAERAtoll-free888-326-2372ordirect815-526-7600withanyquestions.AERAMEMBERSHIPDUESSelecttheappropriatepersonnelcategoryforyourshop.NumberofshoppersonnelI1-3........................................37030.83monthI4-8........................................45337.75monthI9-24......................................58548.75monthI25ormore............................69157.58month ADVERTISERINDEXAccessIndustries...........................................................5ACL..............................................................................27AERA..............................................606384-8597-98AETC...........................................................................41BrockSupply...............................................................61CIFIC............................................................................11Cloyes............................................................................9CTPCostexTractorParts...................insidebackcoverCWTIndustries...............................................................1Dart..............................................................................55DNJEngineComponents...................outsidebackcoverDrivenRacingOil..........................................................79Durabond.....................................................................10Elgin.............................................................................37EndurancePowerProducts.........................................75EnginePartsGroupInc.EPGI....................................18Enginequest.................................................................15ESCOIndustries...........................................................19FederalMogulFel-Pro..........................................20-21Fluidampr.....................................................................52FowlerSalesService.................................................76FreightQuote................................................................86Goodson......................................................................38Hastings................................................insidefrontcoverJamison.......................................................................49JoeBakerEquipmentSales.........................................62L.A.Sleeve....................................................................86MAHLEClevite...............................................................7MartinWells.................................................................77Maxiforce.....................................................................71Melling..........................................................................43PEP.......................................................................2630QualCast......................................................................48QualityPowerProducts................................................57Regis............................................................................31Rottler........................................................................100S.B.International............................................................3SafetyAutoParts.........................................................51SEMAShow.................................................................25Sunnen........................................................................53TomsAgri-Diesel..........................................................73Topline....................................................................82-83Tracto-PartsCenter......................................................59UltrasonicLLC............................................................45UnitedEngineandMachineUEM...............................39Vibratech......................................................................81ADVERTISINGOPPORTUNITIESGetyouradvertisingmessagedirectlyintotheshopswhoarebuild-ingrebuildingandinstallingenginesprofessionallybyadvertisinginEngineProfessionalmagazine.Engineprofessionalsworldwidewillreceivethisfull-colorpublicationfourtimesperyear.Eachissuewillbefilledwithhighlytechnicalandapplication-drivenarticlesfromourstaffofwritersaswellasfeaturecontributionsfromindustryprofessionals.Formoreinformationdownloadamediakitfromourwebsiteatwww.aera.orgeporcontactouradsalesstaff.AdSalesHalFowler404-427-0171halfowlersales.comJimRickoff507-457-8975jimrickoffgmail.comForadpaymentcirculationmembershipinformationCallAERAtoll-free888-326-2372or815-526-7600.engineprofessionalWWW.AERA.ORGEP99MonthlyPaymentOptionsAERAnowoffersmonthlyinstallmentpaymentoptionsforyourannualAERAmembershipandPRO-SISsupportfees.CreditcardDirectwithdrawlfrombankaccountTherewillbenoadditionalfeesifyouelecttopaymonthly.ExampleAsmall1-3manshoppaysanannualrateof370or30.83permonthfor12monthscreditcardordirectwithdrawlfrombankaccount.FormoreinformationcallKarenat888-326-2372ore-mailkarenaera.org.AERAEngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600fax888-329-2372815-526-7601www.aera.orgemailinfoaera.org 100OCT-DEC2013engineprofessionalANAERAINTERNATIONALQUARTERLYPUBLICATIONTHECUTTINGEDGEThestandardforenginebuildingequipmentsince1923Over20F79ACNCMachiningCentersinstalledworldwidein2012RottereivssomuchfCaliforniBradAndDennisineoringorouptesaretpaceacyanccudvantagefavemathiuction.pnaveeasytoashingtonUSAWInc.BGMachineidBiDrtingsooeeantoeutespi.aeccuequipmenottlerRashingtonUSAInc..mteirsourwicismostimportaiacisiontemacineteirpsequipmentistechnologicallyadvancedandextrwhichismostimportantwhenyouvensaveprmeynextEnglandManagingDirectoridLeD.sizeenginesLHGroupSertaffordshirEnglandLHGroupServicesManagingDirectorrmeiumJohannesburgSouthAfricatomoMetrcrDaryJohannesburgSouthAfricaeEngineeringutomotivbuildingeqbuildingeqandarThestuipmentsince1orenginedfandar923uipmentsince1orengine923emailcontactrottlermfg.com.facebook.comrottlermfgwww.youtube.comrottlermfgwwwottlerrwTHECUTemailcontactrottlermfg.com.facebook.comrottlermfg.youtube.comrottlermfgmfg.comottlerTINGEDGETHECUT1-800-452-0534125387270502entW8029South200thStreet1-800-452-0534