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Modern Engine Blueprinting Techniques: A Practical Guide to Precision Engine Building

Overview

Engines are built to fall within a wide set of standards and specifications, often not optimized to meet the original design. In short, cheap and fast engine production results in a sloppy final product. Of course, this is not idea for high-performance engines. To maximize the performance of any engine, it must be balanced and blueprinted to the exact tolerances that the factory should have adhered to in the first place. Four cylinder, V-8, American or import, the performance of all engines is greatly improved by...
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Modern Engine Blueprinting Techniques: A Practical Guide to Precision Engine Blueprinting

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Overview

Engines are built to fall within a wide set of standards and specifications, often not optimized to meet the original design. In short, cheap and fast engine production results in a sloppy final product. Of course, this is not idea for high-performance engines. To maximize the performance of any engine, it must be balanced and blueprinted to the exact tolerances that the factory should have adhered to in the first place. Four cylinder, V-8, American or import, the performance of all engines is greatly improved by balancing and blueprinting. Dedicated enthusiasts and professional racers balance and blueprint their engines because the engines will produce more horsepower and torque, more efficiently use fuel, run cooler and last longer.

In this book, expert engine builder and veteran author Mike Mavrigian explains and illustrates the most discriminating engine building techniques, so the engine is perfectly balanced, matched, and optimized. Balancing and blueprinting is a time consuming and exacting process, but the investment in time pays off with superior performance. Through the process, you carefully measure, adjust, machine and fit each part together with precision tolerances, optimizing the design and maximizing performance. The book covers the block, crankshaft, connecting rods, pistons, cylinder heads, intake manifolds, camshaft, measuring tools and final assembly techniques.

For more than 50 years, balancing and blueprinting has been an accepted and common practice for maximizing performance. An enthusiast or professional that invests the time to precisely build an engine in this fashion will be rewarded with an engine that will run strong and last for years. This book provides an unprecedented level of detail and instruction on the process of balancing and blueprinting your engine.

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Editorial Reviews

Midwest Book Review - Mike Bumbeck
"Modern Engine Blueprinting Techniques is a 'must' reference for any who would build high-performance engines blueprinted to exact tolerances, and comes from an expert engine builder who provides in-depth, step-by-step coverage of the topic. From measuring and machining within precise specifications to fitting parts together, optimizing designs and ordering and working with custom parts, this comes packed with color photos of parts and processes and is very specific in its instructions. Also included are insights on parts costs and their history and how affordability can be built into the process. The result is a powerful survey, highly recommended for any working with engines." -Midwest Book Review, March 2014
Midwest Book Review
"Modern Engine Blueprinting Techniques is a 'must' reference for any who would build high-performance engines blueprinted to exact tolerances, and comes from an expert engine builder who provides in-depth, step-by-step coverage of the topic. From measuring and machining within precise specifications to fitting parts together, optimizing designs and ordering and working with custom parts, this comes packed with color photos of parts and processes and is very specific in its instructions. Also included are insights on parts costs and their history and how affordability can be built into the process. The result is a powerful survey, highly recommended for any working with engines." -Midwest Book Review, March 2014
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Product Details

  • ISBN-13: 9781613250471
  • Publisher: Cartech
  • Publication date: 9/15/2013
  • Pages: 192
  • Sales rank: 622,717
  • Product dimensions: 8.40 (w) x 10.90 (h) x 0.50 (d)

Meet the Author

Mike Mavrigian is a veteran book author and certified member of the National Institute of Automotive Service Excellence. He is the editor-in-chief of Auto Service Professional. He also owns and operates Birchwood Automotive Group, which assembles project vehicles, builds custom engines, and performs restorations.
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Table of Contents

Acknowledgments 5
Introduction 5
Chapter 1: Flaw Detection 8
Sonic Testers 8
Hand-Held Magnetic Particle Testers 9
Wet Mag Bench Testers 10
Dye Penetrant 10
Pressure Testing 11
Chapter 2: Engine Blocks 12
Flaw Checking the Block 13
Decking the Block 14
Correcting Cylinder Bores 16
Oil Restrictors and Screens 16
Lifter Valley Surface 17
Rod and Crank Clearance 17
Oil Hole Alignment 19
Threaded Holes 19
Chapter 3: Block Machining 20
Main Bore Align Honing 20
Deck Resurfacing 22
Cylinder Honing 23
Cylinder Boring 23
Plateau Finishing 27
Cylinder Bore Distortion 27
Lifter Bores 29
Hot Honing 29
Camshaft Bore 30
Chapter 4: Oiling Systems 31
Wet Sump Systems 31
Dry Sump Systems 34
External Oil Coolers 37
Oil Restrictors 37
Oil Drainback 37
Intermediate Shaft 38
High-Pressure High-Volume Pumps 38
Pre-Lube Before Initial Startup 39
Chapter 5: Engine Math 40
Bore and Stroke 40
Connecting Rod Length 41
Rod Ratio 43
Piston Compression Height 46
Compression Ratio (part 1) 46
Combustion Chamber Volume 47
Piston Dome Volume 47
Head Gasket Volume 48
Deck Height Volume 48
Cylinder Swept Volume 48
Compression Ratio (part 2) 48
Chapter 6: Crankshafts 49
Crankshaft Types 49
Surface Hardening 51
Reducing Rotating Mass 51
Inspection 52
Stroker Clearance 53
Shot Peening 57
Stress Relieving 57
Counterweight Modifications 59
Cross Drilling 59
Chamfering Oil Holes 59
Chapter 7: Connecting Rods 60
Rod Types 60
Center-to-Center Length 65
Piston-to-Rod Clearance 65
Rod-to-Block Clearance 65
Rod-to-Camshaft Clearance 65
Rod Bearing Clearance 66
Rod Side Clearance 66
Beam Design 67
Rod Bolt Tightening 67
Connecting Rod Inspection 74
Chapter 8: Pistons 75
Performance Pistons 75
Piston-to-Wall Clearance 77
Piston Diameter 78
Piston Skirt to Crankshaft Clearance 78
Coatings 78
Piston Pins 78
Ring Grooves 80
Piston-to-Head Clearance 80
Piston-to-Valve Clearance 81
Piston Compression Distance 82
Compression Ratio 82
Deck Height 82
Gasket Volume 83
Piston Dome Volume 83
Combustion Chamber Volume 84
Valve Pockets 84
Ordering Custom Pistons 85
Chapter 9: Piston Rings 92
Ring Types 92
Tension and Gap 94
Piston Ring Trends 95
Determining Ring Depth 98
Ring Installation Methods 98
Chapter 10: Camshafts 99
Cam Types 99
Protecting the Cam 101
Cam Runout 102
Cam Endplay 102
Degreeing the Cam 102
Adjusting Cam Timing 105
Lobe Separation Angles 105
GM LS Cam Lifters 105
Special Firing Order Camshafts 106
Camshaft Needle Bearings 107
Distributor Gears 108
Chapter 11: Cylinder Heads 109
Cast Iron versus Aluminum 109
Deck Surface Finish 111
Deck Flatness 112
Valves 112
Ports and Runners 114
Finishing Bare Cylinder Heads 115
Inspection and Reconditioning 117
Flow Bench Testing 119
Cylinder Head Installation 120
Chapter 12: Valves, Springs, Retainers and Locks 121
Valve Inspection 121
Valve Seats 122
Performance Valve Technology 124
Valvesprings 127
Retainer Fit 130
Valvespring Seats 134
Retainers and Locks 134
Chapter 13: Rocker Arms 136
Rocker Arm Ratio 136
Guideplates 137
Roller Rockers 138
Rocker Arm Materials 141
OHC Followers 141
Valve Cover Clearance 141
Upgrading OEM LS Rocker Arm Trunnions 142
Chapter 14: Pushrods 145
Check for Runout 145
Pushrod Length 145
Guideplates 151
Pushrod Diameter 151
Pushrod Wall Thickness 152
Pushrod End Types 152
Clean the Pushrods 152

Chapter 15: Intake Manifolds 153
Manifold Types 153
Port Matching 155
Intake Plenum 156
Intake Port Surface 159
Manifold Bolts 159
Converting LS to Carb 161
Manifold Surface Protections 161
Carb Spacers 164
Chapter 16: Balancing 165
Internal versus External Balance 166
Weight Matching 166
Bobweights 167
Balancing Procedures 170
Chapter 17: Timing Systems 172
Chain Drive 172
Belt Drive 173
Gear Drive 175
Chapter 18: Engine Performance Coatings and Treatments 177
Coating Types 177
Cryogenic Stress Relief 180
Vibratory Stress Relief 182
Hard Cylinder Coating 183
Source Guide 185

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