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Thread: engine porting

  1. #1 Thumbs up engine porting 
    Join Date
    Jun 2007
    Location
    mannhiem, Germany
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    44
    FIRST OF ALL DO THIS AT YOUR OWN RISK. I DO NOT HOLD ANY REPONSABLITY FOR AND DAMAGE YOU DO TO YOU ENGINE. BUT THIS WILL HELP ALL OF YOU PORT A ENGINE AND MAKE ABOUT TWICE THE POWER YOU ARE NOW.
    --------------------------------------------------------------------------
    Because of on going requests for something more step by step
    I followed my porting tasks today by taking photos so you can see the sequence.

    This engine utilizes all the porting tricks talked about on earlier threads, without going crazy on making massive size ports requireing a LOT more effort.

    Degree of work should be fairly easy for a novice too do :rolleyes and those who want to do more servere cutting ?? Visit the F.A.Q's or grafics area for related threads and see how WILD you can go.

    Enjoy

    This first photo, the tooling marked 1 thru 4 ..... And referanced at each photo to one used.

    #1) a 1/2" eliptical on 1/4" shank
    #2) a 1/4" ball end cylinder
    #3) a 1/4" ball on 1/8" shank
    #4) a 1/8" ball end cylinder
    All being CARBIDE with chipbreaker profiles.
    engine porting

    engine porting

    This shows 3 steps, 1st being the transfer bridge has been cut down @ 1/2" from cylinder base.(In a mill) 2nd the eyebrow cut made to transfer window facing intake port.(cutter #3) 3rd a vertical cut made to meet eyebrow so entire vertical edge of port can be opened up & blended into eyebrow area.(cutter #2)

    engine porting

    This photo the intake side transfer runner all cut and blended into eyebrow. (blended in with cutter #4)

    engine porting

    The shortened transfer passage bridge is sharpened. (cutter #4)

    ***** This next step DO WITH CAUTION !! ... If unsure you can be VERY steady & use the right cutter, Omit this step & leave Ex side transfer passages alone *****

    engine porting

    engine porting

    Now we have moved to the Exhaust side transfer passages & cut out the EX edge of upper transfer area to increase the width (This done with a 1/4 ball end cylinder (cutter #2) Keep cutter against outside area of transfer passage so the radious of the cutter makes an undercut edge that maintains the flow away from ex port. ( See above *****)


    engine porting

    Now the intake window, raised slightly next to ring nub & widened to give @ 1/8" sealing edge width. (cutter #2)

    engine porting

    The otherside of intake port, just widened. (cutter #2)

    engine porting

    View once intake port was cleaned up and finished. (cutter #2 & #4)

    engine porting

    engine porting

    Stock exhaust port & once modified to @178 degrees. (cutter #2)

    engine porting

    .002" cut made on top of piston (Total of .004" of diameter)

    engine porting

    V shape cut out to increase area, also 1/2 of lightening process removing materal that would support a second ring. Other side not done yet. (cutter #2)


    engine porting

    Area outside of pin boss area cut to force flow outward into transfer passages. (cutter #2)


    engine porting

    A stock cylinder shown above ... below the modified one.


    engine porting

    The finished cylinder having had ALL the finishing blending work done & port edges chamfered. (cutters 2,3 & 4) Port chamfering done by hand with 220 then 600 wet dry paper.

    engine porting


    Crankshaft Turbo mod, shown with a stock one. (1" belt sander)


    engine porting


    Close up of the finished turbo crank mod.


    engine porting


    The crankcase done like this on both halfs (cutter #1)


    engine porting


    How cases look with crank installed. ( view is crank position 90 degrees BBDC)

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  2. #2 Default  
    Join Date
    Jun 2007
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    mannhiem, Germany
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    engine porting


    Crank position just BBDC (Note : factory ramps in cases left there & for GOOD reason) ramps dirrect charge up Ex side transfer edge.


    engine porting


    The intake manifold opened up to match cylinder & carbs end opened up to .625" diameter. (cutter #2)


    engine porting


    A pile of chips from this job thats 1/4" deep and bigger than a silver dollar !! @ 2 1/2" around ( .50 cent shown :lol )

    Thats all folks .... Have fun

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  3. #3 Default  
    Join Date
    Mar 2007
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    Strathmore, Alberta
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    Real Name
    Mike
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    That's a great description of how to port! Thanks Frenchy!

    FG Leopard
    FG Monster Beetle 4x4
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  4. #4 Default  
    Join Date
    Feb 2007
    Location
    Goodwood, Ontario
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    Im just thinking to myself how many motors I would have to blow up until I got it right.

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  5. #5 Default  
    Join Date
    Feb 2007
    Location
    Campbell River, BC
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    Real Name
    Clayton
    I'm thinking send it to Frenchy LOL!!!

    I like the step by step and I like the bearing mod.. GREAT information

    We have stuck the thread.

    Clayton
    Vertigo Performance


    http://5thscaleracing.com/vb/image.php?type=sigpic&userid=11&dateline=117807681  9
    Vertigo Easy Access Clutch Unit, The absolute quickest way to access the HPI Baja clutch.
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  6. #6 Default  
    Join Date
    May 2007
    Location
    S.E.Michigan
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    7
    Ok I have to ask.Since thats a 4 bolt cylinder from ? and the ports are very different from the Zen and CY 2 bolt set ups are you saying that this mod is transferable to the 2 bolt heads?
    The ports on a 2 bolt are off center and the transfer ports are alot different than whats being posted above.
    You can see from these pics they are very different.
    engine porting
    engine porting
    And this is a Cy 36mm that has been modified
    engine porting

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  7. #7 Default  
    Join Date
    Jun 2007
    Location
    mannhiem, Germany
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    44
    Yes this will work with the engine you have in the pictures. The engine is a G260PUM zenoha. The only differance is that it is water cooled and the G260RC is air cooled. This mod will work if you do it. I have 4 G260PUMs engines and 2 G260rc motors and they look the same on the inside and they will bolt to the other and run the same. Also the CY is just a copy of the zenohas and they look about the same inside.
    Cheers
    Mike

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  8. #8 Default  
    Would you happen to have a pic of one of your 2 bolt Zens you could post.I'm also very interested.
    Thanks TT

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  9. #9 Default  
    Join Date
    Feb 2007
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    1,195
    I'm going to try these mods on my stock xrc engine... that way if I do screw it up, im not losing much

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  10. #10 Talking  
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    Jun 2007
    Location
    mannhiem, Germany
    Posts
    44
    Great
    I hope it works out good for you. Let us know how you work out with it. I will get the pictures asap posted here.
    Mike

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