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 Hugo's engine build at the Magical Place (Vallero's Machine Shop)

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Wed Sep 28, 2011 11:25 pm

I remember Lynda driving that bus to high school. It was quick!
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 1:26 am

These studs are too long for this narrow motor (bottom of picture). The rocker shaft and manifold won't fit. The head studs need to be shortened.



Quickly grind them down.



All better. Smile



I will be running 48IDA Webers on this motor. Ray has a secret as to how he makes these carbs very "streetable". One reason that we are making this a narrow motor is so that they will fit. But we will have to modify the manifolds so that we won't have to pop out the decklid with the air cleaners on.

He has some spread port Berg manifolds that we wanted to use. But it will take way too much machining on both them and the heads, and we don't have that much time right now. So, at a later date, he will be making a set of heads for the car for the spread ports. It's my daily driver, that way I can be driving the car in the meantime and he can do the new ones as time allows. We will tear it down and swap that out at a later date. Smile But, here's a video of a set that he modified for his old racecar, when it had fuel injection.



Lynda's old motor had Scat Trak manifolds that Ray ported 30 years ago. They are the one's on the left, the new ones that came with my Webers are on the right. The nicer thing about the old ones is that the channel at the base has more material to grind away to make them bigger.





Ray was going to cut Lynda's down for the sake of time (not as much machining), but we couldn't bring ourselves to do that to these beautiful old school manifolds, so we are cutting the new ones down.



He sent them out to Bast Bros. welding since his heliarc welder was moved to a new room and will trip the breaker to do aluminum. It's not a pretty job, but Ray will machine these later to clean them up. Here's one with the original length old Scat Trak.





He has started porting the new short ones, but still need a bit more (compared to Lynda's old ones).



The Bridgeport mill knocked out of index in order to do this:



Next up, we are going to put the motor together to see how the top end stuff is going to fit. It's a lot more challenging and time consuming to build a motor completely from scratch!
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 9:30 am

Dawn,

what good job you are doing on this, We all know how hard this is to do ,an come out

with good pics. and vids Again dam good job Dawn..........
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 5:27 pm

Sorting through $2500 worth of parts from CB Performance.



We are going to assemble the motor on the rack to check if everything fits well. When building a motor from scratch, it's not uncommon that many things will interfere with other things and need modifying. We want to do this now before final assembly.

This was done a few days earlier before the manifolds were cut (in order to clear the decklid), so that we could measure where to cut them. The linkage in this picture shows how it will have to be modified to clear the alternator after they are shortened.



Better pic of these beauties. Dual Weber 48 IDA's.



The lever on the right is unnecessary, it is just a throttle stop. We will cut it off both sides so that it looks better. They ran these as singles in Italy originally and apparently needed the lever, and Spain copied it.



Alternator instead of a generator. The tin behind the alternator is black. Tidbit from Ray, he prefers black to chrome for quality over looks. CBP sells chrome and black. Chrome - china. Black - VW. Smile



Competition merged exhaust.



Muffler. We will have to cut off this flange, it is too small.



Completed motor with exhaust (prior to cutting manifolds).



Here is after they were cut and we decided to raise the linkage mounts on the carbs. Ray is going to make spacers for the mount screws out of push rods tubes.



Raised linkage mounts.



View from the front of the engine. Note the carbs are tilted a few degrees inward to help clear the decklid. Webers can go 15 degrees in or out and still run properly.



It's starting to get exciting to see what it will look like!


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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 6:29 pm

Holy Sh-t!! Shocked

That thing looks mean!!
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 7:01 pm

That exhaust is bad ass! Big ole carbs! I love it!

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 7:12 pm

The fan shroud is small, so there's not a lot of room for the coil. The regulator is inside the alternator. We want to tuck the coil in behind the alternator mount, but it won't quite fit with the CB mount for it. We'll need to grind a little off. How cool that it happens to be red, the car is OG red also? Smile View from the front of the engine. "Front" means the front of the car...



After grinding, fits nicely now, with room for the strap.



View from the rear of the car. The shroud needed a bit of fabricating to fit also.



And with the distributor.




Last edited by dsimas on Sat Oct 01, 2011 5:56 pm; edited 1 time in total
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 7:13 pm

Mateo wrote:
That exhaust is bad ass! Big ole carbs! I love it!

Yeah, I am "borrowing" that exhaust from a nice guy that will get it after me since I don't want to do without heater boxes on my Daily.... Any idea who that guy is Mateo? Wink
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 8:07 pm

WHAT?!?!?! NO MAGNETO lol! OR DISTRUBORLESS INGNITION? scratch

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Fri Sep 30, 2011 8:44 pm

Looking good Dawn. That setup is just sweet!!

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sat Oct 01, 2011 4:38 am

Thanks Dann!

Cliff, I haven't updated exactly what the distributor is: it's a billet electronic Magna Spark II. But even Ray's old racecar would turn 13,000 rpms with points! So, I think it'll be fine and it looks better this way. Cool
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sat Oct 01, 2011 9:31 am

13,000 rpms?? That's amazing!
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sat Oct 01, 2011 10:06 am

Like previously stated 13k rpms is nuts! What will yours be turning?
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sat Oct 01, 2011 11:00 am

silvertonguedevil wrote:
13,000 rpms?? That's amazing!

ESPECIALLY WITH POINTS!!!!!! HE HAD TO BE CHANGING THE POINTS LIKE AFTER EVERY RACE THO ????

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sat Oct 01, 2011 5:45 pm


Chris, mine will be capable of about 7000rpm.

Cliff, no, he didn't have to change them. He set them closer so they wouldn't get hammered. He'd put it in the distributor machine (Sun?) and set it for 10K rpm (distributor turns at half that - 5K) and the machine would show when it starts missing, then he'd tweak it and get it dialed in to the closest setting that was possible and run it like that to be sure it would run well. He'd run it on the machine for an hour, so a few seconds on the track certainly didn't hurt them. They were set at .002 or so!

So, next up on this motor build was final assembly. Ray always washes his hands well and keeps everything spotless. The case gets a good bath in the washer.



Using an Engle K8 cam. Here's its Cam Card.



We have to add the cam gear. This shows oil pump drive slot. Ray uses locktite on the bolts so they won't come loose.





All performance cams come with provisions for the gear to bolt on, rather than preassembled, so that the builder has the choice of what gear sets to use. We are not putting any advance or retard washers and are running it straight up.



We have racing bearings and they are notched, but the case was not on one. So, Ray had to grind off the tang.



It's very important to be sure that the lifters clear the case before sealing it.



Here Ray takes this opportunity to explain "overlap".



Now on to assembling the crank. Here Ray is showing how to check for proper rod play, it should sit tight against the crankshaft as opposed to tilting side and side or rocking.



Ray has been getting racing spacers lately that have been tricky to get on without wedging on the shaft (and risking damaging it). A racing spacer is solid, as opposed to a stock one that has a gap in it to expand. It goes between the crank gear and distributor drive. He heats it up on a hot plate and has to be quick about it and this one went on as good as could be expected, yay!



Don't wait until the motor is together to see if the pulley fits. You may need to hone the pulley or polish the snout of the crank. Ray had to heat the pulley to get it to fit, which is nice and tight and will not need any work to get it on later.



You never want to start a new motor dry! This shows that he has oiled everything well as it goes together. When we checked for any play, the cam gear did have some backlash, so we swapped it out with another one. We are looking for is zero backlash, but yet for it to move freely. In the past you could order cam gears in plus and minus #'s. Now you have to depend on manufacturers' variations in gear width, so you have to be selective for the gear that you get.



Ready to assemble the case using Ultra Grey.



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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sat Oct 01, 2011 7:32 pm

dsimas wrote:
Cliff, no, he didn't have to change them. He set them closer so they wouldn't get hammered. He'd put it in the distributor machine (Sun?) and set it for 10K rpm (distributor turns at half that - 5K) and the machine would show when it starts missing, then he'd tweak it and get it dialed in to the closest setting that was possible and run it like that to be sure it would run well. He'd run it on the machine for an hour, so a few seconds on the track certainly didn't hurt them. They were set at .002 or so!

HE HAS A DISTRIBUTER MACHINE!?!?!?! Shocked

I GOT A CHANCE TO PLAY WITH ONE WHEN I WAS BACK IN SCHOOL. OH MY GOD!!!!!!! affraid IF YOU RUN POINTS IN ANYTHING THAT IS THE ONLY WAS TO SET THE POINTS GAP Twisted Evil . THOSE MACHINES ARE PRICELESS IN MY OPINION FOR POINTS. I DONT HAVE ONE Mad SO THATS WHY I RUN THE ELECTRONIC IGNITION.

THIS HAS GOT TO BE THE BEST THREAD EVER!!!!!!! cheers "THIS IS THE GOOD STUFF." QUOTE FROM JOE DIRT lol! IF YA DIDNT KNOW.

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sun Oct 02, 2011 4:45 pm


"Houston, we have a problem."

Sad

So, this isn't that uncommon that you get into a project and hit some snags and rethink things. Ray was not able to remove enough material from Lynda's old racebus heads to cc them to 46cc like we needed to get the compression down. Those heads had been fly cut too much and he was going to lose a lot of squench area, not to mention they would just plain lose integrity. Unbeknownst to me, he was going to press on with the build in order to get the car and I to Fontana Bugorama in a week because he didn't want to let me down. But we'd have to tow it, rather than drive it, because of the high compression. The upside in Ray's mind was that we could be a serious contender in the Cal Look Challenge. He got sidetracked in that it's my Daily Driver and full race is not really my main goal. He was justifying it in his mind with saying he'd make me a proper set of heads after Fontana, swap them out, and make my Driver later.

Time was running out and Tony Klink came by that night to help with the final assembly. Tony and Ray are like twins separated at birth, I swear they read each other's minds. It is spooky to watch, they work together with symbiosis and it's like watching a ballet. Well, okay, dudes doing a ballet, but still it's like a choreographed dance. Wink Anyone else trying to help would only slow Ray down. Tony helps speed things along. Here are the clowns for the night:



Here's a video of Tony at Test And Tune last year.



Here's his motor, Ray is a sponsor and shares his secrets with Tony only.



At this point I would only get in their way, so I wasn't really involved, other than taking pictures. I heard a lot of exclamations: "Dude, that's a full race motor!" and other such mutterings, which were a concern to me....but....

They put on the heads and the rockers to measure the push rod length.



Ray usually uses aluminum push rods, but had some steel ones that turned out to be the right length, again feeling that they would suffice since it was only going to be doing passes and not driven. To counter act the high compression on the narrow motor, they put in a .040 head gasket and two .020 barrel shims (NOT what I had in mind) to add .080 total distance and get it to a reasonable compression to run. Add some racing gas and Dawn was going to kick a$$ at the track in a week and these guys were set on high!

When I saw the direction this was headed, I finally had to stop the freight train that these innovative racers were becoming. Sad Fun as it all sounded, I have been without my Daily for quite a while now and hauling it to LA was not what I wanted, I like driving my car. And then redoing so much upon return for more down time is not what I want. There was no time to machine a new set of heads within a week, so I said I'd have to sit out Fontana and for him to please build the engine just once and start working on some new heads. Boy, it wasn't easy for me as a girl to tell these guys, like two Happy Puppies playing with the best toy on earth, that the fun was over.

Hugo isn't going to be done in the next few days after all, but we are back on track and not cutting any more corners due to a short time crunch, which is better. Tony and Ray are still racing Zerstorer next weekend, of course. We are counting on him still holding the National Record in his class (PRA - Pro Gas) and winning the point series, it's all good!
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Mon Oct 03, 2011 1:41 pm

We got a new set of heads and sent them out again to Bast to be welded to add material to the intake pad, so he can raise the intake port on the short side.

Here's the difference on the intake side. The lower one is a brand new one. The middle is mine with the welding done. The top one is Lynda's that have been machined to show the goal.



Putting a head into the angle plate in order to pick up the angle of the cylinder head from this stock unwelded, uncut head, so that we can then machine the new welded head without knocking the Bridgeport any further out of index.



He machined the pad, then was working on porting the intakes. But the manifolds won't clear a spark plug wrench because they've been shortened so much. He'll grind a socket to pair with this engine to change spark plugs. He's never cut manifolds down like this and cannot grind more off them to clear. Other bugs with IDAs either run cut velocity stacks or pop out the decklid. We want to have air cleaners under the hood.



We chose to go with 1.3 rockers, which lessens the lift on a K8, it will be .498. The cam card shows the lift at .534, and we want to stay under .500. Engle's K8 normally would be ground for 1.4:1.



We ordered 7/16ths double taper aluminum pushrods from Smith Brothers. Standard is 3/8ths. But the larger ones will be much stiffer with more strength integrity by tapering at the ends. The taper also allows them to clear the tubes, provides more clearance, and reduces overall weight.

In the past, Ray had some custom valve guides made to order that he will be using. He sells these if anyone is interested. He will hone them to order, the guide is almost the size of the boss. It provides extra stability on the outer end by the valve spring, where it needs it.







Now THAT's a lightened flywheel. 11#. The stock one is 17#. I drive 45 miles a day on Hwy 49 to work, so Ray wants to be sure that I have a nice rapid acceleration rate for hills and passing. Yeah, that's our story and we're sticking to it... Wink



So, still moving forward...
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Mon Oct 03, 2011 7:41 pm

I'm sure you will just dread the hills once this engine is built Wink
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Mon Oct 03, 2011 9:19 pm

You guys are really going all out on this. It just goes to show how much work is really involved in building it correctly. This is one of the greatest threads ever.

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Sat Oct 08, 2011 12:54 pm

We are just getting ready to leave for Fontana for Bugorama with Tony and the Zerstorer. But last night, Ray got the heads flycut. Smile

Centering the mill over the cylinder head.



First he cuts the head to 94's, then he cuts the top for clearance of the barrel.



Then he checks for clearance between the top of the cylinder fin and the first fin on the head.



Before (in the back) and after (in front). It was only a minmum cut to take the step out and cut the size to 94. It's preliminary since we don't know the cc's of the head yet and there's still a mega shroud right now.



We are going to run zero deck with .040 copper shims, which are needed to acheive .040 between the head of the piston and the squench area. We don't want the explosion to take place in the cylinder, but in the combustion chamber. Many people space the base of the cylinders to achieve their targeted compression, but by doing so they have a lazier mix light. Their barrels are blue on the top from the heat of the explosion taking place in the barrel. We will achieve the compression ratio by grinding the combustion chamber. All the heat and power is pushed into the head and into the piston for a more complete burn.

The copper gaskets serve two purposes:

1) As the engine RPM increases, the rod stretches and the head of the piston grows up to .035 at 7000rpm. So if you have less than .040 overall deck clearance, the piston will strike the squench area.

2) There is an iron barrel against an aluminum head and they are two very dissimilar metals in their expansion when hot. Copper absorbs the abrasion caused by the expansion. The shim follows the head back and forth and prevents the head from being worn from skating in and out against the cylinder.

Next we will install the valve seats in order to cc the heads. Then cc them to acheive the 9.68:1, and that will determine how much he will unshroud the combustion chamber around the valves. That will be next week when we get back. Off to the races now, wish us luck!
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Tue Oct 11, 2011 10:51 pm

Yes good luck. You guys are making great progress.

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Wed Oct 12, 2011 1:59 pm



First and most importantly: WE WON AT FONTANA BUGORAMA! Details will ensue, but I'm still working on catching up right now....



So, back to Hugo's heads. Ray's custom valve guides (shown in previous post) are in place on the exhaust side and will be modified in place. They are much longer and will be ground within the head when Ray ports the exhaust port. The intake guides cannot be in place during porting and unshrouding the heads because it would damage them. Here's the head in the Valve And Seat Machine.



Ray will now be machining the bowl and unshrouding by hand with a ball mill cutter. But we already showed that when we did it to Lynda's old racebus heads, so no need to repost him doing that here.

The intake valve guide is mounted here on a valve guide pilot to be tapered. It took a while to find the right sized pilot.





There is now a 2 degree taper on the guide. The reason for doing this is air flow. This part of the guide sits inside the intake port, and there will now be less material blocking air flow, along with the shape being important. Two degrees results in a long slender taper for optimum air flow.

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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Wed Oct 12, 2011 3:01 pm

NICE!!

I was starting to wonder about you. It was awfully quiet around here.
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PostSubject: Re: Hugo's engine build at the Magical Place (Vallero's Machine Shop)   Wed Oct 12, 2011 7:51 pm

UM... Maybe I need to ask Tony this question, but what are Buckskin Lady Leathers???

I don't know what they are, but I think Jenn needs some...

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