cylinder head print?

[lord_verminaard]

Fabrication forum at VWVortex, thread is called "DIY guide for casting parts" and he's doing a lot of amazing stuff.  He is planning on casting his own cylinder head at some point.  Just something to keep an eye on.  I doubt he will consider making other types of heads but if he can do it with the types of equipment (basic stuff) he is using, then anyone else who has the skills could probably do it too.  It's a LONG thread but worth every minute of reading.

Nothing wrong with some Chinese stuff.  They are leading the world in mass-produced forging and casting.  Of course some of it is junk too, but any one of us could have a complete cast part drawn up and designed, we could send the design to a foundry in China and have a part in our hands in no-time.  034 Motorsport is having a foundry in China make some of their turbo manifolds.  Only way they could keep costs down and still get a quality part make to their specs- I've got no problem with that.

Building the inner molds will be the hard part, especially when taking into account the shrinkage of the casting- other than that, the casting itself will probably be very inexpensive.  The final machining on the other hand, will be quite expensive and that's something you would probably want done in an English-speaking country. 

Brendan

[Rabbit on Roids]

that would be the way to do it, get them cast in china, and machined right here at home..

[macka]

If you sent them a head, I bet they'd start knocking them out machined and all and ebay them, after you you had your order filled. On a side note I emailed the company my cousin used to get coolant jackets made to his spec.

[tSoG-84bit]

well, I think this is far beyond my skillset or timeframe, but... I planned on putting a small machine shop in the barn, might as well add a smelter to the list of things to buy/build/have.

out of curiosity, but a little off topic, unless I'm mistaken, it would simplify the design to create a waterjacketless head would it not? my cousin and I have tooled around with building a drag rabbit, and rather than fill in the waterjacket to strengthen the head, would it be of any benefit to remove it from existence entirely? does anyone run a waterless VW diesel? I've got way too many projects right now to even consider an attempt at this, but with my neighbors help, (he does this with tons of steel at a time for a living) we may be able to make something happen, eventually...

[NintendoKD]

very cheap and easy to build
http://www.corvusmoon.com/kiln.htm
there is some other neat stuff for free bouncing about the internet, as well as the fellow on the whoretex who is forging his own parts "AMAZING THREAD!"

[NintendoKD]

I would build my own but I live on a military installation on borrowed land and the rules state that building a smelter in ones backyard is not bad..... just frowned upon.  I love my free A/C so naturally I follow the rules.

[rabbitman]

well, I think this is far beyond my skillset or timeframe, but... I planned on putting a small machine shop in the barn, might as well add a smelter to the list of things to buy/build/have.

out of curiosity, but a little off topic, unless I'm mistaken, it would simplify the design to create a waterjacketless head would it not? my cousin and I have tooled around with building a drag rabbit, and rather than fill in the waterjacket to strengthen the head, would it be of any benefit to remove it from existence entirely? does anyone run a waterless VW diesel? I've got way too many projects right now to even consider an attempt at this, but with my neighbors help, (he does this with tons of steel at a time for a living) we may be able to make something happen, eventually...

So it wouldn't be a daily driver then..........I'd want water cooling.

[Rabbit on Roids]

a solid head on a diesel would be alright, but it would be nothing more than a drag car. plain and simple. it could run for mno more than like 5 minutes at a time, max. the head is the part that absorbs the most heat. those prechambers get REAL HOT.

[NintendoKD]

yeah kinda need a water jacket of some kind

[Smokey Eddy]

My noggin tells me that a beast of a diesel would be a 24 valve V6 tdi alluminum top & bottom all cast as a single piece - with water jackets...
you would have to install the valves with a grippy arm tool from the bottom of each of the cylinder sleeves.
throw some titanium con rods, pistons [ceramic coated of course], crank, valves[also ceramic] and you've got an interesting mix.
Include computer controled pnematic valve train (like in a formula 1) and you've got a VERY interesting mix. Also, no timing belt.
Also, be sure to include room for an injector nozzle that would inject distilled water, no2 and LPG (or LNG) all through the same nozzle - beside the diesel injector.
Direct injection for both the main accelerant (diesel) and water,no2 and LNG/LPG.
Something worth mentioning would be that it would be a dry sump and twin charged with big VNT's. Hopefully the h20 would keep the EGT's in the realm of the VNT's.
if not, a supercharger and a larger turbo, like a T3/T4, would be suitable. Perhaps bigger than a T3 actually.
all that lng, no2 and water might even call for an HY35. perhaps even an HX35.
my 2 cents.  

I should also include that the manifolds would all be equal length runners, plenums for the intake and ram horn style exhaust equal length headers for ideal turbo spooling.
I would also like to point out that this would fit somewhat easily in any MK4 with the AC removed and a AWD tranny.
and as for intercooling i think liquid nitrogen could be a suitable heat soak to add into the intake mix OR a FMIC or water to air IC.

[ShoulderMan]

That would be nice, very nice...
  But I think ill have a hard enough time paying for the iron head for now.

 Speaking of which,  what kind of figures do you think we are looking at. 1K, 1500, 2K each?

[macka]

That would be nice, very nice...
  But I think ill have a hard enough time paying for the iron head for now.

 Speaking of which,  what kind of figures do you think we are looking at. 1K, 1500, 2K each?

If all goes well maybe 500 USD per, possibly less if plain jane cast is used.

[catlin_cava]

Hopefully that AAZ head I sent you will come in handy for something more then a paperweight lol

[NintendoKD]

already waaaaaay ahead of ya   I just knew it would come in handy, if I kept it around.  "now  what do I use for a paperweight?"

[catlin_cava]

I think maybe I could come up with something else if you want other paperweight lol. Wait a few months I may have an ABA motor thats going to be junk lol