4AGE Porting - OST-032: Skippy gets a head

[oldeskewltoy]

I've recently purchased a daily-able FX16 so I don't have to use Surreptitious(AE71) all the time...



I named the FX "Skippy", and knew upon purchase that it didn't run.



This is what was found when the head was pulled... something broke, and eventually got embedded - see arrow



So.... OST-032 is Skippy's new head!





stripped and ready for cleaning........





Can anyone tell me why one chamber is already clean????



More to come.....

[jondee86]

Because it steam cleaned itself, but the pics are not showing ??

Cheers... jondee86

[oldeskewltoy]

Because it steam cleaned itself, but the pics are not showing ??

Cheers... jondee86

not sure what happened to the pics originally... but I've fixed that....

blown head gasket, water jacket breach = steam clean. (?)

normally this would be a great guess....

Ignition failure in number one.
Un-burnt fuel soaked the chamber and over time it cleaned all the carbon off, I saw this once in a 4AFE head.

as is this.....

But in reality this was a VERY loaded question - apologies This chamber was the chamber used to make the chamber casting....








more to come......

[oldeskewltoy]

So Skippy's head is back from cleaning and pressure checking. The chamber depths and the seat depth all look VERY good. There is some excess material that was left behind after the head was machined @ Toyota, that will all get cleaned up :thumbsup:




It measures just about what an uncut head is suppose to measure - easily within the .001" tolerance of this caliper




Work begins on chamber/bowls of #4 cylinder





More to come....

[Ashh]

waiitt.... why did you need to take a cast/negative of one cylinder?

[roadsailing]

quick question from a total non porter:

in my levin and trueno bible it says one should remove the "joggles" from the head, does this just mean grinding off the rough bits in the casting? i'm probably going to have the head off mine soon (if I can't get the stick rope down the sparkplug hole trick to work) and want to give it a quick tickle, probably without taking the valves out for longer than it takes to do stem seals.

[oldeskewltoy]

waiitt.... why did you need to take a cast/negative of one cylinder?

For a different project... about 2 years ago. Did some chamber, and port casting

quick question from a total non porter:

in my levin and trueno bible it says one should remove the "joggles" from the head, does this just mean grinding off the rough bits in the casting? i'm probably going to have the head off mine soon (if I can't get the stick rope down the sparkplug hole trick to work) and want to give it a quick tickle, probably without taking the valves out for longer than it takes to do stem seals.

this is how I interrupt removing the joggles




To do this will require a complete dismantle of the head.... got to get it clean before it goes back in

[oldeskewltoy]

Work begins

and continues.......

@ cylinder #4....


deshrouding....





...and working the exhaust....





2 cylinders down,





2 to go.... more to come....

[roadsailing]

this is how I interrupt removing the joggles




To do this will require a complete dismantle of the head.... got to get it clean before it goes back in

pffft i'll just give it a good blow out with the air compressor

nah clean is the way to go, cheers!

[oldeskewltoy]

It's far easier to take the direct path......then the path with the bend



more to come.......

[oldeskewltoy]

It's far easier to take the direct path......then the path with the bend

bends are gone......




more to come....

[oldeskewltoy]

Now that the casting has been massaged... It'll go off to the shop on Monday to get its 3 angle, and have the head surfaced.

More to come....

[oldeskewltoy]

So... Skippy's head is back and it carries a fresh 3 angle valve job, and a minimal machining - .004".

I only had the head cut .004" so I could keep some of the deshrouding volume - target chamber volume of 36.5cc. I did this so I could keep the static compression high, but manageable @ about 10.7 to 1, and tighten the squish gap by about 20%

Specs 3.209" bore, 3.0315" stroke, .036 gasket, deck is .001 (under), piston volume 2/10 of a cc crown, with a 36.5cc chamber.

preparing to check chamber volume.... note the wooden shims under the head to get it at a slight angle





measuring chamber #1....




and the result......??????? Bullseye 36.5cc!!





The chambers are now perfect, Skippy's head is now ready for reassembly....




"Perfect"? It appears that chamber #4 is tight, or so it seems in the photo. It WAS a bit tight, I worked the chamber walls a little adding a 1/10 of a cc to the chamber.


This was a partial head when I began, the valves in this head were not originals to this head, so in this case although being re-assembled, I fully expect SOME dis-assembly of the valves for those needing to be tipped.

This was a partial head when I began, the valves in this head were not originals to this head, so in this case although being re-assembled, I fully expect SOME dis-assembly of the valves for those needing to be tipped.

I managed to get the intake set... a few thin shims were needed. the exhaust side is another story...

#1 valve, even with the thinnest shim I had was still a no pass, so I'm planning on taking a "big swing" @ the tip of #1... a few others are almost as bad....





more to come.....

[Celica RA45]

with all the work you have done ,wouldnt it be easier to just get 4 heads and digitize them on a cnc machine. get them all cnc ported and also the seats cnc d done would work out better than a hand port any day

[oldeskewltoy]

with all the work you have done ,wouldnt it be easier to just get 4 heads and digitize them on a cnc machine. get them all cnc ported and also the seats cnc d done would work out better than a hand port any day

likely... but then I'd be a couch potato....


With all the different kinds of casting flaws.... I doubt (don't know...) you could have only one CNC program..... BUT you might have a rough out.... and then hand finish. As head castings have gotten more consistent, CNC CAN be better... but as with anything computer controlled... it requires the correct inputs.

The race shop who does some of my valve jobs... still does everything by hand.... and no one makes more 4A power then they do..........