The Honing Business Cylinder Bore-Specific Honing Procedures Assure Optimum Performance from a Rebuilt Engine

EP 04-2008 Cover 4/2/08 10:05 AM Page 1

LEARN MORE ABOUT AERA MEMBERSHIP AND HOW IT CAN HELP MAKE YOUR BUSINESS THE BEST IT CAN BE

The Honing Business Cylinder bore-specific honing procedures assure optimum performance from a rebuilt engine

The Perfection of Diesel

an AERA international quarterly publication Engine Cylinder Bores APRIL - JUNE 2008 OEM honing considerations as they relate to the engine remanufacturing industry

New Honing Options for Hypereutectic Aluminum Cylinder Bores Tips on honing this special aluminum alloy cylinder material the right way

PLUS M • Bob Greenwood • Technical Bulletins • AERA E85 Shootout Results EP 04-2008 Cover 4/2/08 10:05 AM Page 2

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EP 04-2008 1-18 4/2/08 9:43 AM Page 1

WE HAVE A SUPERIORITY COMPLEX.

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engine professional APR-JUN 2008 1 EP 04-2008 1-18 4/2/08 9:45 AM Page 2

CONTENTS

4 FROM THE PUBLISHER By John Goodman VOLUME 1, NUMBER 2 An AERA membership can help make your business the best it can be. PUBLISHER AERA - Engine Builders Association 6 INDUSTRY NEWS 500 Coventry Lane, Suite 180 Welcome to new AERA members, calendar of Crystal Lake, IL 60014 events, news and views. 847-541-6550 847-541-5808 fax 8 THE HONING BUSINESS Chairman of the Board By Dave Emanuel Domingo Gonzales Cylinder bore-specific procedures assure optimum Pharr, TX performance from a rebuilt engine. First Vice Chairman Allen Lyon 10 PERFECTION OF DIESEL ENGINE Farmington, NM CYLINDER BORES Second Vice Chairman By David Chobany Mike Eighmy A review of OEM honing considerations as they Rockford, IL relate to the engine remanufacturing industry. Treasurer 8 Rob Munro 20 NEW HONING OPTIONS FOR Kamloops, BC Canada HYPEREUTECTIC ALUMINUM President CYLINDER BORES John Goodman By Tim Meara Know the do’s and don’ts when honing this EDITOR special aluminum alloy cylinder material filled John Goodman [email protected] with very hard glass-like particles. ASSOCIATE EDITOR 30 BUSINESS NEWS Jim Rickoff By Bob Greenwood [email protected] Having bank financing problems? Know the rules of the game! TECHNICAL EDITORS Dave Hagen 34 IN TOUCH 20 [email protected] By Jim Rickoff Steve Fox Results of the AERA E85 Power Shootout held [email protected] on the show floor of the Hotrod Show in Indy. Mike Caruso [email protected] 49 TECH BULLETINS Gary Lewis [email protected] 54 AERA TECH SERVICES Mike Eighmy By Dave Hagen, Mike Caruso and Steve Fox [email protected] AERA members have free access to ASE-certified Master Machinists with COMPTROLLER Ellen Mechlin the expertise and connections to answer [email protected] your tough technical questions. 34 GRAPHIC DESIGN 60 PRODUCT NEWS Maria Beyerstedt [email protected]

ADVERTISING SALES Jim Rickoff [email protected] Hal Fowler [email protected]

PRODUCTION Jan Juhl [email protected]

54 CIRCULATION Karen Tendering [email protected]

INTERNATIONAL LIAISON Yolanda Carranza [email protected]

CHIEF TECHNOLOGY ARCHITECT Richard Rooks [email protected]

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FROM THE PUBLISHER BY JOHN GOODMAN, AERA PRESIDENT

An AERA membership can help make your business the best it can be

We at AERA headquarters hope you listed in PRO-SIS are OEM derived. with all sorts of obscure issues. Even enjoyed the first edition of our Many replacement parts you use are rare parts have been sourced by quarterly magazine, Engine aftermarket. In some cases, simply posting needs. AERA tech Professional (EP). Central to its aftermarket parts improve design department monitors these threads publication is our promise to keep and functionality by solving OEM regularly and has helped shops solve content shop relevant and component flaws left unchecked due difficult problems. It should be application oriented. The AERA tech to engine obsolescence. Material and mentioned that most threads dealing department fields machining and machining improvements of with more specific shop issues assembly questions daily and now aftermarket parts may deviate from require AERA membership to has a vehicle to share some of the OEM clearances and tolerance. access. But AERA members who answers with the entire industry. Having aftermarket part information post on the forum are a gregarious Taking this a step further, we feel a in concert with manufacturer lot and are often found posting on responsibility to the entire engine specifications go a long way to help the General Information threads as building/rebuilding community to help engine shops machine for and install well. in any way that makes sense. To that parts correctly. Inclusion of parts and end, EP will share a sample of part specifications is an ongoing The AERA website is one of the most current knowledge on specific process and will develop within PRO- active in our industry rivaling daily subjects helping all engine shops SIS as more manufacturers see value visit count of SEMA and other much build better engines. Those of you in having their parts and specs larger association websites. I would who are AERA members already available to shops using PRO-SIS on encourage the entire industry to know how important AERA a daily basis. Look for more “how-to” bookmark the AERA forum. It is the membership is to the success of content in current versions of PRO- beginning of the best engine tech your business. Having an ability to SIS and a gradual introduction to network resource going.I make unlimited daily tech calls for PRO-SIS XP, a new, full-featured any engine technical information you database written in robust MS require is a vital service found no Sequel Server Express. You won’t other place but through AERA believe what new information XP will membership. Those shops who are bring to you or how deep this not AERA members, we challenge information availability goes. Stay you to look closely at what is offered. tuned. EP magazine will help you realize what can be gained through AERA Lastly, I would like to invite AERA membership. members and the engine building industry at large to visit our website Prior to becoming president of EP will continue having a regular forum www.aera.org/fm Presently, AERA, John Goodman was director column on PRO-SIS, AERA’s engine only a handful of regulars frequent of the Advanced Technology Center specification database (which is an the technical threads of this forum. (ATC) for Micromatic-Textron. The ATC focused on manufacturing AERA member-only benefit). Over the Their plea is for more shop techs to honing solutions and studies for past several years, PRO-SIS has weigh in with comments, ideas and OEM engine manufacturers. Testing developed many new features that solutions. This small network of of traditional and unique honing abrasive systems, coolants, fixtures, may be overlooked by users. Most professionals has helped each other tools and software were primary engine specifications and tolerances and even some non-engine shops responsibilities of the ATC lab.

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industry news

AERA welcomes • Servicio Automotriz, Harry’s in the cleaning room new members Schaumburg, IL and became proficient in every calendar • Springfield Engine Supply, aspect of the shop. From ACTIVE Springfield, MO head and block work to APRIL 14-17 • Arcan Machine, • Tobler’s Engines, crankshaft grinding and SAE WORLD Toronto, ON CANADA Morrow, OH engine balancing, there isn’t CONGRESS Arrow Engine & Machine, an operation in a shop Kenny • • TNS Custom Engines, Detroit, MI Chattanooga, TN Maiden, NC can’t perform. He truly is a www.sae.org/congress • BGS. Inc, Universalmotor Cia. Ltda, deserving recipient of this • MAY 8, 13, 15 Lexington, KY Sucre, Quito, ECUADOR award. ASE SPRING TESTING Carquest Auto Parts, • www.ase.com Winchester, VA ASSOCIATE Elgin Industries named Industria de Maquinas • CARQUEST West Valley, • exclusive aftermarket Chinelatto Ltda, JUNE 19-21 West Valley, UT AUTOMECHANIKA Limeira, SP BRAZIL source of Eaton diesel • Cash & Carry Engine, CANADA Exchange, Mesa, AZ MEMBERGETTERS engine valves Toronto, Ontario, Canada www.automechanika Central Interior Rebuilders, Dave Monyhan, Elgin Industries and Eaton • • canada.ca Kamloops, BC CANADA Goodson Tools & Supplies, Corporation have announced a new partnership in the • Ding’s Custom Cycle, Winona, MN marketing and distribution of JULY 9-11 Dubois, WY • Fuad Abu Hadhood PAACE premium-quality, OE- • Engine Technology, The National Machine AUTOMECHANIKA Lansing, MI Shop, Jeddah, Saudi technology Eaton diesel valves Mexico City, Mexico for the replacement parts • Foaz Industrial Equipment, Arabia www.paace Jeddah, SAUDI ARABIA market. Effective immediately, automechanika.com Elgin is the exclusive source of • Heads Up Machine & AERA Member Speed, Fort McLeod, the complete offering of AUG. 29-31 RUJAC SHOW AB CANADA Kenny Burns wins Eaton-manufactured the 2007 MAHLE replacement valves for all Guadalajara, Mexico • Internotor, www.rujac.com.mx Chernivtsi, UKRAINE Clevite Machinist of diesel engine applications. One of the largest and IRT Grupo, the Year Award SEPT. 16-21 • most respected engine parts Quito, ECUADOR AUTOMECHANIKA AERA Member Kenny Burns manufacturers for the Jeffs Carquest & Machine, Frankfurt, Germany • wins the 2007 MAHLE Clevite automotive and commercial Crescent City, CA Machinist of the Year Award. engine markets, Elgin will offer Melton Sales & Service, NOV. 4-6 • Kenny Burns, AERA Eaton diesel technologies AAPEX SHOW Burlington Township, NJ member and machine shop through its extensive network Sands Expo Center, • Mercer Machine & manager for Harry’s Machine of distributors across North Las Vegas, NV Performance, Works, Inc., of Dodge City, America and in Central and www.aapexshow.com Lawrence, KS Kansas is the 18th recipient of South America. the Mahle Clevite Machinist of • Precision Automotive, For more information NOV. 4-7 the Year Award. SEMA SHOW Texhoma, OK regarding Eaton replacement Kenny is one of the great Las Vegas Convention Center, • Precision Machine, diesel valves and the rest of machinists that our industry Las Vegas, NV Waco, TX the Elgin aftermarket offering, has to offer. He was mentored www.semashow.com • R & B Automotive Machine, please contact your engine Riverton, WY by a great past recipient of this award the late Russell parts supplier, call 1-800-323- DEC. 11-18 Rectificadora Internacional, • Rogers. Russell won the 6764, send an e-mail to PRI SHOW Rio Coca, Quito, Orlando, FL award in 1992 before passing [email protected], or go ECUADOR www.performanceracing.com away suddenly in April of 2004 online: www.elginind.com. • Rectificadora Navarrete, at the young age of 42. I Tumbaco, Quito, always knew Kenny would AERA to attend ECUADOR someday receive this honor Refacciones y engine association • because Russell would often meeting in London Rectificaciones Oscar, tell me how talented Kenny Puerto Vallarta, MEXICO was and it was just a matter In April, AERA President • S & K Automotive, of time. John Goodman will meet in Mineral Wells, TX Kenny is an ASE certified London with engine building • S & R Machine, “Master Machinist” with associations from several Moncks Corner, SC over 20 years of industry different countries to discuss • Schumann’s Sales & experience (all of them at common issues and their Service, Blue Grass, IA Harry’s). He started working at solutions.

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The Honing Business Cylinder bore-specific procedures assure optimum performance from a rebuilt engine

BY DAVE EMANUEL

Back in the day, when an Since engines don’t run Although cylinder honing engine needed to be honed— for long, if at all, without a isn’t as simple a process as it you honed it. If you were a cylinder head in place, has been in the past, it is not do-it-yourselfer, you broke “torque plate honing” makes particularly complicated. The out your trusty handheld a lot of sense, and has descriptions of OEM honing drill, clamped the chuck proven itself by providing processes contained in the down on a ball-type hone superior piston ring seal, oil accompanying articles may and proceeded to “break the control and durability. For a seem to imply otherwise, but the complexity of those glaze” or “refinish the time, “torque plate honing” processes have more to do cylinder bores”. If you were was as good as it got, but a true “high-tech” machinist, with mass production than With six technically oriented then automakers had to go automotive books and over 1,500 you had the block on an with machining. Many and make things complicated automotive machine shops magazine articles to his credit, engine stand during the Dave Emanuel is regarded as one of by developing new cylinder are currently machining honing operation, which was bore and piston ring the nation’s most respected aluminum and diesel engine automotive journalists. During the required to knock off the materials. Concurrently, rough edges left by a boring cylinder bores to OEM past 20 years, his work has appeared more stringent emissions and quality specifications. As in popular publications such as Motor bar. But as likely as not, the fuel economy requirements, they have demonstrated, all Trend, Road & Track, Hot Rod, engine hadn’t seen a boring combined with changes in it takes are the proper tools, Corvette Fever and Popular Science bar since it left factory—it the composition of fuels and abrasives and coolants (all of to name only a few of the more than was being rebuilt while still twenty magazines. oils made an already which are currently in the car (or truck). Of Dave’s technical expertise and complicated situation even available). course, if you were extensive hands-on experience, more complex. Conventional wisdom combined with his personal attempting to refinish the As you’ll see by reading would suggest that it’s not relationships with many of the bores with a high degree of nation’s top high performance engine through the accompanying reasonable to produce OEM precision, you used an quality cylinder bores builders and Detroit engineers, allows adjustable hone equipped articles, a variety of cylinder him to provide readers with unique bore-specific honing without the use of OEM insights into the high performance with actual honing stones. machining equipment. As procedures are required to and racing aspects of engines and Then, someone had to go usual, conventional wisdom assure optimum performance drivelines. Dave is also involved with and ruin everything by is wrong. An automotive private enterprise and offers insight from a rebuilt engine. spreading the word that machine shop can in fact on yet another possible power cylinder shape is distorted by As with most machining deliver higher precision and source. the stress created when head operations, individual more consistent quality opinions will vary as to the Go online for more information: bolts or studs are torqued to because each engine is www.randomtechnology.com the proper specification. “best” procedure for a handled on an individual That revelation led to the specific application, but there basis. While there certainly is creation of torque plates, can be no argument that a learning curve with some thereby allowing bores to be cylinder honing is no longer of the newer processes, it’s honed while under the same just a simple finishing touch not particularly steep, and stress that exists when a that’s required to be ensure any competent machinist can cylinder head is installed. that the rings seat properly. get up to speed quickly.I

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Perfection of diesel engine cylinder bores

A review of OEM honing considerations as they relate to the engine remanufacturing industry

BY DAVID CHOBANY PHOTOS PROVIDED BY BATES TECHNOLOGIES, INC.

This article will describe OE Diesel Block thousands of bores daily for reciprocation rates, tool typical plateau honing Honing Operation multiple years of service life. reversal points (length of processes used by large The engine blocks are fixtured stroke), feed and expansion original equipment (OE) Machine Tool and have the ability to be rates, as well as the in-process manufacturers of diesel rotated and transferred within air gaging of the bores within High volume machining of engines. Included will be the the machine to allow for each the hone process. This is diesel engine blocks is machine methodologies as bore to be rough and plateau needed to assure that proper typically accomplished using well as the hone tooling, honed in the various stations and consistent pressures are various milling, drilling, abrasives, gauging and and passed on to a post gage applied to the stones during reaming and boring coolant considerations and station to complete the the hone process. This along their effect on bore size, operations as part of a cylinder bore honing process. with precise stroke length and surface finish, and cylindricity. dedicated transfer style The machine tool reversal point accuracy is built The transfer of this OE machining line. The final referenced throughout this in to assure that the stock technology to the engine critical operation performed article will be a typical removal rates and bore remanufacturing shops will be on these blocks would be the Micromatic machine designed geometry shape is met. Diesel discussed with the emphasis honing of the cylinder bores. to hone the cylinder bores of block line tooling is designed on selecting the proper tool This operation is done on a an eight cylinder diesel engine. to run in the rotational range design, abrasive selection and stand alone and dedicated Bore sizes in this example will of 140 to 200 surface feet per metrology to assure a best machine utilizing multiple be approximately 4.00 inches minute. Care is taken early on bore condition to their spindles to accomplish the (101.6mm) in diameter and in the hone process customer. required stock removal as well 5.000 inches (127mm) deep. development to determine the as the finish bore size and appropriate feeds and speeds surface finish structuring Speeds and Feeds required to achieve the desired required from the OE. These Integral to the machine tool is stock removal rates and cycle machines are constructed with a sophisticated programmable times. heavy duty bases and logic controller (PLC) with the precision slides to ability to precisely maintain, Crosshatch accommodate the accuracy control, and adjust the A critical feature of the required to precision hone various spindle speeds, tool cylinder bore that is directly

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FEATURE

Fig. 1: Micromatic OE hone machine shown with Bates tooling designed to hone cylinder bores of engine blocks.

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PERFECTION OF DIESEL ENGINE CYLINDER BORES BY DAVID CHOBANY

2 Fig. 2: Integral to the machine tool is a sophisticated programmable logic controller (PLC) with the ability to precisely maintain, control, and adjust the various spindle speeds, tool reciprocation rates, tool reversal points (length of stroke), feed and expansion rates, as well as the in-process air gaging of the bores within the hone process.

Fig. 3: Hone crosshatch angle definition.

Fig. 4: Single stroke Microsize (fixed diameter tool with mounted diamond abrasives) technique designed to improve upon the bored geometry and to provide a repeatable surface finish to the stroke honing stations.

affected by changes to applications requiring one Cycle times for this style jointly depending upon which feeds/speeds is the crosshatch spindle to hone multiple bores machine to hone and transfer method produces the best angle as designated by the of a six or eight cylinder a V8 diesel block through results within any given OE. A defined crosshatch block. these operations is less than process application. In the pattern is a required cylinder 50 seconds. eight cylinder example noted bore feature that the stroke First Pass Operation above, the honing processes hone is responsible for Single stroke Microsize (fixed Hone Process would utilize both forms of achieving. The main purpose diameter tool with mounted Production tools are designed expansion as follows: of this angle is to retain (hold) diamond abrasives) technique to expand the abrasive stones the appropriate amount of oil designed to improve upon the outward to bore contact and Rough (Base) Hone Process within a given crevice valley bored geometry and to then to hone the wall with a which has been generated in provide a repeatable surface • Stepper feed system. preset amount of work load the rough hone operation. finish to the stroke honing or pressure which is • Tool enters the bore, Most OE’s will specify the stations. determined by the type of stepper feed system expands angles to intersect at or near the abrasives to bore 45° to each other or at 22° to Second and Third Pass material being honed along with the desired end results. contact as the spindle 32° to the horizontal deck Operation rotation begins. surface. Stroke honing stations The machine tool abrasive consisting of four spindles to expansion system is • Tool continues to expand to Machine Cycle Times Rough hone (second pass) and accomplished through either a meet an initial size offset, The number of hone spindles four spindles to Plateau Hone stepper motor or hydraulic/air followed by a second feed on these machines is usually (third pass). Each spindle is torque limit feed systems. velocity programmed to dependant upon cycle time tooled to hone two of the Both are proven methods and meet the final preset size for requirements with many eight bores in each block. can be used independently or this operation.

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Fig. 5: Stoke honing stations consisting of Rough and Plateau passes.

achieving critical surface finish and structuring requirements. The conventional approach to honing in the past produced a finish honed bore surface consisting of a high peak to valley ratio (referred to as Peak Honing) which relied on the engine piston ring package to shear the top of the peaks during a break in period in order to produce a smoother sliding and bearing surface. The advancing technology of honing cylinder bores has progressed to Plateau Honing which produces a finish honed surface that is relatively smooth and overlays oil • The tool stokes to a set inherent in the block bore contact and spindle retention valleys and lower position (lower design. rotation begins. crosshatch patterns which reversal point) then reverses • An in-tool air gage system • A predetermined stroke and moves to a set upper have been produced by the monitors the bore size at all count is initiated depth of cut from the previous position (upper reversal times and signals the point). These set points are rough hone operation. motion control and • Abrasives remain expanded precisely controlled and Hone tools used at the OE expansion unit when the at a predetermined load monitored by the machines level are designed and built to final preset bore size is until the stroke count is use of finite linear position function as high precision, detected. done. indicators. close tolerance and durable • A stroke run-out cycle • End of cycle command is tools. The tool itself consists • The reversal set points are occurs followed up by initiated which collapses the of a hone head (referred to as designed to stroke the hone collapsing the abrasives and abrasives and retracts tool. a pineapple) which is fitted stones so that 25 to 33% of tool withdrawal from the with wear guides, a feed cone the stone length exits the part. bore on both ends. The Tooling and Abrasives assembly and a universal joint exact percentage of stone Hone tooling design along designed to allow a slight exiting the bore is based on Plateau Hone Process with abrasive selection is float of the tool to the piece pre-production hone considered to be one of the part. These tools are designed • Pressure feed system. process studies to determine most critical elements needed to allow for a maximum best bore geometry that can • Hone tool enters the bore to assure a hone process that number of stones in the hone be achieved with respect to simultaneously as the is highly capable of providing head (per specific bore size) to any stoke or wall support torque limit feed pressure predictable and repeatable assure best bore geometry limitations that may be expands the abrasives to bore geometry while also possible.®

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PERFECTION OF DIESEL ENGINE CYLINDER BORES BY DAVID CHOBANY

6 Fig. 6: Plateau Hone Tooling produces the final surface plateau level of 70 to 90% of a total surface area as defined by the ratio of the bearing surface length to a surface length measured at a depth below the 5% plateau level — as measured from the highest surface point as reflected in the Abbott Curve (BAC) calculation and corresponding chart. (Photo used with permission from the Society of Manufacturing Engineers.)

Fig. 7: Post air gage heads monitor pre set attributes and alerts are activated if a deviation occurs outside of the size tolerance range so that a correction can be made to the process.

Rough (Base) Hone Tooling • Inherent in-process air gaging allows for automatic • 12 stone tool body. size control of the bores as • Responsible for the they are being machined in majority of the bore stock the block. removal (~ .0025” / .0635mm). Plateau Hone Tooling • Designed to correct and • 12 stone tool body with improve upon incoming 2.000” (50.8mm) long x bore geometry conditions .093” (2.3622mm) wide such as out of round, taper, abrasives. barrel, hourglass, etc. • Designed specifically for • The abrasive stone removal of the peak surface dimensions along with the left from the rough machine tool accuracy on operation and to produce stroke reversal allow for the required finish bore maximum cutting action size, surface finish and throughout the full length structuring. of the bore, even with • Minimal stock removal restricted through bore rates (~ .0002” / conditions. .00508mm). • A predetermined stroke block or liner material and is • Produces the final surface • Proprietary abrasive grit count and feed pressure compatible with the makeup plateau level of 70 to 90% and grade selection sintered allow abrasives to hone the of the metal bond honing of a total surface area as in a medium/hard metal wall to meet final finish size stones. The proper selection of defined by the ratio of the bond matrix to allow for a along with surface finish honing fluids used in bearing surface length to a free cutting action and a and structuring conjunction with a high surface length measured at definable depth of cut to requirements. quality metal bond abrasive produce the base Rk, Rvk a depth below the 5% selection has led to higher and Vo specifications (oil plateau level — as part quality improvements in retention valley depth and measured from the highest Coolants and both size control and width requirements). A surface point as reflected in Filtration geometry. Coolant supplier relative crevice valley depth the Abbott Curve (BAC) such as Castrol, Nalco, and width is created to calculation and Most modern block line hone Houghton and others have assure the appropriate corresponding chart. machines use water based experience in the honing amount of oil is retained in • Abrasive grit (D35) and honing coolants with a environment and should be any one area of the bore at grade selection in a special lubrication package designed consulted along with your all times. blended metal bond matrix. to work within a specific abrasive supplier to determine

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the appropriate choice of the Air Gauging 8 correct coolant or lubricant to and Metrology use in your application. A critical feature of any Rough hone tooling is honing application is the provided with inherent air proper selection of a filtration gage capability to allow for methodology. Large block line the in-process sizing of the hones typically use special bores as they are honed. filter media integral to a large Additionally a post gage dedicated gravity filtration or station performs a 100% vacuum filter systems. In check of each bore by addition many of these media gathering and recording filter applications are assisted measurements at three depth by magnetic separators, levels of the bore in both an X canisters, or tubular backwash and Y axis. The data collected reflects actual bore size, filters. A hone filtration roundness and taper for each system should be capable to bore. Tolerance limits for filter the chips (swarf) these attributes are pre-set and Fig. 8: A PAT Incometer gage recording is made of the bore axially every 10º and over 5 depth levels within the cylinder bore. This generated by the finest grit alerts are activated if a abrasive stone used in the information is compiled and produces a symmetric (wire cage) view deviation outside of the of the bore shape as honed. This aids the OE in determining if any process which is reflected in tolerance range occurs so that there are inherent piece part issues such as lack of wall support, final surface finish of the OE. a correction to the process can casting imperfections, etc. or part processing issues relating to the Typical systems of today will be made. hone that may have an impact on quality and guide them toward corrective actions that may be required to allow compliance. filter out to <10micron size Initial bore geometry and with a 50ppm dirt load target. metrology tolerances are

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PERFECTION OF DIESEL ENGINE CYLINDER BORES BY DAVID CHOBANY

9 Fig. 9: Surface finishes are accurately measured off line with a profileometer.

GLOSSARY

Rk – Core Roughness Depth determined in the pre- as honed. This aids the OE in spindle hone machines that The long term running production stage through a determining if any there are have a style and functionality surface which will developmental and statistical inherent piece part issues such similar to those found at the influence the honing process. This process as lack of wall support, OE engine production performance and life of leads to the most efficient tool casting imperfections, etc. or facilities. Additionally the cylinder. design, abrasive selection and part processing issues relating companies such as Rottler and Rpk – Reduced machine working pressures to to the hone that may have an Sunnen build and market Peak Height assure a capable and reliable impact on quality and guide alternate style hone machines A measurement of the peaks of the surface in production hone process. them toward corrective designed for use in the engine actions that may be required the cylinder bore. These Particular attention is remanufacturing industry. A peaks will be the areas given to the ability of the to allow compliance. thorough evaluation should be of most rapid wear when hone to perfect bore made of all the available hone the engine is first run. geometries passed on from the OE Technology machines as they relate to Rvk previous boring operation and Transfer to the your style of remanufacturing A measurement of the oil also to produce honed bores and to assure they meet the retaining capability of the Remanufacturing valleys of the surface that meet cylindricity demands that will be placed Industry (valley depth) produced requirements in the range of upon them. during the machining <.010mm (.000394”). In the Hone Machine process (plateau honing) production environment, off- The OE hone process as Key review points should Vo line quality checks for bore described in this article uses include: Oil retention volume of a geometry are accomplished multiple spindles controlled surface cross hatch. • Robust construction and using a PAT Incometer Gage by state of the art logic to Metrology designed to show bore manage and control the stability in machine base. Method of measurement. roundness and straightness precision stroke, expansion, • Proper duty motor with Profileometer (cylindricity) down to 2.5 and air gage systems required horsepower to effectively A precision instrument microns. For this example a to rough and plateau hone the hone using diamond used to measure or recording is made of the bore “trace” surface finish. cylinder bores of diesel engine abrasives. axially every 10º and over five blocks. The machines are Abbot Curve depth levels within the constructed using heavy duty • Heavy duty and durable A graphic representation cylinder bore. This bases and precision slides. construction of all working of specifications for a information is compiled and Many manufactures of the components of the stroke surface finish. produces a symmetric (wire OE style of dedicated block and feed systems (gears, cage) view of the bore shape hones offer single or two belts, etc)

16 APR-JUN 2008 engine professional EP 04-2008 1-18 4/2/08 9:44 AM Page 17

• Ability to precisely control available tooling and abrasive geometry and surface finishes to assure their ability to tool stroke speed and stone packages in the marketplace per your specific engine equally and easily expand the feed expansion. to the styles used by the OE cylinder bore specifications. abrasives within the tight • Accuracy and repeatability industry. One should seek a Proper diamond abrasive tolerances of the tool body. durable hone head designed to selection will allow for the to maintain stroke reversal Too tight or too loose a fit use the maximum amount of best available crystal shapes points. may restrict the ability of the stones in a given bore size to and friability as they may stone to effectively accomplish • Ability to accurately gage provide for a longer life and relate to the material being their work. or monitor bore size in- more repeatable bore honed. Additionally critical tool process. geometry. There are readily The hone stones should be wear items such as feed cone • Ability to measure surface available hone heads (with designed with free cutting and expander wear, stone finish accurately with a drive-shafts) whose design abrasives to allow the primary pocket tolerances, and profileometer. originated within the OE hone stock removal that is required cleanliness should be checked environment but have been to meet the cycle time frequently. A PM watch list adapted to fit and function on objectives while assuring that should also be established to Tooling and Abrasives any hone machines found in that the desired bore geometry inspect and monitor any hone Once the proper machine is use today in the and oil retention parameters machine wear issues such a selected it is most critical that remanufacturing industry. are established. Proper belt or gear wear, alignment, you begin to look early on at Stone suppliers that have a selection of bond matrix, etc. determining and choosing the known history in the OE crystal size and characteristic Coolant selection should most efficient hone tooling industry should be sought out of the finish or plateau stones be made based on the type of and abrasive systems based on to provide guidance and should allow for a defined material being honed. It is a design to maximize direction in the proper surface that meets many of advisable that you coordinate efficiencies in your honing selection of the honing the current plateau the coolant selection with process. abrasive that will provide specifications of today. your hone stone abrasive It is recommended that a consistent and repeatable Preventative maintenance supplier to assure comparison be made of the stock removal rates bore of the hone tooling is critical compatibility with the

Joe Baker Equipment Sales 888-440-9429 One call gets it all! Berco machines, Berco repair parts!

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engine professional APR-JUN 2008 17 EP 04-2008 1-18 4/2/08 9:44 AM Page 18

PERFECTION OF DIESEL ENGINE CYLINDER BORES BY DAVID CHOBANY

composition of the abrasive/ CNC machine tools including Recap and abrasive system best suits bond matrix. machining centers, lathes, and the individual type of Filtration should be sized vertical chuckers. The hone Technology exists today to remanufacturing process that to remove the smallest chip tools are built to fit into the allow the remanufacture of a business may be involved (swarf) that is removed in you various style of machine tool engine blocks to utilize hone with.I hone operation. holders such as CAT, HSK, tooling and abrasive systems etc., and utilize the coolant that are representative of Honing on CNC pressure (thru spindle) to those used in the OE industry. Machining Centers expand and control the Factors such as bore geometry An opportunity now exists for cutting pressure required of and finish requirements may those in the remanufacturing the abrasives. be impacted by the inability of industry to potentially utilize The addition of the in-tool some lighter duty hones to existing or new CNC meet the accuracies provided air gage system allows for equipment to complete the by the OE production hone continuous monitoring of part hone process. A flexible machine tools. Additionally diameter during the honing honing system has been the reduction of wall support operation. This also allows developed by a leading OE created by re-boring the David Chobany is a Senior Member of the Society of Manufacturing Engineers tooling and abrasive supplier for the potential “to close the cylinder bores prior to honing loop” with prior operations (SME). Over the past years he has that brings the same design of will influence the final shape presented technical honing and tooling, abrasive and in- such as finish boring. This and size characteristics as training seminars to international process air gaging that is used would allow for a more compared to the OE. SME audiences, corporate process within many of the OE engine compliant size control to the It is recommended that a engineers and independent manufacturers of today. hone which in turn would comparison be made of all the metalworking businesses. He has over provide more consistent and 15 years of technical expertise in the This patented tooling currently available technology metalworking industry and is currently package is designed to repeatable surface structuring to discern which combination employed as Vice President of Bates function within many styles of that the industry requires. of hone machine and tooling Technologies.

Farris EP 2008 12/23/07 10:16 AM Page 1

Specializing in Used/Rebuilt Engine Rebuilding Equipment FARRIS EQUIPMENT SALES is one of the largest dealers of used/rebuilt engine rebuilding equipment in the United States. We have been blessed to ship our equipment to nearly every state in the USA and to over 40 other countries around the world. Contact SAM FARRIS or DON STONE We invite you to visit our website for photos and pricing: 3001 Interstate 27, Lubbock, TX 79404 www.farrisequipment.com E-mail: [email protected] The photos will give you an idea of the quality of our machines and also show you our facilities and people. Buy the Right piece, at the Right price, Warranty provided with every rebuilt machine we sell. FROM THE RIGHT PEOPLE!! Call 800-882-1808 for the FARRIST DEAL around!

18 APR-JUN 2008 engine professional EP 04-2008 19-32 4/2/08 9:48 AM Page 19

Race Series Tri-Metal Bearings provide optimum performance, endurance and durability essential for higher RPM Engines.

Improved overlay and reduced Design and Metallurgy Features: Increased crush for thickness for better seating increased fatigue strength

No ﬂash plating for Medium Rod bearings have better seating and eccentricity hardened steel backing that Large chamfer to accom- 3/4 groove provides optimum oil thermal transfer Tight wall helps maintain crush under modate larger crankshaft supply to rods and maximum load tolerance high load and temperature ﬁllets carrying capacity (0.00015) + - conditions

Bearings That Boast a Distinguished Pedigree and Track Record. Race Series performance bearings are products of more than a half-century of ACL research, design, metallurgy and manufacturing experience. They are used extensively by racers and engine builders in the U.S. and around the world. ACL’s experience includes designing and manufacturing bearings, gaskets and other car and truck components for GM, Ford and Toyota. Race Series bearings are available for numerous performance engines (including import sports engines) and in many diﬀerent sizes. For additional information, brochures and availability sources, contact ACL at 800-847-5521.

Record-Setting Proof of Performance. Race Series engine bearings were in the engine of Phil Veldheer’s ‘69 Camaro when he raced to a new national record (120 MPH, 10.83 seconds) in the IHRA class F/CM. Parsons and Meyers Race Engines (Dayton, OH) built the engine and Phil specified Race Series bearings. Phil owns five different drag racers and they all have Race Series bearings in their engines.

ACL Distribution, Inc. www.aclus.com

engine professional APR-JUN 2008 19 EP 04-2008 19-32 4/2/08 9:48 AM Page 20

New Honing Options for Hypereutectic Aluminum Cylinder Bores

Mercury Marine, BMW, Porsche, Mercedes Benz and other engine manufacturers use a special aluminum alloy cylinder material filled with very hard, glass-like particles. You need to know the do’s and don’ts when honing this alloy.

BY TIM MEARA PHOTOS PROVIDED BY SUNNEN PRODUCTS COMPANY

Background excellent sealing, improved dimensional Consider that a minimum land width between cylinders must still be Alusil®, Lokasil®, Silitec®, DiASil, stability, improved heat dissipation, maintained, even with an iron liner. So Mercosil, ALBOND® — it sounds like a reduced weight, better recyclability, lower the liner-equipped engine is still foreign language, but these are all trade manufacturing cost and higher durability unnecessarily large, still has differential names or trademarks for what is – compared to the traditional aluminum expansion and reduced heat dissipation generically known as hypereutectic block with cast-iron cylinder liners. issues, still needs a heavier and larger aluminum, a new/old material for cylinder Aluminum cylinder evolution cooling system, etc. bore wear surfaces. Hypereutectic A major advance came in 1971 when aluminum is both new and old. Its Since gasoline burned and forced a piston GM used Reynolds A390 aluminum alloy down a cylinder for the first time, cousins, hypoeutectic and eutectic in the linerless Vega block. A390 is a aluminum, have been used for pistons and aluminum has been the metal of choice hypereutectic alloy saturated with silicon, connecting rods for a number of years. when light weight was the most critical such that silicon particles are dispersed Hypereutectic aluminum saw one of its requirement for an internal combustion throughout the alloy similar to chocolate earliest applications as the wear surface in engine. This is as true today as it was in chips in cookies. “Saturated” is the key an unlined cylinder in some Porsche 1902 when the Wright Brothers were word. Small amounts of silicon will engines in the 1960’s. The 1971 Chevrolet unable to purchase a suitable commercial dissolve in aluminum and become Vega was the first true production engine for their experimental airplane and inseparable, but above the saturation automotive engine with a liner-less built their own, casting the aluminum point (the “eutectic” point), silicon will hypereutectic aluminum cylinder bore as block. precipitate out in crystal form. Typically, the wear surface. Despite the car’s Automotive OEMs seized upon this begins to take place at around a 12% reputation, the cylinder concept was aluminum for the same reason and found silicon concentration, and the ahead of its time. manufacturing advantages, too: lower hypereutectic cylinder surfaces in use No matter what trade name is used for cost casting processes and easier today range from 12% to 20% or more this alloy or how the cylinder was machining. Aluminum automotive engine in silicon concentration. Depending on created, this material is something blocks are pretty much the norm today, the manufacturer, traces of other elements rebuilders should understand because it and the standard solution for a cylinder likely to be in the alloy can include may represent the future of cylinder wear surface has been, and still is, a gray copper, manganese, magnesium, technology and will probably start iron liner. While low-cost, durable, and phosphorus and strontium. showing up more frequently in rebuild easy to manufacture (the key decision After traditional machining of the Vega shops. points for OEM’s), engines using the iron- engines, the factory cylinder surface was When properly finished, hypereutectic liner solution have inherent disadvantages produced by chemical etching to create a aluminum presents a surface to the piston in weight, size, thermal conductivity, surface where individual silicon particles rings that’s roughly equivalent to glass. differential thermal expansion and protruded a small distance (perhaps 1.0 The resulting engine has lower friction, recyclability. µm/0.00004" or a little more back then)

20 APR-JUN 2008 engine professional EP 04-2008 19-32 4/2/08 9:48 AM Page 21

Fig. 1 & 2: Two different illustrations portray the working surface of a hypereutectic aluminum cylinder wall. Typical protrusion of the silicon crystals is 0.00002".

above the aluminum cylinder surface. This process in cylinder preparation was, and still is, called the exposure step, whether done by the OEM or rebuilder. The intent is for the piston rings to 2 ride on the silicon particles, not the aluminum cylinder wall. Hypereutectic aluminum cylinders have evolved considerably since the Vega. And while GM led the way with the Vega engine, today Europe 3 and Japan are leading the trend to the linerless aluminum block. OEM’s using the material include Mercedes, Audi, Porsche, BMW, Volvo, VW, Jaguar, Yamaha, and Honda. Manufacturers of power sport vehicles, outboard motors and compressors also use hypereutectic cylinders.

Finishing without chemicals Hypereutectic aluminum crankcases present another obstacle for metal cutting, For the OEM, chemical etching of the which has led to advancements in the way cylinder wall was a non-traditional the alloy is formulated. Silicon particles process and an intermediate step. The quickly destroy cutting tools. Several 4 OEM wants to pour the block and put it solutions have evolved. Tooling has in a transfer line. Chemical etching also improved with PCD and similar materials. became increasingly burdensome as Much effort has also been focused on environmental regulations tightened. improving tooling life by altering Whether it’s in a rebuild shop or an metallurgy to reduce silicon particle size, OEM plant, the key to preparing the while retaining the excellent tribological cylinder surface is to expose a properties of the hypereutectic surface. tribologically optimized wear surface of Based on SEM (scanning electron silicon that withstands the grinding microscope) and VICO-Scan studies of friction of pistons rings on the bore early cylinder surfaces and new products surface. This requires relieving a small on the market today, it appears the silicon amount of aluminum from around the crystals have been reduced in size from silicon particles. The ideal surface should about 10 µm originally to about 1 µm Fig. 3: Ideal honed surface imaged by have flats on the silicon crystals and today, which would materially improved SEM (scanning electron microscope) crystal protrusion of 0.5-1.0 micron the machinability of the material. shows smooth-surface, round-edge above the aluminum, with a minimum of OEMs also devised ways to localize silicon crystals (dark areas) protruding holes (crystals torn from aluminum) and and limit the use of silicon through the above the aluminum base. fractured crystals. The end product can be use of cast-in hypereutectic aluminum Fig. 4: Close-up of crystal from Fig. 3, visualized as lily pads (hard silicon) sitting liners, selective die casting and flame- which shows smooth surface, free of on still water. sprayed coatings. Casting the block fractures or scoring.

engine professional APR-JUN 2008 21 EP 04-2008 19-32 4/2/08 9:48 AM Page 22 AXE EP 2008 12/21/07 9:32 AM Page 1

NEW HONING OPTIONS… BY TIM MEARA 5 It all starts with AXE Equipment From teardown to assembly, or if you want to put that special car up and out of the way until that perfect Sunday drive, look no further than Axe Equipment.

Axe Equipment has a large selection of products to help every engine rebuilder get the job done easily and without any hesitation, each and every day, saving you time and money.

Fig. 5: Surface scans of various hypereutectic cylinder walls producd by different manufacturers and methods. Red patches are silicon and reflect different sizes and distributions of particles that can be found on the market.

• Submersible Pressure Testers • Glass Bead Blasters around special liners complicates the have identical specifications – similar to molding step and production rate. Flame the situation with plateau specifications • Aqueous Spray Washers • High Pressure Aqueous Spray Washers spraying represents an additional process for cast iron. Several block manufacturers • Rinse Tanks • Parts Tumblers step between the mold and the transfer have patented manufacturing • Agitating Hot Tanks • Filtration Systems line. Tech Tip technologies, so rebuilders can expect to The Holy Grail is the ideal combination Boring or rough honing see variety in the alloys and the physical • Waste Water Evaporator • Engine Stands of metallurgy, cutting tools and lowest- hypereutectic aluminum alloy with make-up of the cylinder wall. • Auto Lifts – Residential and cost casting technology that allows various cutting insert materials, There are, however, some generally Race Trailers machining blocks straight from the mold, metal bonded superabrasives or common requirements for honing and some OEMs have found it. even common vitrified bonded hypereutectic aluminum cylinders. First is abrasive tends to crush or the need for excellent geometry. Take it from the staff at the University of Finished cylinder bore fracture an inordinate number of Cylindricity limits of 0.013 mm (0.0005") specifications surface-available silicon crystals are typical. Limits are also placed on the Northwestern Ohio in Lima, OH. From the rebuilder’s side, Sunnen required for load carrying percentage of fractured or displaced developed a GM-certified method for capacity. As such, it would be a silicon crystals at the surface, which must Call or visit our website for violation of material properties to restoring a factory-quality surface for the be free of any torn or folded metal. all your engine rebuilding needs. Vega engine. Damaged bores were honed simply bore and hone Because the silicon crystals are oversize using conventional abrasives, hypereutectic aluminum alloys distributed throughout the metal in a followed by an “exposure” step using a without further surface and homogeneous manner, there will always special lapping paste and felt honing pads. crystal preparation. To that end, be some that are nearly machined through The process could be used with hand-held boring and honing alone will only and will be displaced from the surface. portable tools or honing machines. It serve to damage the cylinder Specifications typically call for about produced excellent results and was ideal surface and create high 80% intact particles. for occasional users. That process has expectation of complete sliding There must be a minimum of sub- since evolved, thanks to metal-bond seal failure. Surface preparation surface fractured material. This is largely diamond abrasives, and today there is a beyond finish honing is a must. a function of the prior boring step and the new honing option for OEMs or amount of material removed by honing. production rebuilders, as well as the low- Lastly, the exposed silicon particles volume rebuilder. It should be noted, too, by over-boring or honing. The honing must protrude above the base aluminum 1040 North Union, P.O.Box 296 that rebuilders have the option to use a process described here will work with this from 0.1 to 1.0µm. The exposure height Council Grove, KS 66846 replacement, press-fit hypereutectic replacement liner, too. is related to the size of the silicon particles aluminum cylinder liner available from In our honing process development in the alloy. Smaller particle size will 800-251-0018 Fax 620-767-5482 Kolbenschmidt, if a cylinder is damaged work, we found that no two mean less exposure height. 0.5µm www.axeequipment.com beyond the point where it can be repaired manufacturers of hypereutectic cylinders exposure height is about average today.®

22 APR-JUN 2008 engine professional EPAXE 04-2008 EP 2008 19-32 12/21/07 4/2/08 9:32 9:48 AM AM Page Page 1 23

It all starts with AXE Equipment From teardown to assembly, or if you want to put that special car up and out of the way until that perfect Sunday drive, look no further than Axe Equipment.

Axe Equipment has a large selection of products to help every engine rebuilder get the job done easily and without any hesitation, each and every day, saving you time and money.

• Submersible Pressure Testers • Glass Bead Blasters • Aqueous Spray Washers • High Pressure Aqueous Spray Washers • Rinse Tanks • Parts Tumblers • Agitating Hot Tanks • Filtration Systems • Waste Water Evaporator • Engine Stands • Auto Lifts – Residential and Race Trailers

Take it from the staff at the University of Northwestern Ohio in Lima, OH.

Call or visit our website for all your engine rebuilding needs.

1040 North Union, P.O.Box 296 Council Grove, KS 66846 800-251-0018 Fax 620-767-5482 www.axeequipment.com

engine professional APR-JUN 2008 23

EP 04-2008 19-32 4/3/08 10:29 AM Page 24

NEW HONING OPTIONS… BY TIM MEARA

(continued from page 22) 6 will typically be rather flat (5-10 degrees) due to the slow stroking speed. Instead of Honing Process a crosshatch, the aluminum cylinder relies Assuming the cylinder was bored using on the area between the silicon crystals to high quality machinery and PCD or equal hold its oil film. Keep in mind that the inserts, the honing process will have two goal in the initial steps is produce a very or three steps: honing, finish honing and accurate bore with a fine (mirror) finish. exposure. From a honing standpoint, MAN-845 Honing Oil is the minimum working with hypereutectic aluminum is requirement and it should be filtered to at somewhat the reverse of working with least 10 µm, preferably 5 µm. No water- cast iron – the end result is measured as a based coolants should be used. In our desired roughness or peak height of the process development work, we found that exposed silicon. high-performance EP oil caused a sludge The essence of the honing process for build-up, which impeded contact with the hypereutectic aluminum is to first produce Fig. 6: A two-stage GHTS honing tool, which can ultra-fine honing grit used in the exposure an ultra-smooth, mirror-finish surface be used for roughing and semi-finishing of step. This is the result of the extreme with the initial honing steps, then finish hypereutectic aluminum. surface area and high energy found in with an exposure step that will actually freshly cut, ultra-fine metal chips. These increase the roughness, as measured with speed, stroke length, etc. should be similar conditions facilitate far more aggressive a profilometer, by relieving softer to those used for ordinary precision work. chemical activity with the oil additives aluminum from around the silicon. The Feed rates are selected to complement the than would be experienced with larger desired end result is an exposed surface of part geometry and abrasive metal chips. rounded-edge primary silicon particles. characteristics. All abrasive should be In most cases, the first two honing steps Tooling for the initial steps should be fully trued to produce 100% surface can be accomplished with conventional or selected according to traditional contact at the diameter corresponding to diamond abrasives. However, because of guidelines for high-precision honing. the finish-honing step. Crosshatch angle is the high value of these engine blocks and Machine settings, such as RPM, stroking less important than with cast iron and the wide variety of OEM materials and manufacturing methods, it is critical for a rebuilder to know the exact recommendation for reconditioning abrasives or consult a honing abrasive supplier. Some cylinder materials may simply require metal-bonded diamond for Takin’ it to all of the steps. Conventional abrasives with bronze guide shoes are unquestionably the most economical the Max option for infrequent work with hypereutectic aluminum. In production or Words any Sport Compact Lover ech OEM work, diamond is preferable for the understands. And nothing maximizes T nol first two honing passes. Sport Compacts better than RTCats. ogy The first honing step may not be required if the block has been bored with Random Technology has always been the leader in true high flow a final finish of <=0.5 Ra µm (19 µin.) If catalytic converters. For good reason. We continually experiment with necessary, as a first honing step we chemistry and substrate technology. So when it comes to horsepower, quality, value or warranty coverage, Random Technology SuperStainless™ catalytic con- recommend removal of 25 µm (.001 in.), verters are the best. Not the cheapest. Just the best. Don’t be confused by copies. The using classic abrasives or a 29 µm important differences are on the inside. Only RTCats feature our exclusive PSX technol- diamond, to produce a finish <=0.5 Ra ogy, which combines advanced chemistry with high quality ceramic or metal matrix µm. cores. The result is a converter that delivers: The second finish-honing step removes Direct Fits Available 2.5 µm (.0001 in.), again using traditional • The highest flow for MAXIMUM power for all popular • Highest efficiency for optimum emissions control abrasive or a 9 µm diamond to produce a • Longest warranty — 50,000 mile performance warranty applications finish <=0.1 Ra µm (3.9 µin.) • Unrivalled fit and finish The final exposure step requires a new Doesn’t your Sport Compact specially developed, elastomer-bond abrasive (XM27), using light honing deserve the best? force. For the exposure step, we 4430 Tuck Road, Loganville, GA 30052 recommend tooling with the greatest abrasive surface contact area. This step is based on time, typically 1 to 11/2 minutes Fax (770) 554-4244,554-4242 www.randomtechnlogy.com for 0.5 µm exposure height. Longer cycle times are not harmful, because the process Federal law prohibits the removal or replacement ofproperly functioning original equipment catalytic converters. Aftermarket catalytic converters are not legal for installation on OBD - II vehicles in California

24 APR-JUN 2008 engine professional EP 04-2008 19-32 4/2/08 9:49 AM Page 25 EP 04-2008 19-32 4/2/08 9:49 AM Page 26

NEW HONING OPTIONS… BY TIM MEARA

7 Fig. 7: This illustration shows the action of the elastomer-bond honing stone used in the relieving step. It conforms to the surface with minimal pressure, allowing the abrasive to remove soft aluminum with little to no effect on the silicon crystals.

Fig. 8: Original Profilometer trace (lower) of 0.157” (4 mm) length on a hypereutectic cylinder wall is shown at greater magnification (upper) to highlight the characteristic silicon-crystal “bumps” of about 0.00002” (0.5 mm) height whichreflect a correctly finished surface.

is somewhat self limiting. It is absolutely 8 critical that honing force or pressure be kept as low as possibly, while still maintaining tool stability. Surfaces shown in the accompanying illustrations were honed with less than 5 lb/in2 pressure. The elastomer based “stone” is purpose-designed to overcome three limitations of rigid abrasive in the silicon exposure process. First, the elastomer serves as a cushion, deforming to allow individual abrasive particles to literally bounce over the silicon particles, while still being rigid enough to cut the surrounding aluminum. Second, the elastomer dampens or limits the overall force applied to the abrasive, making the process very forgiving of variations in pressure from the honing machine feed system. The honing tool diametrical expansion does not have to exactly match the rate at which the cylinder is increasing in diameter from stock removal. Third, the elastomer conforms to any taper or out of roundness in the cylinder, allowing it to remove very small (0.5µm/side) amounts of material, uniformly throughout the cylinder. With rigid instrument – after exposure. This is abrasive, any out of roundness in the bore because the instrument senses the exposed would result in abrasive cutting pressure silicon crystals as surface finish features variations as the honing tool rotated. (peaks). Several traces of the stylus across the surface may be needed before the Critical Point — stylus hits a silicon particle to verify peak Process Verification height. The absence of a peak means you Any shop planning to do work on probably need to make another trace. The hypereutectic cylinders must have a presence of a peak verifies success. If no Profilometer® or similar instrument for peaks are encountered after 8-10 traces, contact surface texture measurement to more time on the exposure step is needed. Tim Meara is the Senior Honing Technician for verify results. The instrument should Hypereutectic aluminum is not yet a Sunnen Products Company in St. Louis, MO. produce a trace, not just a readout, and mainstream material, and the different For more information, please call 314-781-2100 must be capable of Rk, Rpk and Rvk alloys and OEM manufacturing methods or go online: www.sunnen.com. measurements. These engine blocks can ensure there is no “standard” to refer to cost $4000 or more, so honing without a yet. However, the honing techniques Alusil and Lokasil are registered trademarks of KS Aluminium-Technologie AG. Silitec is outlined here were developed for OEM Profilometer to verify results would be a registered trademark of DaimlerChrysler negligent. use and can easily be practiced in AG. ALBOND is a registered trademark of Prior to the exposure step, the rebuilding. Nevertheless, until it becomes Mahle GmbH. Mercosil is a registered Profilometer will should show a very as familiar as cast iron, rebuilders may trademark of Brunswick Corporation. smooth surface (<0.1 µm Ra), which want to proceed with caution, and consult Profilometer is a registered trademark of becomes rougher – according to the a honing abrasive supplier as needed.I Warner & Swasey Company.

26 APR-JUN 2008 engine professional EP 04-2008 19-32 4/2/08 9:49 AM Page 27 EP 04-2008 19-32 4/2/08 9:49 AM Page 28

Even if just one AERA tech bulletin helps $50 prevent an engine comeback, BONUS Join AERA today and your membership receive a $50 gift certificate good toward is well worth its dues. any new purchase of Goodson shop supplies. May not be applied toward existing account balances. RELIABLE RESOURCES QUARTERLY MAGAZINE To maintain an edge in this technically- You will receive ENGINE PROFESSIONAL changing industry, you need resources you can magazine on a quarterly basis. This new depend on.AERA is a specialized network of publication is packed with highly technical, professional engine builders, rebuilders, application-driven articles that will help you production engine remanufacturers and and your business thrive. installers with the expertise and connections to get you the information you need, when you A.E.R.AID need it. In order to better deliver up-to-date information on a timely basis, AERA has ASE-CERTIFIED TECHNICAL SUPPORT established A.E.R.Aid. Once a year, members will receive the A.E.R.AID. In addition to the As an AERA member, you have toll-free access latest PRO-SIS update, the A.E.R.AID CD will to three ASE-certified Master Machinists to help also contain PRO-SIS (both Spanish and English you find answers to tough technical questions. trial versions), a trial version of AERA SMS (AERA Shop Management Solutions software) SPECIALIZED SOFTWARE and AERA manuals. AERA has developed specialized software to help make your work easier... Shop Financial A VOICE IN WASHINGTON Analyzer (SFA) is an easy-to-use program that A voice in Washington, D.C. helps keep will help give you a better grasp of your government representatives informed of our profitability and what you can do to improve it. industry's interests. SFA software is free to all members. PRO-SIS engine specification software helps you find REGIONAL CONFERENCES engine specs with just a click of your mouse. Regional conferences provide technical PRO-SIS software is free to all members; a $299 presentations and unique shop skills instruction annual support fee is required. Shop to all who attend. Along with the outlined Management Solutions (SMS) is a technical programs, leading manufacturers of full-featured, Windows-based software engine building/rebuilding tools, supplies, designed to handle the business needs of services, parts and machinery are invited to engine builders, rebuilders and installers. SMS attend these conferences. Meeting suppliers in software is free to all members; a $299 annual a relaxed atmosphere is a great way to begin lifelong relationships that will help you prosper. support fee is required. Visit www.aera.org for more information. SCHOLARSHIPS AND GRANTS The Engine Builders Educational Foundation MEMBERSHIP DIRECTORY AND (EREF) offers grants and scholarships to help SPECIFICATION MANUALS foster growth in the industry and assist those Every year, AERA updates and publishes its who desire engine building/rebuilding training. Membership Directory. During the odd- For more information, go online: www.eref.org. numbered years, AERA distributes its Cylinder Head and Block, Connecting Rod and SPECIAL DISCOUNTS Crankshaft Specification Manuals. During the AERA has partnered up with a number of even-numbered years, AERA distributes its companies to help AERA members reduce costs Flywheel Specification Manual. The membership by offering special discounts on insurance, directory and all four specification manuals are shipping, utilities, waste removal and a variety free to all members. of other services.

Join online today! www.aera.org

28 APR-JUN 2008 engine professional EP 04-2008 19-32 4/2/08 9:49 AM Page 29

U.S. APPLICATION FOR ACTIVE MEMBERSHIP

ELIGIBLITY REQUIREMENTS: Applicant should be a proprietorship, partnership or corporation that has adequate automotive shop equipment and performs either engine machining, engine modification, engine assembly or engine installation and whose principal business serves the automotive, truck, tractor, marine, diesel and other classes of retail, industrial and commercial accounts and not primarily sell used parts (which term does not include remanufactured parts) in their main place of business.

1. Please remit a sheet of company letterhead, company business card or company invoice with application. 2. If your business meets the above criteria, please complete the form below. (Please print legibly or type.)

COMPANY INFORMATION

Company Name Date business started

Contact Person (one name only)

Business Address

City, State, Zip

Phone Fax

Email Website

How many personnel in your shop? (include part-time personnel)

Please check the appropriate categories for listing in the AERA Membership Directory: AERA MEMBERSHIP DUES I AC – Custom, passenger car and light truck engine rebuilding Select the appropriate personnel category for your shop. I AD – Diesel, heavy-duty and industrial engine rebuilding Number of shop personnel: I AF – Foreign, motorcycle and small engine rebuilding I AH – High-performance engine rebuilding I 1 - 3...... $295 I AL – Drive line rebuilding I 4 - 8...... $360 I AM – Marine engine rebuilding I 9 - 24...... $465 I AP – Production engine rebuilding (100+ per month) I 25 or more ...... $550 I AY – Cylinder head rebuilding specialist I Optional duplicate mailing ...... $150 I AI – Engine installation I Other

PAYMENT MUST ACCOMPANY APPLICATION I Entire amount enclosed $

CREDIT CARD: I VISA I MasterCard I American Express I CHECK (please make checks payable to AERA)

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I attest that my firm meets the above requirements and give AERA permission to verify the information.

Signature Title

Send application and payment to: AERA, 500 Coventry Lane, Suite 180, Crystal Lake, IL 60014. Or — fax your completed application with payment toll-free to 1-888-329-2372. You may also apply online at www.aera.org. If you are already an AERA member, please give this application to a friend.

engine professional APR-JUN 2008 29 EP 04-2008 19-32 4/2/08 9:49 AM Page 30

BUSINESS NEWS BY BOB GREENWOOD

Having bank financing problems? Know the rules of the game!

Engine builders from coast to coast have experienced problems Current liabilities are items payable within the next with financing their business from the traditional banks. They accounting cycle such as your trade payables, principal and truly feel they have been blackballed from obtaining proper and interest on loans, and all taxes (payroll taxes, sales tax, corporate fair financing from their banking institution. Many also have income tax). If you give the bank an annual Financial Statement, been forced to over secure what loans they do have which can the current liabilities will be debts that are due within the next “eat into” the business and personal equity position. This doesn’t year. If you provide the bank with a quarterly Financial have to be the way of doing business with the bank if one Statement, the current liabilities are debts due within the next understands the rules of the game. This article will review the quarter. criteria business owners must be aware of and address in order to A strong current ratio above the generally accepted 2 to 1 have a positive banking experience. (written 2:1), (or current assets twice that of current liabilities) The first rule to clearly understand is that the average bank will contribute a smile to your banker’s face. is not a risk lender. They are equity lenders. Banks want the “sure If this ratio is declining from one year to the next, it could be thing”, that is, loan the money out, get paid as agreed to on time, a very strong sign to the bank the business is heading into and collect interest. When you think of it that is a pretty simple trouble. game plan but in reality the company asking for the money must meet proper financial criteria to maximize its banking 2. Debt to Tangible Net Worth (Retained Earnings) relationship. That is where the business owner has to study and This ratio is an indication of how much a business is borrowing understand the rules. in relation to the amount of equity invested in it. Note the word The following are the basic analysis that the bank will do “tangible”. on your business each time you hand them a Financial Statement. This means if you have a number on your Balance Sheet in Do your own analysis before you hand the Statement to the bank the Assets called “goodwill” – it is traditionally meaningless to a and you will be able to determine what kind of reception you banker’s mind as they know they can’t collect “air” – so they take should expect from them. that number off the Balance Sheet all together which in essence reduces your Retained Earnings number. The bank wants to see 1. Current Ratio genuine (concrete, obvious, solid) net worth (retained earnings). This ratio is sometimes called the ‘working capital’ ratio and it The lower this ratio goes the greater the cushion against losses to tells the banker how easily the shop can meet its current debts. creditors. The banker will take the total of your current assets such as In our industry, a debt to tangible net worth ratio of 2:1 is your cash in the bank (bank balance), the accounts receivable often sited as acceptable. Total debt divided by net worth. That balance, inventory on hand, and short-term notes (i.e. 30 or 90 means total borrowing (total of all debt, not just what you owe day term deposits), and divide it by the current liabilities. the bank) should amount to no more than two times the amount

30 APR-JUN 2008 engine professional EP 04-2008 19-32 4/2/08 9:49 AM Page 31 SUNN-27088 Honing Eng Build.qxd 6/29/07 11:50 AM Page 1

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www.sunnen.com • 800-772-2878 A07-1 EP 04-2008 19-32 4/2/08 9:49 AM Page 32

BUSINESS NEWS BY BOB GREENWOOD

of tangible net worth (retained of our total sales were a the shop’s bottom line. earnings) in the business. charge during the year and the However, when a shop A ratio under two (for rest were cash or credit card. cannot take advantage of example a ratio of 1.53 to 1) Without that information the discount opportunities, we would make the business bank may assume 100% of have found that the shop appear to be in good shape. A the sales were a charge to usually has a problem with ratio of .50 to 1 means you begin with. They would accounts receivable and/or the are in great shape. calculate the age of your total shop gross profit Build credible assets and receivables by taking the percentage, as a trend in the reduce your debt to within accounts receivable balance business. this criteria and I’m sure your and divide it by total sales and Robert (Bob) Greenwood is banker will pay for your next multiply that answer by 365. 6. Tangible Retained President and C.E.O. of lunch out together because Obviously when the ratio Automotive Aftermarket Earnings Growth E-Learning Centre Ltd. he/she wants your business. works out to 45 days, 60 In order for an engine (www.aaec.ca) providing shop days, 90 days or more, then business management resources 3. Gross Profit Percent the shop’s credit policies and building business to grow, it and interactive education collection procedures must be profitable “after tax”. through the internet. He also This is a key measure to a definitely need some attention. These after-tax profits delivers live industry specific bank as it is often used to As well, the ratio must be increase the retained earnings business management courses. determine the health of a compared to previous years to number of the business. Plan Bob writes monthly articles for Canadian Technician Magazine shop’s sales transactions. see if the collection period is your business to have a This percentage indicates in Canada and Aftermarket lengthening. Total accounts minimum retained earnings proper execution of a Business Magazine and Engine receivable balance, in an growth of 20% per year. Professional Magazine in the businesses mark-up and independent engine re- Consider that with healthy United States. He can be pricing policies. building shop, should not retained earnings, reached at 1-800-267-5497 or A falling gross profit exceed 20% of average Management will never be E-mail him [email protected]. percentage from one year to monthly sales. Average unemployed and competent the next could indicate the monthly sales are calculated staff will have job security for shop is not increasing its over the last 6 months. prices in relation to its costs. life. Accounts receivable are a Management should also Gross Profit percent is credibility (shop to banker calculated by taking the total properly plan the payment of relationship) destroyer in our dividends with the gross profit dollars and divide industry. it by the total sales dollars. accountant, since this method of shareholder remuneration An engine building shop 5. Age of Payables should realize a minimum reduces the retained earnings total shop gross profit, This ratio shows the banker number on the Financial including the labor how long the shop is taking to Statement. component without the pay its suppliers. machinist wages factored in, If a shop normally has 30 As you can appreciate, days to pay its bills and if the of 70%. banks can also look at other ratio works out to more than We find the most common criteria when evaluating your that — for example 63 days problem as to why a shop business, but you can be — the banker may assume does not achieve 70% is due assured that when all of the that the shop will have a poor to ineffective labor billing above ratios and guidelines relationship with suppliers. practices. In other words are met, that reception by A poor relationship with labor not being billed out for your bank will be far more suppliers is a risk factor the the time spent and at the positive and constructive bank does not want to buy wrong rate in relation to the compared to the cooler into. machinist wages paid. reception many shop owners To calculate the age of take the total may otherwise experience. 4. Age of Receivables payables payables and divide it by the Slow down and do the math. This ratio needs to be looked total purchases and multiply Focus on building and at in relation to its selling that answer by 365. following these guidelines in terms with the customers. In It is extremely beneficial to your business and I am very our industry we work in 30 pay in full by the 10th of the confident your business day terms, and the banks are month following because financial stress levels will clearly aware of that. suppliers usually offer an come down substantially and Most banks are not given additional discount (2% net your banking relationship will the sales mix of the shop by 10th is the norm). This be better than it has ever the owner; for example 60% discount would go directly to been.I

32 APR-JUN 2008 engine professional EP 04-2008 33-48 4/2/08 9:56 AM Page 33 EP 04-2008 33-48 4/2/08 9:56 AM Page 34

IN TOUCH BY JIM RICKOFF

Results of the AERA E85 Power Shootout Held on the show floor at the Hotrod Trade Show in Indianapolis, Feb. 29 and Mar. 1

The second annual E85 Power Members of the Shootout was held Feb. 29 and Mar. 1, three competing 2008, at the Hotrod and Restoration teams pose with their engines in Trade Show held at the Indiana front of the AERA Convention Center in Indianapolis, E85 Power Shootout Indiana. This year’s shootout fielded dyno test cell at the Hotrod Trade Show three teams — all AERA members — in Indianapolis. competing for the grand prize of $5000. This engine dynamometer competition used a formula that averaged horse power plus torque through a range between 2500-6000 rpms divided by cubic inches to come up with a number that determined a winner. E85 fuel was chosen largely to showcase the potential this high- octane rated renewable fuel has A crowd especially in hotrods. The average Joe of people doesn’t have to worry about racing gathered each day fuel for his hotrod or the storage and to watch availability issues that are often a pain the teams to deal with. Most states have E85 run their engines pumps now and the cost is very through attractive. the dyno. In a nutshell, the engines were normally aspirated, either fuel injected or carbureted, E85 powered and not to exceed eight cylinders. Two strokes, diesel engines and Wankel x stroke x 6.2832. Bore is measured to turbochargers, nitrous oxide, or other configurations were not allowed. three (3) significant digits. Power such devices, were not allowed. The Cubic inch is calculated by bore x bore adders such as superchargers, competitors had to determine the most

34 APR-JUN 2008 engine professional EP 04-2008 33-48 4/2/08 9:56 AM Page 35 EP 04-2008 33-48 4/2/08 9:56 AM Page 36

IN TOUCH BY JIM RICKOFF

First place winners were Joe Degraw and Stacey Redmond, owners of Grawmondbecks Automotive Machine in Mason City, Iowa. Their 408 cubic inch carbureted small block Ford posted peak horsepower at 623 hp and peak torque at 613 ft/lbs.

Second place winner was Dean Yatchyshyn, owner of Cresap Automotive Machine in Cumberland, Maryland. Their 565 cubic inch Chevy Big Block showed peak horsepower of 814 hp and peak torque at 783 ft/lbs.

Third place winners were Kevin Frische, Paul Higgins and their team of students from the University of Northwestern Ohio. Their Chevy 406 cubic inch small block showed peak horsepower at 572 hp and peak torque at 525 ft/lbs.

optimal cubic inch displacement to was carbureted. This engine showed posting peak horsepower at 623 hp obtain maximum horsepower and peak horsepower of 814 hp and peak and peak torque at 613 ft/lbs. torque at 783 ft/lbs. These numbers torque per cubic inch. Remember, the competition allowed averaged between 2500-6000 rpm Kevin Frische and Paul Higgins the competitors to determine the most then divided by 565 gave them a score both instructors at the University of optimal cubic inch displacement to that placed them second in the Northwestern Ohio brought a team of obtain maximum horsepower and competition good for $2500. students and a Chevy 406 cubic inch torque per cubic inch over the range of small block that fielded a Hat fuel Last but not least were the boys rpm. All of the competitors’ skills injector system. This engine showed from Mason City, Iowa. Joe Degraw showed a great deal of professionalism peak horsepower at 572 hp and peak and Stacey Redmond, owners of and knowledge of what can be torque at 525 ft/lbs. These numbers Grawmondbecks Automotive produced using E85 fuel pumped right averaged between 2500-6000 rpm Machine, competed last year at the out of the filling station just down the then divided by 406 gave them a score shootout and won first place with a road. small block Chevy. This year they that placed them third in the showed up with a 408 cubic inch To continue the dialog about this competition good for $1500. carbureted small block Ford and won fuel and its potential in hotrods, Dean Yatchyshyn owner of Cresap the competition again. Admittedly AERA hosted an E85 roundtable at Automotive Machine in Cumberland, Ford guys at heart, Joe, Stacey and the show on Saturday morning. AERA Maryland brought a very impressive their crew were well prepared and invited professionals in the area of 565 cubic inch Chevy Big Block which walked away with the $5000 prize fuel, carburetors, fuel systems, fuel

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IN TOUCH BY JIM RICKOFF

Show. However, they are looking for a sponsor to help defray the costs and to put up the purse money. If you or Results Grawmondbecks U of NW Ohio Cresap anyone you know are interested, Peak Horsepower 623 572 814 please contact AERA president John Goodman at 1-888-326-2372 or Peak Torque 613 525 783 email [email protected]. As always, good profitable selling.I pumps and an engine builder to help team of professionals who all have answer any questions hotrod builders, experience using this fuel. Joe Degraw engine builders and consumers may especially had some great impact on have about E85 fueled hotrod engines. this group since he has built several Kyle Fickler from Aeromotive Inc., Jay engines using E85. Joe pointed out Rohrback from Fast Technologies, many of the issues this fuel brings out Marty Brown from Quick Fuel can be handled with compression and Technologies, Tim Wusz from Rocket fuel delivery. We’ll follow up with an Brand Racing Fuel and Joe Degraw in-depth interview with Joe in the next from Grawmondbecks Automotive issue of Engine Professional — which Machine answered questions for over features an entire issue built around Jim Rickoff is the Associate Editor an hour and one-half regarding the use the theme of “alternate fuels”. of Engine Professional magazine and AERA’s marketing consultant. If you have of E85 fuel. And WOW, did we have AERA is considering having a third any questions, comments or concerns, people with questions! Many myths annual E85 Power Shootout next year please call 507-457-8975 or e-mail: and rumors were put to bed by this at the Hotrod and Restoration Trade [email protected]

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40 APR-JUN 2008 engine professional EPREGIS 04-2008 2008 33-48EP 12/21/07 4/2/08 1:239:56 PMAM Page 141

SERVING ENGINE BUILDERS & REBUILDERS SINCE 1959 TOOLS & SUPPLIES FOR • CLEANING • INSPECTION, TESTING & CRACK REPAIR • VALVE GUIDE WORK • VALVE SEAT WORK • VALVE REFACING • VALVE SPRING WORK • PORTING & POLISHING • RESURFACING • CYLINDER BORING & HONING • CAMSHAFT WORK • ROD & PISTON WORK • BLOCK WORK • CRANKSHAFT WORK • FLYWHEEL WORK • ASSEMBLY SUPPLIES • BRAKE WORK • MISCELLANEOUS SHOP TOOLS • LUBRICANTS, COOLANTS & CONCENTRATES

engine professional APR-JUN 2008 41 EP 04-2008 33-48 4/2/08 9:57 AM Page 42

42 APR-JUN 2008 engine professional EP 04-2008 33-48 4/2/08 9:57 AM Page 43 EP 04-2008 33-48 4/2/08 9:57 AM Page 44 EQ Choc_AERA_EnProf_FP_022208:EQ ChocFullPg Ad 2/22/08 4:06 PM Page 1

Kalitta Motorsports owns the time slip for the quickest ET in the history of NHRA drag racing – 4.420 seconds. We use only Bronze-Liners from Goodson in all of our engines. – Kalitta Motorsports, Goodson customer since 1997 Thin-wall .030" Bronze-Liners The way the In stock and ready pros fix guides! for same day Phosphor-Bronze liners run cooler than integral guides or cast iron liners, plus they last longer. shipping! Their integral cross-hatch promotes oil retention and the rounded nose design makes installation quick and easy. Goodson carries guides from 5.5mm 3 to ⁄8" with all of the dimensionally correct LOOKING FOR THE RIGHT TIMING COVER? tooling. Liners are available in boxes of 16 or 100 and tooling is available by the A crankshaft for a 4.2 Ford truck? A matched head bolt set? Or a performance head for your hot rod? Go to enginequest.com for kit or by the piece. instant gratification. EngineQuest (EQ) is the “Partner to the Call 1-800-533-8010 Professional.” For almost 20 years, we've supplied cores and engine today to order! parts to rebuilders, machine shops and parts suppliers. Shipping from 6 locations nationwide, with industry-leading customer support Mention Offer Code JEP and we’ll give you and warranties, EQ is pure parts indulgence. ORDER ONLINE – 10% off your order of $150 or more! Hurry, offer expires June 30, 2008. enginequest.com call 800.426.8771, 702.649.7776 or full service fast ... just like you remember see your distributor. 156 Galewski Drive • Winona, MN 55987 800-533-8010 • 507-452-1830 • www.goodson.com EP 04-2008 33-48 4/2/08 9:57 AM Page 45 EQ Choc_AERA_EnProf_FP_022208:EQ ChocFullPg Ad 2/22/08 4:06 PM Page 1

LOOKING FOR THE RIGHT TIMING COVER? A crankshaft for a 4.2 Ford truck? A matched head bolt set? Or a performance head for your hot rod? Go to enginequest.com for instant gratification. EngineQuest (EQ) is the “Partner to the Professional.” For almost 20 years, we've supplied cores and engine parts to rebuilders, machine shops and parts suppliers. Shipping from 6 locations nationwide, with industry-leading customer support and warranties, EQ is pure parts indulgence. ORDER ONLINE – enginequest.com call 800.426.8771, 702.649.7776 or see your distributor.

engine professional APR-JUN 2008 45 DCM158_Flywheel Grinder AD.qxd 2/13/08 11:21 AM Page 1 EP 04-2008 33-48 4/2/08 9:57 AM Page 46 SG 7000 FlywheelFlywheel Grinder Grinder

THE DCM TECHNOLOGY DIFFERENCE Increase your profits with the DCM SG 7000 Series Flywheel Grinder... it’s like a cash machine for your shop. Flywheel Grinding continues to generate valuable revenue for machine shops and parts suppliers. The “One-Stop” shopping approach provides your customers with the convenience they are looking for, and it also boosts parts sales and encourages repeat business. If you are spending time and money sending your grinding jobs out...talk to DCM, we can show you how the SG 7000 can become your own personal cash machine. The Features Standard by You Want Design

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• Spring loaded self-adjusting • One-piece base casting with reinforcing ACME leadscrew nut ribs assures maximum rigidity • Removable 12 gallon coolant • Optional Intelligent AutoFeed system with pump and settling tray frees up the operator • Optional corner cutter tool does • Optional heavy-duty 10 hp both internal and external corners grinding motor

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48 APR-JUN 2008 engine professional EP 04-2008 49-64 4/3/08 10:14 AM Page 49

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M62, M70 and M73 engines. Alusil 1. Pressure gloss marks, smoothness, TB 1852 version has smooth gray cylinder bore individual blank points e.g. in middle Cylinder Boring & Honing finish without crosshatch marks. of cylinder or in the area of cylinder Caution for 1992-96 Honda A quick way to know what type of head bolts. Re-use this crankcase. 2.2 & 2.3L Engines cylinder block you have is by the casting number. Block casting numbers are 2. Ring shaped prints visible in the upper The AERA Technical Committee offers located on the right side of the block next and lower reversal range of piston the following information on a cylinder to the coolant drain bolt. rings, are not a reason for complaint. boring and honing caution for 1992-96 Re-use crankcase. Honda 2.2 & 2.3L engines. These engines are used in many different Honda vehicles and use a fiber-reinforced metal (FRM) in the cylinder bores. Those bores are also a nonferrous metal and require special attention during the oversize operations. During manufacturing, a rigid hone using a GC-600-J or finer stone designed for nonferrous metal was used to finish hone the cylinder bores. Honing pressure should be adjusted to 29-43 psi (200-300 kpa), while the hone head is rotating at Casting Number Cylinder Block Version 3. Visible streaks, traces of rubbing 45-50 rpm. The desired crosshatch 1725970-1714212 M60 B30 Nikasil pattern is 60° for a proper piston ring starting from the first piston ring, run seal. To prevent stone loading and debris 1745871 M60 B30 Alusil out after approximately 30 mm. build-up, cleaning the stones every five 1725963-1742998 M60 B40 Nikasil Traces of dry rubbing which cannot be cycles is recommended. 1745872 M60 B40 Alusil felt, caused by oil film being washed off by fuel, e.g. during frequent cold After the bores have been honed to 1745873 M62 B44 Alusil final size, the block should be cleaned starts in short distance driving. These with hot, soapy water and then dried. A traces of rubbing which occur cleaning solvent is not advised as it has a principally in the area of the cylinder tendency to only redistribute honing grit. TB 2497 head bolts and on the pressure side are Aftermarket honing stone suppliers Cylinder Wall Inspection not a problem provided they are have indicated that using a silicon for 1993-2006 Mercedes Benz smoothed. The piston rings are not carbide, 400-grit stone, is capable of 5.0L Engines damaged. Re-use crankcase. providing the desired finish and The AERA Technical Committee offers crosshatch required for this cylinder the following information regarding block. cylinder wall inspection for 1993-2006 Mercedes Benz 5.0L engines. This information should be considered any TB 2113 time the cylinder heads have been Cylinder Block Identification on removed on this engine. BMW 4.0L DOHC M60 Engines The following information has been published by Mercedes in paper The AERA Technical Committee offers #AH01.00-P-0300-01A, entitled General the following information on cylinder Information on Inspecting Cylinder Walls. block identification for BMW 4.0L Follow the steps and sequences and 4. All around blank, mirror-like, polished DOHC M60 Engines. BMW has used associated photos to assist evaluating each cylinder surfaces mostly starting from two different cylinder wall-finishing cylinder wall. the first piston ring, in the upper processes during production, which are cylinder range, with measurable and called Nikasil and Alusil. Each block is fit partial cylinder wear. Cylinder wall with pistons and piston rings especially unusable. for the cylinder bore finish and should never be interchanged. 5. Rough streaks, friction seizure starting Nikasil is an aluminum alloy block from the first and second piston ring, with nickel dispersion-coated cylinder run out only in the cylinder bottom bores and was used on the M60 engines section. Traces of rubbing as described and replacement blocks. Nikasil version in item 3, which have advanced to incorporates crosshatch hone marks in the signs of seizure. Piston rings may also bore finish. Alusil is an aluminum silicon be damaged. If damage can be felt, alloy used in M60 replacements and cylinder wall unusable.

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6. Individual continuous scratches caused by contaminations, e.g. through reverse pulsation of soot particles out of the exhaust. Re-use crankcase. 7. Piston seizure Cylinder wall usually perceptibly roughened over the entire length. Material deposits and perceptible traces of seizure on cylinder wall and at piston skirt. Cylinder wall unusable. 8. Brown coloration of the cylinder surface oil varnish is over large areas of the cylinder barrel and indicates that the engine was driven at a high temperature level. Re-use crankcase provided no impermissible cylinder distortion is present. Oil varnish above piston ring zone is normal and is not a reason for complaint.

TB 2498 Cylinder Wall Boring & Honing for Mercedes Benz 5.0L Engines The AERA Technical Committee offers the following information regarding cylinder wall boring & honing for Mercedes Benz 5.0L engines. This information AERA Technical should be considered any time the cylinder heads have been removed on this engine. Bulletins also The following information has been published by Mercedes in paper AR01.40-P-9201AA, entitled Measuring, Boring and Honing Cylinder Bores. available online Reference the following any time these operations are being considered for the above mentioned engine. We will be sending “Engine Professional” magazine quarterly. The technical bulletins in English and Spanish 1. Measure cylinder bore: NOTE: Measure cleaned can be found online at www.aera.org — as always, if cylinder bores with an internal measuring you have any questions or if you need technical support instrument at the 3 measuring points (1, 2, 3) in send an e-mail to [email protected]. longitudinal (A) and transverse direction (B). Estaremos enviando la revista, “Engine Professional” 2. Set honing machine for pre-honing. trimestralmente. Los boletines técnicos en Español e 3. Cylinder bore pre-honing. NOTE: With full honing Ingles los pueden encontrar en la pagina web de AERA, oil feed. www.aera.org — como siempre, si tienen preguntas o si necesitan ayuda técnica comuníquese con Yolanda o 4. Measure cylinder bore. NOTE: Immediately after envíe un correo electrónico a [email protected]. pre-honing, an oversize of approx. +0.02 mm is obtained because of heating. 5. Set honing machine for precision honing. www.aera.org 6. Cylinder bore precision honing. NOTE: with full honing oil feed.

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observed. One should also note the same is true for all cylinder boring and honing 1,2,3 Measuring points of cylinder bore a – Upper reversal point of first piston ring operations. Follow the steps listed below A – Longitudinal direction b – Bottom dead center of piston B – Transverse direction c – Bottom reversal point of oil scraper ring to create a desirable cylinder wall finish.

Cylinder Bore Honing 1. Used carefully, the cylinder bore resizing hone, recommended Chrysler tool C-823 or equivalent, equipped with 220 grit stones, is the best tool for this honing procedure. In addition to deglazing, it will reduce taper and out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up a bore and maintain the required limits. 2. Deglazing of the cylinder walls may be done using a cylinder surfacing hone with Chrysler recommended tool C- 3501 or equivalent equipped with 280 grit stones. If the cylinder bore is straight and round, 20 - 60 strokes (depending on the bores condition) 7. Measure cylinder bore. NOTE: NOTE: Do not coat cylinder bore! will be sufficient to provide a Immediately after precision honing, satisfactory surface. Be sure to use 17. Lap cylinder bore and expose silicone an oversize of approx. +0.01 mm is light honing oil. Do not use engine or crystals. NOTE: Without honing oil obtained because of heating. transmission oil, mineral spirits or feed. Stock removal is not kerosene. Inspect cylinder walls after 8. Chamfer cylinder bore. Except model measurable. each 20 strokes. 463 18. Clean cylinder bore and dry. 9. Set honing machine for polishing. CAUTION: Clean crankcase very carefully free of silicone carbide 10. Polish cylinder bore. NOTE: Polish paste. If possible clean crankcase in a with full honing oil feed up to repair major assembly washing machine, so final dimension. that no cylinder wall damage can 11. Measure cylinder bore. NOTE: occur due to other remaining residue Allow crankcase to cool down to at a later engine run. approx. 20 degrees C before 19. Inspect cylinder bore NOTE: Allow measuring. crankcase to cool down to approx. 12. Thoroughly clean cylinder bore and 20 degrees C before inspecting. dry. 13. Set honing machine for lapping. TB 2499 NOTE: On same diameter as after Cylinder Measuring & Honing polishing (final diameter). for 2004-2007 Chrysler 2.4L 1 – Cylinder bore cross hatch pattern. 2 – 40-60° 14. Rub in cylinder bore and felt insert VIN S Engines with silicone carbide paste. NOTE: The AERA Technical Committee offers 3. Honing should be done by moving the The cylinder wall must be dry. Only the following information regarding hone up and down fast enough to get the specified silicone carbide paste cylinder wall measuring and honing for a cross-hatch pattern. When hone may be used. Only this one 2004-2007 Chrysler 2.4L VIN S engines. marks intersect at 40 to 60 degrees, guarantees the specified final result. This two piece cast iron cylinder block the cross hatch angle is most does not allow overbore to repair cylinder 15. Lap cylinder bore and expose silicone satisfactory for proper seating of rings bores. crystals. NOTE: Without honing oil (See illustration above). feed. It should be noted the lower bedplate portion of the block should be properly 4. A controlled hone motor speed 16. Once again coat felt insert with torqued to the upper block while any between 200 - 300 RPM is necessary silicon carbide paste. cylinder bore measurements are being to obtain the proper crosshatch angle.

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The number of up and down strokes per minute can be regulated to get the desired 40 - 60 degree angle. Faster up and down strokes increase the cross-hatch angle. 5. After honing, it is necessary that the block be cleaned again to remove all traces of abrasive. CAUTION: Ensure all abrasives are removed from engine parts after honing. It is recommended that a solution of soap and hot water be used with a nylon brush and the parts then thoroughly dried. This is usually a two step process involving two buckets of soapy hot water. The bore can be considered clean when it can be wiped clean with a white cloth and cloth remains clean. Oil the bores after cleaning to prevent rusting.

Block Cleaning Clean the cylinder block thoroughly using a suitable non petroleum cleaning solvent.

Cylinder Bore NOTE: The cylinder bores should be measured at normal room temperature, 21°C (70°F). The cylinder walls should be checked for out-of round and taper with a dial bore gauge, such as Chrysler Tool C119 or equivalent (See Figure 2). If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted. Measure the cylinder bore at three levels in directions A and B (see illustration below). Top measurement should be 10 mm (3/8 inch) down and bottom measurement should be 10mm (3/8 inch) up from bottom of bore.

Checking cylinder bore size.

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AERA TECH SERVICES What is AERA? That acronym originally stood for the Automotive Engine Rebuilders Association, but was recently changed to the Engine Builders Association, which better represents our entire group of professionals. This association has been in existence for more than 85 years serving automotive machine shops internationally.

The purpose of the AERA is: The development and encouragement of high standards of workmanship and ethics among its members; the improvement of business conditions through the exchange of information and ideas; the promotion of the common business interests of persons and organizations engaged in the remanufacturing or building of internal combustion engines or basic internal components of such engines in automotive machine shops.

AERA History On July 1, 1922 the Midwest Regrinders Association was formed and held its initial annual meeting in Des Moines, Iowa. Officers were elected and committees were established to handle the following subjects:

• Membership, Selling, Production, Accounting and Adjustments

The following statement is a direct quote taken from the 1922-1924 records of our association at that time:

...to learn the true cost of doing the work and handling the parts used in this service, to learn how to merchandise and sell, and to develop methods that will produce better work and make it possible to turn it out more efficiently and at a lower cost to the consumer.”

It’s amazing to read a quote like this one from the early 1920s and realize that many of the concerns that our forefathers had are still concerns today. That’s not to say many of these issues have not been resolved but rather that the concerns still exist. The Association today has over 3,000 members worldwide, with members mainly in the United States and Canada. Service to our members is our highest priority, whether it is through our publications, the web or in meetings and seminars. Today, this association is a network of professional engine builders, rebuilders and installers with the expertise and connections

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AERA members have FREE access to ASE-certified Master Machinists with the expertise and connections to answer your tough technical questions

BY DAVE HAGEN, MIKE CARUSO, and STEVE FOX CH SERVICES to provide you with the right answers information that allows technicians to out there for technical support on engines. when you need them. Long ago, AERA search that database at a later point in Also, please remember to leave your established a “Standards of Service” time for similar problems or conditions. name. Calling is the most popular method document for both gasoline and diesel Many AERA Technical Bulletins have of contacting the Tech Center as many engines. These documents define the resulted from pattern failures recorded by callers just want to talk to someone else standards for a rebuilt/remanufactured this system over the last 18 years. Your about the particular problem. engine and have clearly differentiated a requests are placed into a queuing system professionally rebuilt/remanufactured which chronologically displays the order engine from a repaired, partially rebuilt or in which they were received and recorded. Remember, you must second hand exchange engine. In addition Doing so allows our tech center personnel to active shop members, AERA welcomes to respond in a timely, ordered sequence. be an AERA member suppliers/manufacturers, manufacturer Depending on the questions or to contact AERA reps and schools to our membership requests made, our personnel may not be technical services! group. required to call back the person to satisfy We’ve been classified as the clearing their request. We’ll simply supply only the house of information regarding internal “facts” by a return FAX. Many tech-line combustion engines. Over the years, users have already figured out how we FAX: Simply fax us your questions on we’ve created a library of information and work and if someone is just looking for a piece of company stationery or references on most engines built since the head specifications, why waste time letterhead (something to help us identify early 1900s. The AERA Technical talking about it (time is money)? We’ll you) will suffice with the questions that Services Department was established in simply fax back the information from you need answered. Some people use a 1988 and is hailed as second to none. PRO-SIS. It’s very important to check blank shop order or invoice that already With more than 300,000 member your fax machine before calling us back has the company information on it. Please questions answered through the years, to follow up on your original call, as use a dark colored pen as it provides a there is always a new challenge with each often times the information is already better printed fax impression. Use our day. there. toll-free, dedicated fax number 888-329- 2372 to transmit your request. Remember Are you looking for Answers to Tough Contacting AERA Technical Services this option is available 24-7. In most Technical Questions? CALL: Dial 888-324-2372 to speak instances, we’ll fax you a reply back As a current AERA member or when you directly to one of the Technical unless otherwise stated. become a member, you’ll have free access Department personnel or leave a message. E-MAIL: Use our [email protected] to ASE Certified Master Machinists. Our weekday tech line hours are 7 am - address to send your questions and These men do not work 24-7 but you do 6 pm CST. If you leave a message comments as it goes to all technicians in have the ability of submitting your (available 24-7), be sure to include your the technical department. Doing so will questions to them in that time frame. AERA ID and call back telephone assure you it reaches all of the department There are three basic methods of number(s). Leave a short description as to personnel. If you send it to only one contacting the AERA Technical Services the nature of your call and one of the individual, it will not be read until that Department, call, fax or e-mail. techs will get back to you as soon as person returns to work if they’re absent Over a year’s time more than 15,000 possible. With this method you’ll need to or working on a project away from their questions are logged and stored in our realize calls placed on weekends or US desk. Remember sending e-mail by this Technical Tracking System. Each call holidays will be responded to the next option is available 24-7. So, if you’re contains specific vehicle/engine business day. We feel it the best service working late and have a question, just

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AERA TECH SERVICES BY DAVE HAGEN, MIKE CARUSO, and STEVE FOX

The most popular resource used in the AERA Tech Services Department is PRO-SIS engine specification software. The technical center also has a vast library of books, specification manuals and OEM service manuals, collected and compiled over the years. Several online technical service companies such as Mitchell’s On-Demand, All Data and Cummins Online are also employed as additional sources of reference, if needed.

send us an e-mail and we will respond the • Please have your membership number diameters in a fraction rather than a following business day. This request ready for verification on all inquiries. decimal. The book doesn’t list torque method is becoming more popular all the • Please be realistic with your timeline values for tightening specifications as time. This option also allows you to requests, as most everyone seems to be there weren’t any good torque wrenches attach a digital photo of a failed in a rush. until 1942. component to the e-mail for better We’ve got a wall of bookshelves technician analysis. In some instances containing hundreds of original Our MAIN Resources equipment service manuals and many we’ll e-mail a response including different Our most popular resource used in the websites with additional information on more archived in our warehouse. We have Technical Services Department is our own a file of microfiche that goes back to the subject. PRO-SIS software program. PRO-SIS Whatever method you’re currently 1918 for Cadillac and numerous other stands for — Professional Specification manufacturers as this was a common way using, it may be to your advantage to try Information Software. In the technical of storing data thirty years ago. one of the others, so give it a try. Below is department, approximately 90% of the a short list of important considerations to calls we answer are done by using our On-Line Services remember while requesting services from own program, PRO-SIS. We employ several online technical the AERA Technical Services Department. PRO-SIS has more than 4600 engines services for further reference and up to listed in it; ranging from an Acura to a date information. They include Mitchell’s • Speak or write clearly when leaving Zetor engine. We have small single On-Demand, All Data and Cummins messages. cylinder engine specs as well up to a V-16 Online. These companies have extensive • Have detailed engine/vehicle details industrial type engine. Current personnel doing data input of the late included (make, model, year, engine specifications included in PRO-SIS are: model engines. These services offer us size, VIN # if possible). Cylinder Head, Cylinder Block, quick reference to basic specifications and • If your phone is busy, it will delay our Connecting Rod, Crankshaft, Camshaft procedure repair information. call back or fax back time. & Torque Values / Tune-Up Specs. Unfortunately, many housing bore The Technical Center has been • If your FAX is used for other specifications are missing in original shop collecting service manual information manuals so we use other methods of communications, it may delay our fax over the last 20 years. Our library of obtaining that information. After back time. books consists of a variety of publishers determining the missing information we • If you’re going to leave the shop work including the Motors Books beginning in will add it to our PRO-SIS software area after leaving AERA a message, 1935. We’ve got one other book that program. please leave us an alternative contact covers vehicles manufactured from 1915- As our services extend across many name. 1942. The specifications supplied back ponds, we also receive inquiries on • Allow for sufficient time for our then, however, were somewhat limited; engines that are not common to this technicians to research your inquiry. for example, they give you crankshaft continent, but popular elsewhere. To

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AERA TECH SERVICES BY DAVE HAGEN, MIKE CARUSO, and STEVE FOX

assist us in that venue, we use a software can also email him directly at information gathering started. “I love the program from Australia called Auto Spec. [email protected] with any suggestions or detective aspect of a new challenge and A week does not go by without the Tech technical questions. enjoy the feeling when we’ve reached our Department looking for an engine we’ve Mike’s hobbies are Family #1, then #2 mark, such as, obtaining an emailed PDF never heard of, either because it is a new drag boats and old mahogany wooden file of a complete service manual from an engine or simply one we’re not familiar runabouts, inboard engines and outboard engine manufacturer. Our library grows with. engines such as the 18 HP Mercury daily with electronic files on engine data Hurricane. Mike strives to continue to and I welcome any member who’s willing Our Current Technical Experts learn something everyday and is currently to contribute. Through the years, we’ve Steve Fox has 20 years experience in the tuning his 2.0L turbo daily driver using a found some of our members are either industry with the first 8 of those years wide-band O2 setup. If you don’t have dealers or distributors of different engine spent in the machine shop. He also a 18 one of these, save up and get one, they’re manufacturers and it’s truly amazing what year member of the drag racing circuit really cool. materials are now available electronically. racing in Super Dave is responsible for daily Comp on and Dave Hagen has a total of 36 years operations of the Technical Services off throughout experience in our industry. Starting out in Department and has worked for AERA those years. a two-man shop the past 19 years in that department. As Steve specializes in Northern an ASE Certified Master Machinist, he in general Minnesota, Dave continues involvement with ASE question automotive work specialized in reviews and has done so since the as well as high cylinder head inception of the Machinist Tests in 1990. performance. rebuild and Dave enjoys “spending time on the Steve has complete engine lake, any lake, and fishing when it’s not been working for the AERA for 12 years assembly for the frozen”. He also enjoys coaching soccer and duties include answering the Tech- first 17 years of and watching his 2 kids various sports Line phones doing problem solving of his career. After teams. You can email him directly at members questions. He is also kept busy taking a position with AERA as their first [email protected] or contact him by phone gathering information to improve the full-time Technical Specialist, his career in at 847-541-7025.I technical services department. Hobbies include going to any form of racing event, especially drag racing. What Steve enjoys the most is spending as much If your car’s time with his family as much as possible. catalytic converter Don’t Red Light You can email him directly at isn’t operating [email protected] or call 815-526-7348. efficiently, it’s Your Engine Mike Caruso (driving a desk now) brings “red-lighting” 42 years of high performance and stock your engine’s Even when brand new, most original equipment converters are restrictive enough rebuilding experience to AERA. He power output. to put a serious dent in an engine’s horsepower curve. And if the fuel or ignition worked on HP engines during 1965-1969 calibration isn’t right, it doesn’t take long for a converter to deteriorate, causing and enjoyed 18 even more restriction and horsepower loss. years in race When your converter needs to be replaced, the best Techno engine shops logy choice is a Random Technology SuperStainless™ after that. Mike catalytic converter. Don’t be confused by cheaper came to AERA PRE-STAGE look-alike copies. The important differences are on after spending the inside. Only RTCats™ feature our exclusive the previous PSX™ technology, which combines advanced 11 years at STAGE chemistry with high quality ceramic or metal matrix FEL-PRO’s High cores. The result is a converter that delivers: Performance The highest flow for MAXIMUM power R&D department where he worked on • Highest efficiency for optimum emissions ® the Loc-wire , Pro-stock, Pro-Mod, and • control Marine gaskets and then on to the FEL- Longest warranty — 50,000 mile PRO Tech-Line. He is an ASE Certified • performance warranty Master Machinist and has supplied a Unrivalled fit and finish wealth of knowledge to AERA members • Doesn’t your Tech for the last 10 years. nology The main two responsibilities Corvette currently for Mike involves answering deserve the members questions and entering new best? (770) 554-4242 engine specifications into PRO-SIS. If 4430 Tuck Road, Loganville, GA 30052, you’ve got a question or special request, Fax (770) 554-4244, www.randomtechnology.com give Mike a call at 847-541-6738. You Federal law prohibits the removal or replacement of properly functioning original equipment catalytic converters. Aftermarket catalytic converters are not legal for installation on OBD - II vehicles in California 58 APR-JUN 2008 engine professional EP 04-2008 49-64 4/3/08 10:14 AM Page 59 EP 04-2008 49-64 4/3/08 10:15 AM Page 60

I product news

an “A” rated insurance company. products to their line of Advanced Whether customer service or claims, the Performance Lubricants. Both the administrator’s representatives will serve Extreme Pressure Lubricant (#3690) and your customers professionally and the 20W50 Semi-Synthetic Race Oil courteously throughout the life of the (#3729) contain the proven friction EngineGuard product warranty. It’s easy modifier, Micron Moly®. Micron Moly® offering EngineGuard and building is a liquid soluble type of moly that plates consumer confidence in your engine to the metal surfaces of the engine and is product. For more information, contact: small enough it won’t get trapped in your Warranty Administration Services, Inc. filter. Once plated, the soluble moly forms at 530-246-8200 or go online: a long lasting lubricant film which www.WASeasy.com. prevents the metal surfaces from coming into contact with each other. By preventing metal-to-metal contact, ® damaging frictional wear is eliminated, Elgin PRO-STOCK which leads to less downtime and longer Brand Unveils .450 engine life. For more information, call (309) 745-9558 or order online: Lift Rule Performance www.hughesengines.com. Camshaft Elgin Industries continues to expand the power and value of its popular Elgin PRO-STOCK® performance brand, as the company has introduced a premium high-performance hydraulic camshaft for Chevy small-block engines competing in .450 lift rule classes. Elgin offers one of the industry’s broadest selections of cam New Regis Catalog grinds, each offering superior performance at an extremely attractive The 2008 Regis Royal Cut Products price. The new Elgin PRO-STOCK catalog is filled with hundreds of new and camshaft #E-1227-P is an ideal choice for improved tools and supplies for engine competition on 3/8- and 1/2-mile oval builders and rebuilders. For a free copy, Goodson Announces tracks in engines operated at 2,200 to call toll-free 800-527-7604 or go online: New 4mm Borescope 5,400 RPM. For more information on www.regisroyalcut.com. Elgin PRO-STOCK camshafts and other Find burrs, sharp edges and other defects premium performance and stock in machined surfaces inaccessible to the replacement engine components for naked eye Don’t sacrifice your reputation virtually any application, call 1-800-323- for quality because of something you 6764, e-mail [email protected] or go couldn’t see. Inspect machined engine online: www.elginind.com. components before assembly to ensure that surfaces aren’t marred by burrs, ™ sharp edges, tiny cracks or other defects EngineGuard that could compromise the job’s integrity and cause failure in the future. This high Product Warranty resolution borescope features for Rebuilt Engines interchangeable white LED and super- bright blue flashlights for leak detection New to engine professionals nationwide, and component inspection. Either can be EngineGuard can replace an existing in- New Advanced used with or without the scope. The ultra- house warranty by reducing liability and thin 4mm shaft allows you to inspect removing the frustrations associated with Performance places larger scopes can’t reach and the administering a plan. This three year, advanced fiber-optic imaging bundle unlimited miles product warranty allows Lubricants from provides exceptional clarity. Use the clip- an advantage over the competition due to Hughes Engines on mirror to pinpoint leaks and flaws in its term and limit of liability. Claims areas such as manifolds, combustion repairs are initiated nationwide at any Today’s “environmentally friendly” oils chambers, differentials, catalytic converts ASE certified service facility. are not necessarily “camshaft friendly”. and more. Order No. BSK-4. For more EngineGuard is offered through an That is why Hughes Engines is proud to information, call 800-533-8010 or go experienced administrator and backed by announce the addition of two new online: www.goodson.com.

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I product news ADVERTISER INDEX

ABS Products ...... 48 ACL...... 19 AERA - Engine Builders Association ...... 28-29 Axe Equipment...... 23 Bates Technologies, Inc...... 64 CWT Industries ...... 3 DCM Tech Inc...... 47 Elgin...... 7 Endurance Power...... 27 Enginequest ...... 45 Farris Equipment Sales ...... 18 Fowler Sales & Service...... 15 Goodson...... 44 Hughes Engines Inc ...... 52 Interchem...... 25 SAKOR Technologies Jamison Equipment ...... 42 ™ Joe Baker Equipment...... 17 VersaDyne Small Joe Gibbs Driven Racing Oil...... 43 Engine Test System King Engine Bearings ...... 33 L.A.Sleeve...... 37 SAKOR Technologies, Inc., a Lock N Stitch ...... 38 recognized leader in the area of engine Mahle...... inside front cover, 1 and powertrain system testing, Maxiforce ...... 52 announces the VersaDyne™, a Peterson ...... 61 completely integrated, turn-key system Popular Equipment Finance ...... 39 for testing small 2-cycle and 4-cycle Probe Industries ...... 50 engines. The VersaDyne is ideal for Radiac Abrasives ...... 35 testing engines found in equipment such Random Technology ...... 24, 58 as small outboard motors, motorcycles, Regis...... 41 ORV’s, tractors, lawn care tools, and RMC Equipment...... 5 generators. Available in sizes ranging from 5 to Roadway...... 59 30 kW, the VersaDyne features the Rock Products ...... outside back cover versatility of a regenerative AC Rottler ...... reader card motoring dynamometer in a Sentry Insurance ...... 63 convertible, horizontal/vertical package. Serdi ...... 53 Utilizing modern Flux Vector Siriani & Associates...... 57 technology, the VersaDyne’s AC Stuska Dyno / Power Test Inc...... 40 motoring dynamometer offers precise Sunnen ...... 31 speed and torque control over a very Vibratech TVD...... 46 wide dynamic range. A single system is World Products...... inside back cover therefore capable of testing engines over a broad range of performance ADVERTISING characteristics. For more information, OPPORTUNITIES call 517/332-7256, e-mail [email protected], or go online: Get your advertising message directly into the shops who are building, rebuilding and www.sakor.com. installing engines professionally by advertising in Engine Professional magazine. Engine professionals worldwide will receive this full-color publication four times per year. I Please send your product news releases Each issue will be filled with highly technical and application-driven articles from our staff to Engine Professional Technical Editor, of writers, as well as feature contributions from industry professionals. Over 15,000 copies Dave Hagen. E-mail: [email protected] or of each issue of Engine Professional will be sent out directly to an audited list of engine fax AERA toll-free 888-329-2372. professionals comprised of engine builders; custom rebuilders; production rebuilders; heavy-duty, marine, industrial, motorcycle, Nascar, NHRA and sprint car shops. Ad Sales • Hal Fowler: 404-427-0171 / [email protected] • Jim Rickoff: 507-457-8975 / [email protected] For ad payment, circulation and membership information: Call AERA toll-free 888-326-2372 or 847-541-6550.

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MAHLE Original® engine parts take the heritage of quality synonymous with both Clevite and MAHLE and bring it to an even higher level. MAHLE Original is the perfect complement to an engine parts line already featuring superior brands like Clevite, Victor Reinz and Perfect Circle. The MAHLE Original brand continues its global recognition; in fact, MAHLE Original is now an exclusive World puts the “hot” in Hot Rod. NASCAR Performance brand in a variety of categories, for more information on this or anything else, visit MAHLE Clevite Inc. online. www.mahleclevite.com We’ve got the hottest blocks and cylinder heads for popular V8s! I Complete dyno-tested engines I Short blocks and partials I Aluminum and cast iron blocks THEY CALL IT (available fully race-prepped) I Aluminum & cast iron heads (available bare or assembled) SMALL BLOCK FORD LS SERIES CHEVY QUALITY I Special big-inch intake manifolds WE SPELL IT MOPAR® HEMI® Now available from World Products are new, highly refined aluminum 426 HEMI blocks that carry a Mopar part number. Also available are aluminum blocks for 440 MAHLE. Wedge applications. They are far superior in quality to the original Chrysler blocks made over 40 years ago and incorporate many important design improvements. NEW! I Our product line is designed with the professional engine builder in mind I Blocks incorporate extra machining options to save you time and money I Expand your business without adding extra personnel or machinery through our race- prepped blocks, short blocks or assemblies

SMALL BLOCK CHEVY BIG BLOCK CHEVY WE EXPORT TAKE ADVANTAGE WORLDWIDE Download the catalog online and find the name Let World become your shop “annex.” Call, OF THE DOLLAR World Products is located in the of your local World Products dealer/WD write or fax to receive a new World catalog. Fortunately for most foreign buyers, Foreign Trade Zone at Long Island www.worldcastings.com 631-981-1918 the exchange rate for the U.S. dollar is MacArthur Airport (ISP) and now at a historic low. Take advantage 51 Trade Zone Court, Ronkonkoma, NY 11779 (Fax: 631-737-0467) specializes in global commerce. Mopar® and HEMI® are registared trademarks of Chrysler. LLC of this situation and stock up now. EP 04-2008 Cover 4/2/08 10:05 AM Page 4