Head porting and relatives

[michaelovitch]

So i present here to you my project.

it's a d24tic from a totaled or junkyarded 900 wich came with a m90.

i bought it 100 euros on a website sales.

My goal is to improve the stock performance by porting and trying to adjust, lighten and find the better way to produce more power and mainly more efficiency with more or less quite stock components.

this engine will have to go in my 245 gl wich will have first a fully rebuilt d24 NA that i bought to a local engine shop owner who rebuilt it for his brother.

the 245

http://i685.photobucket.com/albums/vv215/michaelovitch/2.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/3.jpg


the tic just arriving (but pressure washed yet) from the cote d'azur.


http://i685.photobucket.com/albums/vv215/michaelovitch/DSCN2382800x600.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCN2384800x600.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCN2385800x600.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCN2374800x600.jpg


after a bit of stripping

http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF0788.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/aac2.jpg

The good thing is this engine was equipped with a new aftermarket head.
no cracks between valves and no play at all..:D

the cylinders are not stock bore and it's the third repair measurment that i found.
the cross hatch is beautiful but the engine is seized because it was outside in the moisture.
i just removed the head and i have to work on the "short block" to free it when i will receive my ebay engine stand.

[michaelovitch]

actually the head is off and fully nude time to grind a bit :)


i did this for doing the right job and seriously.


http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1060.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1061.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1062.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1063.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1064.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1065.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1066.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1067.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1068.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1069.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1070.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1071.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1072.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1073.jpg


i can clearly see where the crap foundry/machining remain is and the shape of the port i have to deal with

time some brainage and grindage then.

pics of the head and bottom end will follow as soon i will receive my stand

voilà for now !

[michaelovitch]

Here is a video of some preparation work on the head !

http://www.youtube.com/watch?v=rtKYe6Jkue0

[77volvo245]

You should ship me a M90 to me. Looks like you have a very nice start on your build. I have another D24t I would like to put in a clean 245 as well.

[michaelovitch]

You should ship me a M90 to me. Looks like you have a very nice start on your build. I have another D24t I would like to put in a clean 245 as well.


I could, but i think it's fawking expensive to send it in the US.:confused:

[Jason]

Very nice to see someone really taking their build to this kind of level. Interesting to see castings you made from the intake and exhaust ports. It agrees with what I found on my own head, that is most of the work to be done is right under the valve seat by blending out into the rest of the port. My engine really runs strong up top and I'm sure my port work help somewhat. What are the plans for the engine and car?

Jason

[michaelovitch]

My plans are ,for the car : to improve handling with bigger sway bar on the front mine is 19 mm only
install one in the rear because i've nothing there.
boxing the trailer arms front and rear
steelies to paint right
find thetys and paint black
a stereo


for the engine

port the head gasket matching
valve job homemade 2 angles +polish
lighten conrods and match them, light polish
check and change bearings pistons etc...
change gaskets
head match manifolds intake/ exhaust
ported turbo 'housing outlet is ugly)
adapt a bigger exhaust system
intercooler
electric fan
oil/water cooler from a golf 2 td (it's a rabbit for you i think)
ported oil pump outlet to have nice curves
and all the little things i will can find to improve "efficiency"

i have a rebuilt by a professional d24 na wich will go first so i will have a running car and time to make all those things


but first not to ruin the head when porting !

i fact i work on stock engine but to make it better with not too much money...

[Jason]

Sounds good, only thing I would be careful of is porting the exhaust too much, if you go too big you will loose velocity, from what I have found bigger is not better there. Also might want to think about a bigger turbo, the stocker is pretty small, exhaust housing especially. To take advantage of all that extra flow from the head you'll want a larger turbo with larger exhaust housing that can flow some air without all the drive pressure you get from the stocker. They tend to fall off around 4000 rpms thanks the small exhaust side. My engine pulls strong past 5k rpms untill it starts to defuel.

Jason

[michaelovitch]

yes about the exhaust port.

i will just match the gasket,from the gasket to the deep give a tiny conical shape to have a smooth transition but mainly work on the bias post bowl area wich is very ugly .
it slow down a lot the gaz i think.

the short side radius sucks too.:mad:


i don't know if i want a bigger turbo.
the ar of the stock is ridiculous (36) but it spool soon.
good for daily use.

what about your set up

it's a t4 hot side no ?
how does it work on response ?

[michaelovitch]

step two on the job !

gasket matching !

few pics and a video of the prep work before to use the grinder :p




http://www.youtube.com/watch?v=D1pw97nXxjU



http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1117.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1101.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1102.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1103.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1106.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1108.jpg

[michaelovitch]

Here two vids of the matching



http://www.youtube.com/watch?v=T9qnGqSZysY

http://www.youtube.com/watch?v=zKi0woQGvHQ



There are pics to show the improvement of such a work :

Before

http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1117.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1129.jpg


After

http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1132.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1130.jpg




It's the rough finish and some sanding will come when the bowl wil be clean.

[michaelovitch]

Some big cleaning on the bowl today and a modification on the runners to increase tumble

The exhaust ports are really a mess and had very sharp angles every where
what a shit !

it was quite long but now the short side radius is very smooth on the intake and exhaust ports.

the larger path next to the valve guide have been increasd for more tumnle effect but nothing spectacular however .

I plan on smoothing a bit the boob bump of the guide to have a smoother transition between the brass part and this bump it will help i think.

the vid :

http://www.youtube.com/watch?v=BKWLciOSLyY

[michaelovitch]

BEFORE

http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1092.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1095.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1097.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1098.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1099.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1100.jpg



AFTER

http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1134.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1136.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1137.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1139.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1140.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1143.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1149.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/DSCF1150.jpg


Need some sanding on intake and sanding polishing on exhaust now.


I can see clearly you are all exited by my thread so i will continue :rolleyes:

[VolvoForLife!]

Port matching the gasket means nothing, the manifold and head are what need to be matched.

[michaelovitch]

Yes !

Thank you to correct my mistake.
Thank you for the interest you show here for this thread.

[michaelovitch]

This is what it looks like inside now after some work.

http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1162.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1163.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1164.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1165.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1166.jpg
http://i685.photobucket.com/albums/vv215/michaelovitch/head%20porting/DSCF1167.jpg

[Jason]

Looks nice, pretty much the same thing I did on my engine build, and man does it run strong up top. Cant really say for sure how much it helped, since I went from a totally worn out engine to a fresh rebuild, but I'm sure it helped. You definently took it to another level with your port castings though... Looking forward to seeing the engine build.

Jason

[michaelovitch]

Looks nice, pretty much the same thing I did on my engine build, and man does it run strong up top. Cant really say for sure how much it helped, since I went from a totally worn out engine to a fresh rebuild, but I'm sure it helped. You definently took it to another level with your port castings though... Looking forward to seeing the engine build.

Jason

Thank you for your comment (I feel a little less alone now)

Like you i don't really know what it will do exactly until i dyno it.
I 've only driven a D24 NA with 100000 +miles few minutes so....

But i didn't do a so much sophisticated work with the castings
just to see where i had to go when grinding.
just some bathroom silicone, my smaller finger ,a brush and that's it.


i will make a post on the build and more precisely the short block with the conrods work, weight adjustment oil pump porting etc....

Thanks again for you comment.
the diaper industry thank you too:p

[DWL_Puavo]

When we replaced the cracked head from our LT truck, we had a replacement head from -92 which was obviously very low mileage (btw: the whole head with camshaft cost 150 euros in nearby city).

It was clearly better casting than our original head from -84. Valve and port sizes were the same, but manifold matched quite perfectly and it was much smooter also inside the ports. Also valve adjustment was just as it should.

...didn't notice any difference though, as the "performance" in LT is measured in minutes rather than seconds.