Diesel Engine Machining Alternatives B Series Cummins Light-Duty Diesel Engine Casting Repair

84 Pages·2011·51.75 MB·English

DIESEL PERFORMANCE: DIESEL RACE ENGINE SCENE
AN AERA INTERNATIONAL QUARTERLY PUBLICATION
JULY-SEPTEMBER 2011
Diesel
Engines
GALE BANKS ENGINEERING
DURAMAX DRAG RACE ENGINE
FOR SIDEWINDER S-10.
PHOTO COURTESY OF GALE
BANKS ENGINEERING.
Diesel Engine
Machining Alternatives
B Series Cummins
Light-Duty Diesel
Engine Casting Repair

engine professional WWW.AERA.ORG/EP 1
CONTENTS
VOLUME 4, NUMBER 3
PUBLISHER
4 FROM THE PUBLISHER AERA - Engine Builders Association
500 Coventry Lane, Suite 180
6 INDUSTRY NEWS Crystal Lake, IL 60014
Welcome to new AERA members, 815-526-7600
815-526-7601 fax
calendar of events, news and views
Chairman of the Board
10 DIESEL PERFORMANCE David Bianchi
Seattle, WA
By Mike Mavrigian
First Vice Chairman
An overview of the diesel race engine scene
Dwayne Dugas
New Iberia, LA
26 GUIDE-LINERS FOR DIESEL
26
APPLICATIONS Second Vice Chairman
Ron McMorris
By Pim van den Bergh
Maple Ridge, BC CANADA
34 5 MINUTES WITH AN Treasurer
Dean Yatchyshyn
AERA MEMBER
Cumberland, MD
By Jim Rickoff
President
John Goodman
38 IN TOUCH
By Jim Rickoff EDITOR
Free Tech & Skills Conferences John Goodman
[email protected]
40 REPAIRING DAMAGED
ASSOCIATE EDITOR
LIGHT-DUTY DIESEL 40 Jim Rickoff
ENGINE CASTINGS [email protected]
By Gary Reed
TECHNICAL EDITORS
48 CONFERENCE RECAP Dave Hagen
[email protected]
By Steve Fox
Steve Fox
Sunnen and MAHLE Clevite Regional Conference
[email protected]
at Hendrick Motorsports a huge success
Mike Caruso
50 B SERIES CUMMINS [email protected]
Gary Lewis
By Dwayne J. Dugas
[email protected]
60 DIESEL ENGINE MACHINING Mike Eighmy
ALTERNATIVES 50 [email protected]
By Steve Gettelfinger COMPTROLLER
Ellen Mechlin
68 TECH BULLETINS [email protected]
GRAPHIC DESIGN
Maria Beyerstedt
[email protected]
ADVERTISING SALES
Jim Rickoff
[email protected]
Hal Fowler
[email protected]
60
PRODUCTION
Jan Juhl
[email protected]
Engine Professional®magazine (ISSN 1945-7634) is published
quarterly by Automotive Engine Rebuilders Association.
CIRCULATION
Copyright 2011, Automotive Engine Rebuilders Association.
Karen Tendering
Subscription rates: $70 per year, outside the United States $90,
single copy $20. Publication, editorial and business office: [email protected]
500 Coventry Lane, Suite 180, Crystal Lake, IL 60014.
Editorial: 815-526-7600, Advertising: 507-457-8975, INTERNATIONAL LIAISON
Circulation: 815-526-7600. Send change of address to the above. Yolanda Carranza
The opinions, beliefs and viewpoints expressed by the various [email protected]
authors in this magazine are those of the individual authors and
not of the Automotive Engine Rebuilders Association, which CHIEF TECHNOLOGY
disclaims all responsibility for them. ARCHITECT
Richard Rooks
[email protected]
2 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION
engine professional WWW.AERA.ORG/EP 3
FROM THE PUBLISHER
BY JOHN GOODMAN, AERA PRESIDENT
High Performance Diesels
have arrived
My first experience at the Bonneville Salt Flats was common rail diesel engines are plentiful in the EU
in 1964 for Speed Week. Anyone who ever visited and are beginning to take hold here in the United
Speed Week was treated to the wildest array of States. This new breed of diesel is quiet, clean
racing machinery ever assembled in one place at burning and powerful. Fiat, VW, Audi and Mercedes
the same time. If you build it, there is a class to Benz all have their version of small bore diesels
race it so this environment fosters large amounts of aimed at the US market and some could be
creativity and personal opinion on how to go faster considered hot rods even by gasoline standards.
than anybody has ever gone before. It was at These diminutive turbo diesels can rival
Bonneville where I first saw a diesel-powered performance of gasoline engines with much larger
streamliner and as a teenager wondered why
displacement. There will be compelling arguments
anyone would build such a car powered by, of all
in favor of these engines as consumer
things, a diesel. What transpired over the week was
understanding grows.
to see that diesel liner set a new speed record in
class. Truly an amazing accomplishment and Generally, when an OEM market gains popularity,
should have sparked some curiosity in me as to the aftermarket follows suit and provides customers
why that car owner chose diesel power over all with performance parts. We are beginning to see
other gasoline engines. this happen with diesel engines as well. Although
there have been pioneers like Gale Banks who was
My next trip to Bonneville wasn’t until 1993 when I
one of the first to recognize benefits of high
visited Speed Week once again but this time with
performance diesel engines, it has taken time for
my own car. Once bitten by the Salt, you never fully
the US aftermarket to offer diversity and choice of
recover so there I was, standing on this ancient
components. Engine Professional Magazinewill
lake bed staring out at this pure white expanse
explore this new era of high performance diesel and
thinking how blessed I was to be there. But how
give the reader a glimpse into what is going on and
things have changed. There were no fewer than
four highly modified Kenworth, Peterbuilt and Mac how a diesel engine builder approaches
trucks out to set fastest time of meet in class and performance enhancement. Given a trend toward
maybe take home a world record for the effort. A diesel engines for performance, the high
mix of superchargers and turbos powered these big performance aftermarket may just have new
diesels to speeds in excess of 200+ miles per hour! frontiers to explore and our engine shops new profit
One such truck out of Oregon used a four potential as well.(cid:1)
turbocharged diesel to set a new class record over
232 MPH only limited by tires. I never would have
believed it possible for a truck of this size and
weight to go this fast. Here again, something in this
experience should have told me there is real speed
potential in these diesel engines but alas, it did not.
Around this same time, Audi was developing the R8
diesel powered endurance road racer that
eventually changed how unlimited endurance road
races were done. From six to 24 hours, the R8 was
untouchable. This too should have been a clue to Prior to becoming president of AERA, John Goodman
was director of the Advanced Technology Center (ATC)
speed potential of diesel power but only a few were
for Micromatic-Textron. The ATC focused on
actually looking closely. manufacturing honing solutions and studies for OEM
engine manufacturers. Testing of traditional and unique
Fast forward to 2011 and we see the fruit of all
honing abrasive systems, coolants, fixtures, tools and
these years of diesel development. Small bore, software were primary responsibilities of the ATC lab.
4 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION
engine professional WWW.AERA.ORG/EP 5
(cid:1) industry news calendar
AUGUST 16
AERA welcomes • RPM Machine, assembly but teaches and
TECH & SKILLS
new members Cedar Valley, UT reinforces what a technician REGIONAL
• SRC of Lexington, may already understand about CONFERENCE
ACTIVE Lexington, KY his or her chosen profession. Hosted by Jobbers
• A Extreme Transmission, • Strasburg Automotive, David leads the way for Warehouse Supply
Tallapoosa, GA Lindon, UT many other dedicated engine Minneapolis, MN
machinists interested in proving www.aera.org/conferences
• Baltimore Head Works, • The Hot Rod Shop,
what they know. AERA
Eldersburg, MD Cayce, SC currently has 21 technicians in SEPTEMBER 30
• Brazier Race & Machine, • USA Racing Engines, the online training program. If TECH & SKILLS
Winnipeg, MB CANADA Houston, TX interested in adding to your REGIONAL
• C Smith Automotive, • Valley Automotive, resume of engine experience, CONFERENCE
Hosted by Rottler
Wooler ON CANADA Winchester, VA contact AERA at 815-526-
Kent, WA
• C & T Automotive, • You Do Engines, 7600, extension 202 and ask www.aera.org/conferences
Orem, UT Middleville, MI for Karen Tendering — or email
• Carquest Auto Parts, [email protected]. Karen can NOVEMBER 1-3
Arden, NC ASSOCIATE answer all your questions and AAPEX SHOW
• Charlie’s High Performance, • Euromarketing Ltd, when ready, register you to Sands Expo Center
begin the program.(cid:1) Las Vegas, NV
Tracy, CA Auckland, NEW ZEALAND
www.aapexshow.com
• Comardo Racing Engines, • Nanak Crankshaft Grinders,
In memory of Oscar Scott
Edgewater, FL Nairobi, KENYA NOVEMBER 1-4
Oscar Scott of Don Gross
• DC Cylinder Head, • PA Performance, SEMA SHOW
Sales Company died
Clayton, WI Boyertown, PA Las Vegas Convention Center,
unexpectedly on Monday, June
• Deluxe Auto Machine, • Preto Metals Recycling, Las Vegas, NV
13, at the age of 59. He is AERA Booth #21760
Phoenix, AZ Statham, GA
survived by his wife Faye and www.semashow.com
• E&N Body & Machine, daughters Kirsten and Kailey.
Sevierville, TN MEMBERGETTERS Oscar has worked in the NOVEMBER 28-30
• Eliminator Products, • Dave Monyhan, automotive industry for over 30 ADVANCED
Auburn Hills, MI Goodson Tools & Supplies years. He began his career at ENGINEERING
• Gerlach Performance, Hopper Shop Equipment and TECHNOLOGY
CONFERENCE (AETC)
Eagle, CO then at West Coast Engine
Orange County Convention
Rebuilding in the Los Angeles
• HRT LLC, Durham, NC Center, Orlando, FL
area before landing a job at
• MTP Drivetrain Services, www.aetconline.com
Don Gross Sales Co. in 1980
Many, LA
where he remained an integral
DECEMBER 1-3
• Matts Motorsports, part of the company until his
PRI SHOW
Melbourne, FL passing. Dan Gross noted the
Orange County Convention
• Metal Crafters, pleasure he had in working Center, Orlando, FL
Stevens Point, WI with Oscar traveling half the AERA Booth #4377
AERA congratulates world… ”He became like a www.performanceracing.com
• Montoya Machine Shop,
San Antonio, TX David Roland, the first brother to me. The passion he
• Nut Cracker Racing, to hold a Cylinder Head showed for his work, for his DECEMBER 8-10
family, and for life was inspiring. IMIS SHOW
Salisbury, NC and Engine Machinist
He will be missed.”(cid:1) Indiana Convention Center
• Olive City Auto Parts, Certificate Indianapolis, IN
Corning, CA The Legend of Joe www.imis-indy.com
David Roland, a professor of
• Partens Auto Supply, Automotive Technology at Mondello Continues
DECEMBER 8-10
Omak, WA Macomb Community College,
Calvin Hill tapped as general TECH & SKILLS
• Performance Motorsports – was first to complete the AERA manager of Mondello Tech REGIONAL
Asia, SIP, CHINA online training course for CONFERENCE
Center’s High Performance
• Quenby Auto Center, Cylinder Head and Engine Hosted by AERA at the
Machine Shop
Albemarle, NC Machinist certificates. Mr. IMIS Trade Show
Roland did it in record time by CROSSVILLE, Tenn. – Despite Indianapolis, IN
• R & B Automotive,
completing stringent Joe Mondello’s recent passing, www.imis-indy.com
High Point, NC
requirements in less than four the crew at Mondello Tech
• Rectificado Motor Val,
months. Center in Crossville, Tenn., is
Cucuta, COLOMBIA
Mr. Roland expressed a committed to carrying on the
• Ricks Repair & Machine, strong desire for this type of legacy of their founder. Calvin
Mooresville, NC meaningful program that not Hill has been named general
• Roman Machine Shop, only tests one’s knowledge of manager of the company’s high
Juana Diaz, PR engine machining and performance machine shop
6 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION

(cid:1) industry news
and brings with him a renewed to lead the company and to performance cylinder heads Operations/Engineering for
dedication to building carry on Joe’s legacy. Joe was and engine components, will Dura-Bond Bearing Company
performance engines and their well respected in our industry launch its “Head to Vegas” (A Melling Company).
components. for everything he accomplished promotion on July 1, 2011. The In his new position,
“I’m so pleased to have and he certainly left big shoes grand prize winner will receive McBroom will lead the Dura-
Calvin as part of our team and to fill. I’m excited about the a seven day, six night trip for Bond efforts to oversee
to know that he’ll carry on ‘The challenges and the possibilities two to attend IMCA's Duel in engineering, production,
Mondello Way,’” said Mary and can’t wait to get started.” the Desert event at the Las environmental, new product
Mondello, owner of Mondello The high performance shop Vegas Motor Speedway in development, new production
Tech Center. “Joe was a at Mondello Tech Center November. processes and maintenance
mentor to Calvin, as he was to specializes in engine and For complete contest rules activities. He will lead a
so many of the people Joe cylinder head development and and to enter EQ’s “Head to experienced team to facilitate
knew throughout the years, features superior workmanship Vegas” promotion, visit for future growth of the
and I know Joe would be with the latest technology, www.enginequest.com/headto company. Dura-Bond has seen
proud today.” including the SuperFlow NSCR vegas. The promotion ends on strong growth in the
Hill, owner of Hill 902 dyno cell. For more September 30, 2011.(cid:1)
aftermarket during the last two
Performance in Lakemoor, Ill.,
information, please visit them
years.
has a strong background in online at www.mondello.com.(cid:1) Bob McBroom
Bob has been with Dura-
cylinder head and port
promoted to VP
Bond for over 27 years. He
development and carved an EngineQuest® 2011 Operations/Engineering
developed the popular Dura-
impressive niche in the Pontiac
performance community. Upon IMCA “Head to Vegas” for Dura-Bond Bond High Performance
Promotion
accepting the position, Hill CARSON CITY, Nev. – bearings widely used by the
stated, “I’m honored that Mary LAS VEGAS, Nev. – Bob McBroom, formerly racing industry today along
and the team at Mondello Tech EngineQuest® (EQ®), a leading Engineering Manager, has been with many other engineering
Center has put their trust in me supplier of stock and appointed Vice President of achievements.(cid:1)
8 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION