Machine Head Project

[S2central.net]

Yes and all turbo heads *should* have twenty washers under the VSOS...

Looking forward to some time with kitchen products on this head

Got some more stock of cartridge rolls (medium and fine) to test out on the head - also got stung £30 for a flexishaft gizmo for the dremel.

The valve guides all look grand on this head - no real signs of wear and there was certainly no noticeable lateral movement of valves in them. I just need to get them out so I can start shaping it up.

I'm going to get it flowbenched - before and after - anything special I should know before doing that ? Do I need to provide a set of valves so that measurements can be made at one or more meaningful valve openings - however they would be held in the right position whilst under test.

After the first tests I'll get the guides removed and then I can set to work.

[Flat on my back]

Yep.

Probably best to give him a pair of in. and ex. valves. He'll use much weaker springs for ease of measuring. Might be worth telling him what lift cams you plan to use, so you can see the flow diff. between standard and whatever you plan to use, quantify improvements.

Do you know the flow of a standard head/cam combo? Think there were plots on here somewhere?

Bullet nose guides, high flow valves with three angle cut?

[Mark Halligan]

Yes and all turbo heads *should* have twenty washers under the VSOS...

My heads had the following:

ADU - none

ABY - inlet and exhaust

7A - inlets only

[audiman]

Would advise against steep valve seat angles as they tend to burn out a lot easier. All it would take is a fuel pump failure and running lean for a bit and you would have to strip the head apart for a valve prob.

my 2 cents

[S2central.net]

Just a small update on this... I got the water rail template from MarkH and should be getting that machined soon. Meantime I bought a shiny new water rail to make absolutely sure of alignment and a good fit for the seals.

On the parts system - illustration 121-50 for the ACOQ it clearly states that three extra parts are called up on the ABY against the water rail (Item #26). I ordered them thinking it was some oddball difference - approx 6 quid I think so no biggie... BUT I'm flummoxed to see how they are relevant. I have just looked at same drawing for RS2 and it does NOT call those up. WTF ?

Oh another thing - that diagram doesn't tell what gasket is required for the large connection to the water rail - it shows the gasket in the picture. Just above #28 in the attached image. I assume that gasket must be with the complete head gasket kit, but does anyone know which one ?

Can't find it for RR, 3B, ABY or ADU - sigh.

Paul

[S2central.net]

PDF is here - oops...

[4WheelDrifter]

I'm sure the main gasket for the water manifold is #29 - 027 121 139 A

[Flat on my back]

This one?

Aan?

[4WheelDrifter]

034 198 012 M is the head gasket set for NM, 3B, RR, ABY, AAN and ADU engines.

[S2central.net]

I'm sure the main gasket for the water manifold is #29 - 027 121 139 A

I'll get me coat. How the hell did I miss that? Guess I was too busy looking for a number against it on the drawing and missed it off the text. Duhh...

Someone have the moderators chastise me, tell me I'm not up to the job and give me two and half million quid to leave. Just heard that craziness on the news 2nite about that dork McClaren. I digress.


Paul

[S2central.net]

Right - in a sorry attempt to redeem myself (hehee) - I have a little find.

The water rail for 3B/ABY/ADU is listed as 034 121 187, but the part you get (correctly) is numbered 034 121 193 A.

I also twigged what the extra unknown parts were for when I looked at the rail and saw three holes tapped on the underside... One for MFTS, one for afterrun thermoswitch and uhhhhhhhhhhhhhhhhhhhh one for the water connection to the turbo. Sure enough, thats what it is. Curiously these parts are only called up on sheet 121-50 for the ABY, but they are needed for 3B and ADU. You can see them referenced elsewhere however in 145-25 so that explains it.

Here's all the water rail parts I got so far -

Water rail - 034 121 187
Banjo bits - N 903 580 03, N 904 048 01 and N 013 814 9 (2-off)
Seal - N 028 203 4 (3-off)
Bolt - N 010 217 10 (6-off) - These are 20mm for ABY, apparently its 15mm on 3B
Washer - N 012 226 5 (6-off) - Different from those listed for 3B - weird

The bit I missed is the other water rail gasket - 027 121 139 A

Recorded here for posterity... Might help someone in the future (if only me when I forget this tomorrow afternoon).

Paul

[S2central.net]

And a wee lil pic of shiny new water rail with fitting for turbo connection attached.

[S2central.net]

Bump.... Bit of an update - in a fit of outright boredom and frustration last night I made some space in the garage, got this head on the workbench, whipped out the trusty dremel and some cartridge rolls to start attacking the inlet ports.

It is amazing what those rolls will shift if you let the tool dig in, but it doesn't take long before the dremel starts to get hot.

I went carefully trying different speeds to feel the progress gently. My goal on the inlets was really to just remove casting marks, smooth any edges, open it up a little bit and impart a nice finish - slightly rough.

Using 60-80 grit cartridge rolls to good effect I think. I haven't removed the valve guides yet or had the head tested on a bench for before / after... What I might do is complete the work in two stages across four ports and leave the 5th one in factory finish to see what results show on the bench - it'll be at such a workshop for valve guide fitment and maybe a slight skim to even things out.

Photos to follow from progress so far. I think I need the thinner cartridge rolls as well though for the smaller areas.

[S2central.net]

After much ado... The 1st of some photos tonight - annotated for posterity. This is still work in progress here - not the finished article - going gently, but confidence grows with each lash of the die grinder

1st up is an INlet port before any tweaks - showing some areas for attention.

Paul

[S2central.net]

Same port after some gentle CRT - Cartridge Roll Therapy

I've been a bit naughty here and flared that part of the port ever so subtly without seeing the IM gasket, but I think the shape is better /smoother and if need be will trim the gasket to match exactly along with IM.

I think the port is only shaped like that with those sharp edges cos the drilling operation to accomodate the fuel injector happens after the port is cast.

GUess its too late for someone to advise otherwise, but this just felt right.

Using 60 or 80 grit cartridge rolls and a mains powered dremel to get the feel of things. I need a flexishaft extension gizmo on that or my power drill to get deeper, but this is OK for now as I feel my way around.