still waiting for manifolds to be tig welded, so not much on that front:puke
done a bit more searching for parts though and came up with these babies--1.45 berg rockers N.O.S ---bergs haven't been making these for a while because of a lack of castings and troubles finding a supplier to do em, so scoring these close to home and new at a good price leaves me stoked again. previous owner had em for 18 years and never used em!
well the dude with the tig sure welded up the mannies, before they can be matched they will have to be made flat again.........
to do that, first i attacked em with a hand file.
then used a felt pen to blue 'em...
...the blue ink woulld help me make sure i kept the seating surface nice and even/flat as they were rubbed back and forth on wet & dry sand paper-using a sheet of glass underneath to provide a flat, level surface
when the blu had dissapeared (checking regularly so not to go overboard), they were all flat again...
i then marked the manifolds again, ready for porting.....as you can see, even tho i had enlarged the inlets on the heads a lot, the manifolds were cast quite big and re-locating the bushes i installed would have only caused interference on the side that was not welded.
hooray- two steps backwards one forward
with the christmas rush done and the kids back to school, it's play time again-hooray
templates
top one was used for original porting, with only one side done to help keep em all even...
i used a material sheet to make tight replicas of the new port job (real tight on the studs) of each head, mainly because i could use a knife to cut it out and as such, not disturb the finished porting job.....
this was then used to make two aluminium gaskets/port replicas, which in turn will be used for each manifold! they will also be used for making custom gaskets in the future when the motor is installed
the aluminium plates were then bolted to the mannies,double checked that they were the right way round!, scribed and then it was back to my old favourite-the bloody die grinder!
well thats one more job done. add another 9 hours for the set up and matching of the manifolds.
next job is to pay a visit to Stan Pobjoy and have the heads opened up for the 90.5mm barrels, then i will be able to unshroud the valves and lay back the combustion chamber.
a broken windscreen and consequent rust, paint, window and rubber replacement has caused delays again, but i have been doing something- no - really.. i have...
the heads are back from stans, so i was able to make some of the gaskets from clinkerite sheeting.
the alloy port replicas were bolted to the manifolds with the roughed out gaskets between and taken close to the mark with the flapper wheel (its very tough sheeting).
i then bolted up the manifolds to the heads (again with gaskets between) and used the scourer pad with a long shaft to "port" the gaskets reaching down thru the manifolds!
it took a couple of hours, but now i have three sets of custom gaskets that sit absoloutely flush in the inlet ports.
How long did it take to drop off and collect the heads from Stan's?
BTW
Did you know that someone stole your car earlier in the week?
I was rounding the round-about near the 'Heads primary skool and passed your car but didn't recognise the driver.
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa
How long did it take to drop off and collect the heads from Stan's?
BTW
Did you know that someone stole your car earlier in the week?
I was rounding the round-about near the 'Heads primary skool and passed your car but didn't recognise the driver.
well Stan is an hour away, so it only took 4 1/2 hours to drop them off AND pick them up. before i left i reminded him to only cut to 90.5 size and that i only wanted 1 plug per cylinder.having said that the twin plug job is not all that expensive is it.nice bloke
thats Larry the worlds best panel beater in my car. its not a problem to lend him the bug, he can't drive it any harder than me and if he hits something, its like getting a free Volksrestore panel job:thumb.i hope you noticed the resprayed front end!
dumone wrote:thats Larry the worlds best panel beater in my car. its not a problem to lend him the bug, he can't drive it any harder than me and if he hits something, its like getting a free Volksrestore panel job:thumb.i hope you noticed the resprayed front end!example........
[ Edited on 23-3-06 by dumone ]
Nah mate, didn't see much of the front as he was hooked up sideways around the round-about :P
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa
o.k so with bigger valves installed, the shape and size of the combustion chambers are no longer adequate.
they are also due for enlarging to help flow, both intake and exhaust, with the bigger pistons and cylinders to be used. the gases now have to travel from further away from the center of the head -over a standard set up.
the areas adjacent to the valves will need "unshrouding", so the added flow abilities of the bigger valves can be utilized. they will be taken out towards the edge of the cylinder.
the plug side and opposing sides of the chambers need "laying back" to help direct the gases towards the valves, and encourage good combustion of the fuel by the better efficiency of the spark plugs new exposure....
...anyways, more fuel, better ignition, and quick exiting adds up to more horsepower, so i'm there......!
1st a template will be needed. an icecream lid and a set of berg racing heads, cut for 90.5 with similar size valves and already modified combustion chambers will also come in handy....
GENTLY, GENTLY!, tap around the edges of the chamber with a hammer and you get a pattern ready for cutting out......
cut it out and check how you went. i marked some lines at each of the head stud holes and spark plug hole to help line it up.....
then i blued up my own heads and had a look. the blue areas just under the template is where the material needs to come out of.
i also marked around the seats and plug area,BUT each time a bit of this comes of, i must duely slap myself up the back of the head. or maybe take a break.
looks good, how about down through the cylinder?
looks good through there,the edges of the cylinder sit right on top of the template. but now i'm thinking i might use my actual cylinders to mark the the curves and the template to do the edges along the spark plug and opposing sides.
bugger, now i have scared myself out of it! looks like its time to practice on the worlds most modified, yet usless head.....
that feels better! not a real good representation of how they should look, this one has standard valve seats, so the chambers are "laying" way back! anyways, we will see the real deal tomorrow.
well, spent the best part of the day making some bits and peices to help protect the heads whilst hacking 'em out.:P...
....cut the top off a 92mm piston- to protect the sides of the opened heads.rather a 90.5, but none around. discovered this was very, very helpfull in lineing up the template in each chamber. it provided a reference point from each head stud hole, as well as the spark plug, that could be passed from one chamber to the next.
handy!......
also ground down some valves on both the top and bottoms so they could sit right down on the seat, and leave room to port around the edge......
... made an oversize template to protect the face of the chamber. stan "the man" pobjoy had the forsight to shave these flush so i could get an accurate cc measure down the track. in all likely hood the heads will need fly-cutting again, in case they dont, i will try to protect them.
they are all marked out and ready to go......
....ended up too late to make a start with me ol' mate the die grinder. reshaping the chambers is the sort of thing that needs to be tackled one after the other to help keep it all fresh in the mind,and as such,as even as can be.....
no sense rushing, at least i'm ready for first thing next week
CYA
Craig Torrens6 times Australian, 7 times State Hillclimb Class Champion
certainly doing a great job...........what compression ratio will you be running ? Are you going to cc the heads after you change the combustion chambers, I guess this would then mean a trip back to Stan to machine the heads again ?
will have to cc them after the chambers are done, then build the bottom end, and see if the size of the chambers will allow a correct deck height, if not i'm thinking flycutting a bit at a time- of one chamber-, till its within cc tollerences, to allow right deck height..........will be the go...... then the others will be fly cut to match..........
or am i overthinking?
8.5 compression with ??(memory) deck height is the aim.
have to set another couple of days aside to visit stan..maybe i will use the courier.........i know all about the adventures of him, you, and numerous others now i have been there already😉.....lurved the airplane engine, full propellor on a stand-CRAZY!
[ Edited on 28-3-06 by dumone ]
Craig Torrens6 times Australian, 7 times State Hillclimb Class Champion
mystery!....yes the seats on the case are recessed, but there were barrel spacers included with the kit.
the kit was N.O.S from 1991- needless to say 6.5/1 is no longer neccesary
yeah but the deck height will reign supreme and chambers sized to fit
all i can do at this stage is mimic someone else's head chambers and do some calculating/adjusting down the track to keep the deck height sensible.
which comes first-the chicken or the egg.....
i wouldn't like to tackle modifying the chambers to a pre-determined cc size. i will keep them as even as possible, flycut one till right for deck, machine others...then adjust cc's of all for even compression🤪
the "unshrouding" on the corners runs at an angle directly to the outer edge of the valve seats. this was done for a couple of reasons-
this was the easiest way to keep the chambers even, less material out would mean fewer variations
if i busted past the scribe line, a fly cut would run down the angle and bring the edge of the new chambers back within the cylinder walls.
it's looking like they will need a flycut to reduce the cc's, so less material out would help here
the next step is to make a small flat next to the valve seats, with a nice radiused edge running up the chamber wall towards the cylinder. (we're talking around the 2mm size)- thats next weeks challenge, then they're really finished:thumb
worked on the chambers a bit more today. had to finish off the turns adjacent to the outer edge of the valve seat. gave 'em a proper polish to a mirror finish.
you can sort of see a nice curve from the chamber wall to the seats now.(crappy pics - i miss daylight savings!)
they are sure different to what i started with...
it's all getting a little repetative here, i know. to fix that, the heads are getting outsourced to have the 3 angled valve job and flow tests, which will mean i'm onto the first mock up very soon :thumb
Did you happen to have the heads flowed before you did your work?
Id be interested in the results before and after.
Its worthwhile knowing this if you decide to do further work.
L8tr
E
Im not a complete idiot, quite a few parts are missing....
Ahhh I see.
For whatever reason, i thought you had bought some trick new heads with the big valves blah!
The I looked closer at the "before" pix where the recesses for the new oversize seats has been cut and thought just perhaps they would not look like that ordinarily.....my bad!
Still, some comparisons would be cool!
lookin good anyway dude.
Its sad that the rules dont allow us to unshroud the valves in Formula Vee! Ahh well!
L8tr
E
Im not a complete idiot, quite a few parts are missing....
getting so close now, just a couple of better shots of the turns i've been raving on about.
as said the wall of the chamber went straight to the edge of the seats before i got in there with a tiny barrel type carbide bit, followed by an emery roll, flapper wheel and then polishing pad.
the smudge above the exhaust seat is just that, a grease smear. this one is finished.
yeah Pete, i'd like that, but the missus wouldn't.
the parts for the engine are now spilling out from under our bed. the best place for it all is in the back of my car.
anyways, the chambers are now finished-hooray!they have been transformed from this.....
TO THIS!!!...
stoked with em....
and blow me down if they don't all look pretty damn even...with 16 hours put into them i would hope so.
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