16 valve B motor - living the dream

[Luke]

Here is Ron at M2race digitizing a head.

http://www.youtube.com/watch?v=xHGqSp788f8

Between the scan and the drawings we are able to get a really good sense of the head and how best to square everything up and what needs to be removed and where. Ron suggested an x-ray of the head so we could determine exactly where the waterjackets are and maximize the port design for power, but we (I) decided to keep costs in check we will play it somewhat conservative with the ports (probably still far better than the original saab port design)

And this is the end result where all the upfront time spent modeling pays off. The head can be ported and the combustion chambers cut basically in only a few setups all on the same jig plate!

http://www.youtube.com/watch?v=k2MOKuc4x4Q

[Jordan]

That second video reminded me of Terminator 2...machines building machines...

[DrewP]

I think you will enjoy these Matsuura guru videos:

Matsuura hoggin' the farm

Matsuura Finishing touches


Drew

[Crazyswede]

we are getting a couple of 5 axis mills in at work. Unfortunately they will never be available for personal projects. We also got a water jet in this fall...it might be a little easier to sneak into for an hour.

[aero84]

Hi Luke,

maybe you should consider boring the lifter holes with (I dont know what it's called in english) this kind of boretool.
This tool will give a super smooth surface, and a very precis/exact diameter.

[DeLorean]

Looks like good progress, I was a bit skeptical that this would ever get done when the pics first came out, but it looks possible now! It will be interesting to see this run some day, can't wait.

[Luke]

Hi Luke,

maybe you should consider boring the lifter holes with (I dont know what it's called in english) this kind of boretool.
This tool will give a super smooth surface, and a very precis/exact diameter.

Yeah we call that a boring bar, I have one of those and they do work great although a think the bores may still need a light hone to get a smooth enough finish.

[aero84]

Hey Luke

I used this boring-bar when I worked as toolmaker, we had a Diamondtipped cutter tool for aluminium cutting. Gave a super smooth surface.
But a bit of hone is never bad

[Luke]

Some pictures of the machining in progress. On the main cylinder head the combustion chambers are done and the seats are in (but not cut). The guides still need to be installed.






And the ports, ahh the glorious ports! Its an interesting design with the split for each valve occuring somewhat upstream from the valves and right at the junction of the intake manifold. I forgot to mention that the manifold was also measured and drawn as part of the model, so that we could create the best possible flow path and port shape.

[Geoff]

Wow, looks good!
Are those the intake ports in that picture? Its funky how they meet together at the edge of the cylinder head (talk about a thin wall). So the manifold is round or rectangular and then meets two round channels when it intersects with the head.... I'm thinking flow restriction where the intake gasses meet the flats on the head between the ports... But who cares, it's 1976-a-licious!

[Luke]

Wow, looks good!
Are those the intake ports in that picture? Its funky how they meet together at the edge of the cylinder head (talk about a thin wall). So the manifold is round or rectangular and then meets two round channels when it intersects with the head.... I'm thinking flow restriction where the intake gasses meet the flats on the head between the ports... But who cares, it's 1976-a-licious!

Geoff,
Yep those are the intake ports. The transition starts way upstream in the runners, so by the time it hits the ports the two paths have diverted, its quite beautiful if a bit funky!

[DeLorean]

Neat, that's similar to how the dual plain manifold runners come together on the 90's ford 2.5 / 3.0 duratech motors common in the Contour and Taurus

[Krister K]

Greatest thread since the dawn of internet.

[Luke]

Neat, that's similar to how the dual plain manifold runners come together on the 90's ford 2.5 / 3.0 duratech motors common in the Contour and Taurus

So I looked at the wikipedia article for the duratec 2.5/3.0 and guess what firm did the cylinder head development for ford on that engine.... yep none other than Cosworth, the same company that developed the BDA for Ford (the head that SAAB borrowed more than a few design elements from for the 16V!)

[DeLorean]

Huu, that is interesting. That comment was based on nothing more than casual observations from 1/2 dismantled ford contour / taurus motors I have seen at the junk yards. It is an interesting design for sure, should work well!