OST-030: a case in point
05-07-2015, 09:29 PM
Post: #11
OST-030: a case in point
So with OST-031 now @ the machine shop getting its valve job and surfacing we delve back into OST-030


I've gotten the head back from the machine shop, they have provided a minimum resurfacing .003", to add to the previous clients report of a .008" resurfacing, the current surface is not quite @ .011, closer to .0102". This head is now 115.74mm thick, having had a total of .26mm removed.

Typically with a 10 thou cut you can expect chamber volumes to drop to about 35cc, the deshouding adds about .4cc, to gain volume I had the valve seats machined an extra .003" to gain 1cc in chamber volume, this lowers the valve on the seat allowing for a bit more volume in the chamber. The valve tips were cat an equal amount so use of more common shims sizes is retained.

[Image: AEU86 AE86 - OST-030: a case in point]

So right now the chambers sit @ 36.4cc (1/10cc tolerance)

[Image: AEU86 AE86 - OST-030: a case in point]

oldeskewltoy;6155985 Wrote:All the cam journals look pretty much the same as this...
[Image: AEU86 AE86 - OST-030: a case in point]

Since MR2tailbreaker noticed a "small" problem in his cam and journal clearances using the Poncams, I'll be checking these journals for similar issues.....

The FSM(BGB) states the cam to journal clearance to be .035mm to .072mm, with nothing greater then .1mm

[Image: AEU86 AE86 - OST-030: a case in point]


Using the Plastigage PL-X - The PL-X range is a bit on the tight side for measuring the whole range of the cam to journal - a bit too small for perfect accuracy, but in this case it works adequately.

[Image: AEU86 AE86 - OST-030: a case in point]

This is one of the measurements, you can see it is quite a bit narrower then .045mm which is middle tight of the span in the FSM.

By carefully surfacing the cam cap "feet" we can get this dimesion closer to the center of the specification

[Image: AEU86 AE86 - OST-030: a case in point]



Here is a 2nd journal going from a bit loose....

[Image: AEU86 AE86 - OST-030: a case in point]


to middle of the spec

[Image: AEU86 AE86 - OST-030: a case in point]


Of course the worst one I didn't get a photo of, that was #5 on the intake side... farthest from the oil supply, it was so loose that most of the Plastigage thread was intact when checked, and it too was brought into spec.


Now that the cam journals are all within tolerance, assembly can begin.....



More to come..... Hurray!

Dan -

You can |Sad .... OR you can ask for help!!!

OST Porting service - http://hachiroku.net/forums/showthread.php?t=19991
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05-08-2015, 03:48 AM
Post: #12
OST-030: a case in point
Showing off her angles....

[Image: AEU86 AE86 - OST-030: a case in point]


oldeskewltoy Wrote:Now that the cam journals are all within tolerance, assembly can begin.....


The head and hardware are all laid out, #1 cylinder already has the valves in....

[Image: AEU86 AE86 - OST-030: a case in point]


Now half assembled...

[Image: AEU86 AE86 - OST-030: a case in point]



sometimes during assembly you see something that you just don't like.... tossed the retainer on the left for the one on the right. There was no other damage, I just didn't like that kind of a flaw.

[Image: AEU86 AE86 - OST-030: a case in point]



Fully assembled... now whats left is setting the valve clearances, and getting it back to my client.

[Image: AEU86 AE86 - OST-030: a case in point]





More to come..... Hurray!

Dan -

You can |Sad .... OR you can ask for help!!!

OST Porting service - http://hachiroku.net/forums/showthread.php?t=19991
Find all posts by this user
05-12-2015, 04:46 AM
Post: #13
OST-030: a case in point
Valves @ full lift...

Exhaust....

[Image: AEU86 AE86 - OST-030: a case in point]


Intake...

[Image: AEU86 AE86 - OST-030: a case in point]

oldeskewltoy Wrote:Fully assembled... now whats left is setting the valve clearances, and getting it back to my client.
[Image: AEU86 AE86 - OST-030: a case in point]



Its packaged back in its case.... with the latch zip tied down...

[Image: AEU86 AE86 - OST-030: a case in point]
I heated the end of my punch a bit so I could get it to impress into the ziptie.

All that is left on this is shipping back to my client....

Dan -

You can |Sad .... OR you can ask for help!!!

OST Porting service - http://hachiroku.net/forums/showthread.php?t=19991
Find all posts by this user
05-13-2015, 06:19 PM
Post: #14
OST-030: a case in point
Well done Dan, still impressive despite the fact that I've seen it so many times.

AE86 ex-daily
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05-24-2015, 05:45 PM
Post: #15
OST-030: a case in point
oldeskewltoy Wrote:[Image: AEU86 AE86 - OST-030: a case in point]


All that is left on this is shipping back to my client....


Why I insist on insuring the finished product for its shipment back to it's owner......

[Image: AEU86 AE86 - OST-030: a case in point]



I've been told the head itself did not sustain any damage... but this shows significant intrusion.... so when I say the insurance adds $20, or $30 to the return shipping cost...

its just to COVER YOUR ASSets.

Dan -

You can |Sad .... OR you can ask for help!!!

OST Porting service - http://hachiroku.net/forums/showthread.php?t=19991
Find all posts by this user
05-25-2015, 08:09 AM
Post: #16
OST-030: a case in point
Damn, I do hope he gets some cash back for the case. Some people just don't have any respect for the property of others.

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05-25-2015, 07:56 PM (This post was last modified: 05-25-2015 07:56 PM by banpei.)
Post: #17
OST-030: a case in point
Whoa! Was that deliberate intrusion or just collateral damage by someone dropping the case from the third floor? Huh

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[Image: AEU86 AE86 - OST-030: a case in point]
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05-25-2015, 10:17 PM
Post: #18
OST-030: a case in point
(05-25-2015 07:56 PM)banpei Wrote:  Whoa! Was that deliberate intrusion or just collateral damage by someone dropping the case from the third floor? Huh
I guess it was just bad handling/dropping it in the sort facility/delivery guy

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