20V CQ Tidy Up

[AndyP]

Nice work!

I think you should make a batch of those stainless coolant pipes

[Error404]

They are on my list mate
Just want to test it first


So I did quite a bit of work on the sump to try to correct a few of issues with these motors on track:

Oil surge
Oil drain-back
PCV

I drew up some baffle plates to take some Viton control flaps from Forge

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Chopped the guts out of the sump and welded in:

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Flaps fitted

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Dimple sump drain plug - these are the most powerful sump magnets you can buy, also stainless so will last a lifetime

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I welded in a through-tube and a -12 fitting for an oil drain back. This will connect to another -12 fitting I have fitted to the back of the head, just above the ECT sensor and allow oil that has surged to the back of the head to drain back quicker to the sump. It will also increase the engines ability to balance any crank case pressure with the head, making a cam cover breather more effective.

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Boss welded in for a Bosch oil temp sensor

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All fits nicely with Thomas' PKKM baffle, with oil drain back above the horizontal baffle. I like the name PKKM.... it sounds paramilitary

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Bottom end built up


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I was never content that my oil themostat worked properly, and was seeing pretty consistent 130-135deg oil temps on track. Closer to 100deg is better. After testing the oil stat in some boiling water it didn't move, so guessing its past its best. I bought a Mocal thermostatic sandwich plate with an 80deg stat, which should give the opportunity to run cooler oil temps. Mocal also supply a rebuild kit with a new stat if requried.
So I removed the OEM stat from the housing and plugged the oil cooler lines.

I can easily recommission these if I find I need another oil cooler to keep the oil temps to 100deg.

-4 fitting installed for turbo oil supply.


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Made a stainless -10 fitting for the turbo oil return

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Stainless -6 freeze plug for the turbo coolant supply

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That's about it for now, more over the next couple of weeks

[Thuppu]

Amazing fab and details Alex, just mindblowing!!!

All fits nicely with Thomas' PKKM baffle, with oil drain back above the horizontal baffle. I like the name PKKM.... it sounds paramilitary

Have you tried to google "PKK" lol , it's just idiotic what facebook tries to suggest as friends for our site. Maybe not the most clever idea for a club name haha.

[Error404]

haha, well you are a tarmac terrorist Thomas

[AndyP]

Just Google'd that, they look like a friendly bunch

[ajax1976]

Always love reading your updates mate, well thought out and proper engineering behind everything you do, very inspiring!!

[Tom_]

Stunning work Alex as always in your case , everything clean and shiny...what paint on the block u used?

Tom

[Error404]

Thanks Tom
I used zinc primer, 2k epoxy then 2k acrylic top coat.
The aluminium parts have acid etch primer and 2k acrylic on top

[LukasR]

Hi Alex. Was the re-sleeving expensive? Have you done here in Uk? How did you clean pistons?
Lukas

[newsh]

OCD Awesomeness

[kinaputt]

Great as always!

[Error404]

Thanks
Have been a bit busy to do much recently but hoping to have a full weekend of it this week

Hi Alex. Was the re-sleeving expensive? Have you done here in Uk? How did you clean pistons?
Lukas

Hey Lukas, sorry for the slow reply. Sleeving is not cheap but cheaper than new pistons. Around £120 per bore, but I saved a bit as I bored out quite a lot of the meat myself at work to save the machinist some time, so it worked out about 80 per bore for me. HTH

[Thuppu]

Do you Alex know what material the sleeves are, steel or cast iron, etc..? How thick is the sleeve insert wall?

[Error404]

Hey Thomas, I used spun cast iron liners from Westwood here in the UK. You can use ductile iron which has approx 3x the tensile strength, but also 3x the cost and made to order. Only worthwhile on a very high HP build in my opinion. Spun cast liners are about £35 each from memory, ductile are around £115 each

I used Westwood's p/n WCL 22A which is a stock item, 80.9mm ID, 84.2mm OD and 150.3mm long.

I bored my block most of the way out on the mill, leaving the last few cuts for the engine machinist and his big (more accurate) boring machine
He fitted the liners, decked the block and the top off the liners, then honed out to 81.01 stock bore

[Thuppu]

Nice! Didn't know there are universal inserts available, and at that cost, not bad. Thanks Alex! I also have a AAN block with quite bad groove in one bore.