OST-026: "My White Hatch"

[oldeskewltoy]

Hmmmm, seems like no one in the PacNW has any smallport heads they want to sell???? Really??? http://hachiroku.net/forums/showthread.php?t=35564

I'd ask my aeu86 brethren... but the freight would make it too costly


ANYWAY....... so this one came out of deep dark storage....






In the mean time, I thought I'd carry this post from OST-025 into this thread...

Cliff's notes - OST-025 is a Mazda/Ford 2.2 head from the late 80s, early 90s
http://i79.photobucket.com/albums/j143/o...ef218e.jpg
http://i79.photobucket.com/albums/j143/o...c5ec4d.jpg
http://i79.photobucket.com/albums/j143/o...46637d.jpg

from another forum and thread Wrote:OST, you should do a thread detailing the steps and exact tools/methods you use to port the heads! It'd be an invaluable DIY tool for those of us who are aspiring to port things as well.

same forum... Wrote:As much as I'd love for this to happen, I gotta imagine it's about the same as asking a Magician to reveal his secrets.

Still, for the dyi type there's plenty of tutorials out there to learn from.

I believe I've shared most of the basic tools before... flex shaft Dremel (I'm into my 5th :roll: ) sanding drums... high speed metal cutters, and select grinding stones. I believe I've also shared the procedure, and materials for getting the chambers just right too - I seem to remember Max, from Illegal Garage asking a number of heads ago

It is quite a bit more than the tools, it is the persons ability to properly manipulate the tools for the desired results, look back to OST-017, that began as another persons attempt @ porting... http://i79.photobucket.com/albums/j143/o...orting.jpg

Besides being able to manipulate the tools, I also have a substantial amount of knowledge I've gained from extraordinary sources (cough... Loynings...) that allows me to know the difference between porting, and cylinder head lightening :lol:



A few more pics...

prior to dis-assembly....




and after....




Still kinda nasty.... but the cam journals show no gouging...


an intake view...





and one of the exhaust





By the way... Arie....you were in deed correct, this is an uncut head...






To see the car build - http://club4ag.com/forums/viewtopic.php?f=7&t=1486




More to come..... :mrgreen:

[robokill]

good looking Corolla. Looks nice and seems to be in a good state, Ever resprayed ?

[oldeskewltoy]

robokill Wrote:good looking Corolla. Looks nice and seems to be in a good state, Ever resprayed ?

It isn't actually my car... I put My White Hatch inside of "", hoping you'd get the connection to the actual owners car... my bad


I got the head back from it being cleaned... even a good cleaning makes it look better...


Chambers....




exhaust ports...



These look pretty good... there is enough meat on the port roofs to allow me to get a good shape to them.


intake ports...




Lets look at those intake short radius's.... (1 on right, 4 on left)





Hmmm, and on closer inspection...

cyl 1...


cyl 2...


cyl 3...


cyl 4...




I'll be earning my fee on those....... :lol:


More to come.....

[oldeskewltoy]

Well... the first task for me is always deburring the head. I do this first for a simple reason... I'll be handling this head quite a bit, and if I remove all the casting flash, and machined edge sharpness, I'll be doing my hands a big favor.....


Below are a couple of 2 panel, before and after of the deburring process.



Above is the last four bucket cylinders, and last 2 cam journals (#4 and #5) on the exhaust side of the engine.


And here are the first 4 bucket cylinders and cam journals #2 and #3 for the intake cam




More to come.....

[oldeskewltoy]

oldeskewltoy Wrote:Hmmm, and on closer inspection...

cyl 1...


cyl 2...


cyl 3...


cyl 4...

So... any opinions as to which one is the worst???

[krullibull]

Hmm. Number 3 looks to be worst from the photos but just becasue of that I'm going to say number 2

[oldeskewltoy]

krullibull Wrote:Hmm. Number 3 looks to be worst from the photos but just becasue of that I'm going to say number 2

Reminds me (your indecision) of an old "Let's Make a Deal" (Monty Hall era)....



"Well, contestant, your first instinct was correct, you should have stuck with chamber #3........"

"oh Monty..."


The reason I chose #3 was the factory machining mark came right to the edge of the seat, it had a big nasty under cut in the port floor, and the splitter was poorly machined covering a big part of the seat.



Besides the bowl work... can anyone tell me what else I did that isn't inside the bowls?



Once I managed to get the bowls, and short radius worked out, it was time to begin the port work...



Look past the short radius, into the port. The left side has been reshaped, note the light line from port face to the guide. The right side I've not yet touched, and you can see the "pocket" in front of the guide that I have yet to "excavate"





All the rough work has been finished on the left(#3), you can see the bowl walls are beginning to blend into the port, the bowls, seats and ports on the right(#2) are still untouched.

oldeskewltoy Wrote:I'll be earning my fee on those....... :lol:

nearly 6 hours worth of work on #3's seats, bowls, and port.



More to come.....

[Ivan141]

Quote:Besides the bowl work... can anyone tell me what else I did that isn't inside the bowls?

I spot a deburred/smoothed edge to the sparkplug hole.

[pack]

Amazing work....

[oldeskewltoy]

from another forum Wrote:Looks great, thanks for the pictures and the nice explanations!

I try... besides, I enjoy doing it

pack Wrote:Amazing work....

You make me blush...

Ivan141 Wrote:

Quote:Besides the bowl work... can anyone tell me what else I did that isn't inside the bowls?

I spot a deburred/smoothed edge to the sparkplug hole.

correct! You can see it again in chamber 4 below


And here are the short radius's of intake 4, as above... before on top





Besides the short radius's, I'm also working the intake ports themselves. intake port 4 in mid "excavation"






and after roughing to size... a bit more work left....







another OST 2 panel... 2 down... 2 to go





One of the problems with the 16V 4AGE design is the ports are horizontal. Being horizontal, the air/fuel charge must make a pretty significant turn to reach the back of the valve. In the diagram below you can see what I'm talking about



Both the newer 4AF/7AF port, and the Formula One port are NOT horizontal, this allows for more cylinder filling, and therefore more power potential.

I borrowed the 4AG part of that diagram, enlarged it, and in typical OST fashion I've created a 2 panel that hopefully will show why I work the port roof.... In essence, I've adjusted the port roof a few degrees, this will assist the air/fuel charge to have an easier time making the bend, because adjusting the port roof the way I have is allowing the air/fuel charge to have a shallower angle to get to the valve... only a few degrees... but it all helps!




Now, away from diagrams and to real life....








More to come......