Modern Engine Blueprinting Techniques. Mike Mavrigian

      

       CarTech®

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      © 2013 by Mike Mavrigian

      All rights reserved. No part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without prior permission from the Publisher. All text, photographs, and artwork are the property of the Author unless otherwise noted or credited.

      The information in this work is true and complete to the best of our knowledge. However, all information is presented without any guarantee on the part of the Author or Publisher, who also disclaim any liability incurred in connection with the use of the information and any implied warranties of merchantability or fitness for a particular purpose. Readers are responsible for taking suitable and appropriate safety measures when performing any of the operations or activities described in this work.

      All trademarks, trade names, model names and numbers, and other product designations referred to herein are the property of their respective owners and are used solely for identification purposes. This work is a publication of CarTech, Inc., and has not been licensed, approved, sponsored, or endorsed by any other person or entity. The publisher is not associated with any product, service, or vendor mentioned in this book, and does not endorse the products or services of any vendor mentioned in this book.

      Edit by Paul Johnson

      Layout by Monica Seiberlich

      ISBN 978-1-61325-120-1

      Item No. SA251

      Library of Congress Cataloging-in-Publication Data

      Mavrigian, Mike, author.

       Modern engine blueprinting techniques : a practical guide to precision engine building / by Mike Mavrigian.

       pages cm

       Includes bibliographical references.

       1. Automobiles--Motors--Maintenance and repair. 2. Automobiles--Motors--Modification. 3. Tolerance (Engineering) I. Title.

       TL210.M345 2013

       629.25’04--dc23

      2013011409

      10 9 8 7 6 5 4 3 2 1

       Title Page: Every piston/rod assembly must be measured and weighed so they are within a couple grams of one another. To achieve maximum performance, you must have components on the rotating assembly that are precisely balanced.

       Back Cover Photos

       Top Left: Be sure the wall thickness of the cylinders is thick enough for rebuilding. If it isn’t, you need to junk the block. To sonically test an engine, slowly run the sensor probe along the cylinder wall (in a number of clock positions and from top to bottom) while monitoring the gauge readout.

       Top Right: Measure journal diameters in different clock positions so you take all the necessary measurements. It isn’t a bad idea to perform a backup measurement with a different micrometer.

       Middle Left: A connecting rod vise allows you to remove a rod cap from a new rod, or when tightening rod bolts with the rod off of the crank. Using a common bench vise can cause serious damage to the rod, and burrs or gouges can be created, which can lead to stress cracks and failures. A dedicated purpose-designed rod vise allows securing the rod without damage.

       Middle Right: Spiral locks can be tricky at first but once you install a few it becomes second-nature. After gently spreading the spiral apart, insert one end and “walk” the remainder in a counterclockwise direction into the groove until the final end snaps into place. Some installers use fingers along with a small, flat-blade screwdriver; specialty installer tools are also available.

       Bottom Left: Check the initial cut (note the witness cut through the dye) for uniformity and concentricity.

       Bottom Right: Some LS cylinder heads have integral rocker pedestals; others require separate pedestal rails. This 5.3L LS features rocker rails. Hand snug a couple of rocker bolts to center the rail before fully tightening. Also, be sure to apply high-pressure assembly lube to all valve tips, rocker pushrod cups, and rocker valve tips.

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      CONTENTS

Acknowledgments

Introduction

Chapter 1: Flaw Detection

Sonic Testers

Hand-Held Magnetic Particle Testers

Wet Mag Bench Testers

Dye Penetrant

Pressure Testing

Chapter 2: Engine Blocks

Flaw Checking the Block

Decking the Block

Correcting Cylinder Bores

Oil Restrictors and Screens

Lifter Valley Surface

Rod and Crank Clearance

Oil Hole Alignment