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Old 10-20-2013, 11:55 AM   #1
Karzza
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A Heavy Duty Engine Brace / Girdle

Like some of you have noticed I have been struggling for a while because of case walking .
190rwhp: stock engine, -> no problem
240rwhp: 10mm ARPs, a thin brace, ->a lot of case walking
270rwhp: 12mm ARPs, extra dowel pins, no brace, -> some case walking

As a next step I'm going to change all the M8 case bolts to ARP2000 studs and design a Heavy Duty Brace.
Member Mukle is again helping me with CAD design - thanks Mukle.

Also I would like to see your comments,
to create a perfect product for the purpose.
Open code again like with " The Plenum"
If there is interest we can produce a small series of them.
If no, we will do 1-2 pcs. This is just a hobby w/o a commercial target.

Let's start with the studs.
I desided to use ARP2000 material. Chrome Moly would be ok as well.
While clamping aluminium not so hard material needed.

Main stud's dimensions in case of largened M12 main threads.


...or by using stock M10 main threads:


The rest two M8 brace studs around primary gears:
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300rwhp, E85 fuel
Falicon +3/8" full circle, K1, ceramic CP 4.25" pistons
Pinned cases, ARP 12mm head and main studs
Jones cams, SuperAlloy valves, titan retainers, Ferrea springs
Turbo Garret GT2860R, water cooled, Tial-housing
16 Psi Tial waste gate, Forge BOV, Treadstone IC
Bosch 190lb/hr injectors, Wabro 330lph pump
Bosch 5bar fuel regulator
Daytona VRFIgen3 ECM, Delphi 3bar MAP.
11 plates carbon fibre, billet basket, billet lifter plate
Str cut 2nd,
K&M plenum and -brace
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Old 10-20-2013, 12:08 PM   #2
Karzza
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Here is the first draft of the Brace.
What do you think?

Material is some very strong aluminium.




Three threaded holes in front of it are for "an option".
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300rwhp, E85 fuel
Falicon +3/8" full circle, K1, ceramic CP 4.25" pistons
Pinned cases, ARP 12mm head and main studs
Jones cams, SuperAlloy valves, titan retainers, Ferrea springs
Turbo Garret GT2860R, water cooled, Tial-housing
16 Psi Tial waste gate, Forge BOV, Treadstone IC
Bosch 190lb/hr injectors, Wabro 330lph pump
Bosch 5bar fuel regulator
Daytona VRFIgen3 ECM, Delphi 3bar MAP.
11 plates carbon fibre, billet basket, billet lifter plate
Str cut 2nd,
K&M plenum and -brace
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Old 10-20-2013, 02:18 PM   #3
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just curious .. how come you just dont use one that has been made already Trask / Fitgerald / KSI all have them.. the plenum you designed was top notch so lets see what you can do.. again
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Old 10-20-2013, 02:53 PM   #4
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I think tight tolerance between the studs and brace are critical because any movement leave the brace useless.

Great idea by the way
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Old 10-20-2013, 03:30 PM   #5
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Quote:
Originally Posted by VrodG View Post
I think tight tolerance between the studs and brace are critical because any movement leave the brace useless.

Great idea by the way
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Old 10-20-2013, 08:21 PM   #6
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Very interesting.. Was that done in Solidworks?
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Old 10-20-2013, 08:32 PM   #7
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Karzza,

The KSI Engine Brace has holes in the center to allow the oil to flow through to get down to the pump quicker.

With yours and the other braces the oil will have to flow to the sides of the brace and then down to the pan.

I think if you added holes in the center it would be helpful.

rod
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Old 10-20-2013, 08:47 PM   #8
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Rod, it appears to have 10 hollowed out areas that go all the way thru it
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Old 10-20-2013, 09:29 PM   #9
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check the last pic no holes .
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Old 10-21-2013, 05:11 AM   #10
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Kari, the casing material is AlSi6Cu4, ARP bolt material has very different heat elongation propperties.
A possible solution to reduce the thermal elongation stress would be the use of bushes made of Fe65Ni35-Invar
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Old 10-21-2013, 06:37 AM   #11
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Quote:
Originally Posted by Jan-Dirk View Post
...use of bushes made of Fe65Ni35-Invar
Tell some more, what shape and size bushes do You mean?
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300rwhp, E85 fuel
Falicon +3/8" full circle, K1, ceramic CP 4.25" pistons
Pinned cases, ARP 12mm head and main studs
Jones cams, SuperAlloy valves, titan retainers, Ferrea springs
Turbo Garret GT2860R, water cooled, Tial-housing
16 Psi Tial waste gate, Forge BOV, Treadstone IC
Bosch 190lb/hr injectors, Wabro 330lph pump
Bosch 5bar fuel regulator
Daytona VRFIgen3 ECM, Delphi 3bar MAP.
11 plates carbon fibre, billet basket, billet lifter plate
Str cut 2nd,
K&M plenum and -brace
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Old 10-21-2013, 06:55 AM   #12
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Subscribed i see you are using billet oil pan as well i thought that would have kept it stronger as well
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Old 10-21-2013, 07:36 AM   #13
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Aluminium has approximately double the heat Expansion than steel, Invar has Zero.
My idea was to use longer screws in combination with invar bushes.
See thread https://www.1130cc.com/forums/showthread.php?t=81382 Posts 51 ff

edit: the Basic idea is to achieve a constant clamping force, the fretting of the casing halves is a design issue and not entirely caused by Turbo boost. also complete stock engines show the symptoms.
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Old 10-21-2013, 08:34 AM   #14
Karzza
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Quote:
Originally Posted by Ozracer View Post
...that would have kept it stronger as well
There is a flexible gasket between the pan and case. A Case walking or bending is just some 1/100 mm.
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300rwhp, E85 fuel
Falicon +3/8" full circle, K1, ceramic CP 4.25" pistons
Pinned cases, ARP 12mm head and main studs
Jones cams, SuperAlloy valves, titan retainers, Ferrea springs
Turbo Garret GT2860R, water cooled, Tial-housing
16 Psi Tial waste gate, Forge BOV, Treadstone IC
Bosch 190lb/hr injectors, Wabro 330lph pump
Bosch 5bar fuel regulator
Daytona VRFIgen3 ECM, Delphi 3bar MAP.
11 plates carbon fibre, billet basket, billet lifter plate
Str cut 2nd,
K&M plenum and -brace
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Old 10-21-2013, 11:00 AM   #15
Karzza
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A slightly improved and completed version.

At the moment it feels no holes needed in the Girdle becaus of oil return or crank chamber breathing.



ARP custom made studs are far too expensive
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300rwhp, E85 fuel
Falicon +3/8" full circle, K1, ceramic CP 4.25" pistons
Pinned cases, ARP 12mm head and main studs
Jones cams, SuperAlloy valves, titan retainers, Ferrea springs
Turbo Garret GT2860R, water cooled, Tial-housing
16 Psi Tial waste gate, Forge BOV, Treadstone IC
Bosch 190lb/hr injectors, Wabro 330lph pump
Bosch 5bar fuel regulator
Daytona VRFIgen3 ECM, Delphi 3bar MAP.
11 plates carbon fibre, billet basket, billet lifter plate
Str cut 2nd,
K&M plenum and -brace
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