NorthloopCup likes a challenge, right?

[NorthloopCup]

Well it’s update o’clock!

Cylinder head is now fully assembled and ready for the shimming. Just to reiterate, I f**king HATE BUILDING CYLINDER HEADS. PIECE OF s**t COLLETS BOIL MY URINE.
Now that’s out of the way I’ll bang some pictures up. Lol!
Nicely lapped valves - you’re looking at the grey area on the valve head if you’re not sure which bit to look at

And here we have a mirror image of the grey area on the valve seat.

Fully assembled cylinder head.

And now for something a little different............

So remember I said we needed to sort a cam sensor pickup and mount? Well here’s the 3D printed mount for the sensor pick up.
I think it’s safe to say, it’s a first.

As are the R8 coils on an f4r I think?

More to come.

 

[massivewangers]

Did I miss this, but why are you running the cam sensor like that?

 

[NorthloopCup]

Did I miss this, but why are you running the cam sensor like that?

You didn’t miss is mate. Everywhere else location wise looked/looks s**t, and that included using the cam pulley as a pickup. This works better for our application as the cams don’t have the horseshoe slot.

 

[youngarthur]

I spent many hours in my youth, lapping in valves, and If I has £1 for every collet that pinged past me, never to be seen again, plus several permanent scars around my eyes?. AH the good old days.

 

[frayz]

Lol, I’m sure you guys all know, but to those who don’t.
Grease on the valve collet grooves should stick the collets in and hold them firmly in place when releasing tension on the springs compressor.
(prototype engine build engineer for 15 years)

Nice lap job fella

 

[NorthloopCup]

Lol, I’m sure you guys all know, but to those who don’t.
Grease on the valve collet grooves should stick the collets in and hold them firmly in place when releasing tension on the springs compressor.
(prototype engine build engineer for 15 years)

Nice lap job fella

That’s exactly how I go about doing them mate! Lol! It’s still a f**king spiteful job!

Cheers!

 

[frayz]

That’s exactly how I go about doing them mate! Lol! It’s still a f**king spiteful job!

Cheers!

I guess I was spoilt as I used to use a compressor like this for 99% of my builds.

 

[NorthloopCup]

I guess I was spoilt as I used to use a compressor like this for 99% of my builds.

View attachment 1453685

Nice!

 

[NorthloopCup]

Lockdown update!

Cylinder head shimmed up.

Bring on the trumpets!

Got the lower part of the inlet manifold to match up with the spacers.

And..............f**k off the trumpets!!

What we have here are some 3D printed one-off custom designed inlet trumpets. EVERYTHING in the simulations points towards improvements to air flow. But, as with everything - the proof is in the pudding.

And to finish off, here’s the beginnings of the airbox design. Just the secondary injector mounts to add in.

Enjoy!

 

[Louis]

Lockdown update!

Cylinder head shimmed up.

Bring on the trumpets! View attachment 1466962View attachment 1466964

Got the lower part of the inlet manifold to match up with the spacers.

And..............f**k off the trumpets!!View attachment 1466965View attachment 1466966View attachment 1466968View attachment 1466969

What we have here are some 3D printed one-off custom designed inlet trumpets. EVERYTHING in the simulations points towards improvements to air flow. But, as with everything - the proof is in the pudding.

And to finish off, here’s the beginnings of the airbox design. Just the secondary injector mounts to add in. View attachment 1466976

Enjoy!

Would the plan be to have these 3D Printed in steel eventually?

 

[NorthloopCup]

Would the plan be to have these 3D Printed in steel eventually?

No mate. They’re printed in fuel resistant plastic, so there wouldn’t be any need

 

[Louis]

No mate. They’re printed in fuel resistant plastic, so there wouldn’t be any need

Will you come under any issues with the 3D Print not being gas tight? Or are they being sealed too? Interesting seeing them being used for this!

 

[NorthloopCup]

Will you come under any issues with the 3D Print not being gas tight? Or are they being sealed too? Interesting seeing them being used for this!

Tbh mate they don’t need to be gas tight in that area as they’re before the throttle body

 

[DanMateX]

tasty, will be watching with a keen eye.

do you have a car lined up for this to all slot into?

 

[NorthloopCup]

tasty, will be watching with a keen eye.

do you have a car lined up for this to all slot into?

Yes mate it’s going in a mates race car. I’m just the engine builder

 

[NorthloopCup]

Forgot about these little bits

So we have had a re-design of the cam sensor. I was concerned that the pick up trigger wasn’t going to be large enough. This led to what we now have for the sensor - same position on the end of the cam, just in a different orientation.

Don’t worry! That’s not the finished item. It’s been part 3D printed to check fitment/clearances.

As you can see, it’s improved the surface area which will definitely help the ecu read the signal.

And to finish off we have these little 3D printed spacers for the Audi RS coils that this engine will be running.

Engine building will commence in the coming weeks.

 

[NorthloopCup]

Lockdown update #2

I needed to calculate the compression ratio just in case any adjustments were needed, and it will also be needed come mapping time.

So here’s a few pictures taken during the calculations for the cylinder cc. Working it out is a bit of a pain with the dome of the piston protruding out the top of the block, but a bit of maths and she’s reet! Couldn’t find my plexi glass, so I had to improvise lol! It did the job though!

Here’s some pictures:

Armed with the necessary measurements I made the calculations for the comp ratio. End result is a nice and lively 12.9:1

After that it was time to start pulling it apart to as it will be rebuilt with liberal amounts of graphogen. As you’d expect, here’s some pictures!

N
No oil squirt jets in there!

And the 2 ring pistons with Saenz long rods. How long the pistons will last I don’t know, but I can get them custom made to have 3 rings as and when the time comes.

Wallop!

 

[1985michael182]

What's the picture with the plastic over the cylinder?

 

[Radugns]

What's the picture with the plastic over the cylinder?

Plexi glass to can measure the volume at block surface.

 

[1985michael182]

How?

 

[Radugns]

Seal the plastic on the bore and add oil through a hole. You measure the volume of inserted oil.

 

[NorthloopCup]

How?

You’ll have to google it mate! It’s a simple task of measuring fluid volume in cc’s, a bit of maths and you have your answer.

 

[1985michael182]

Ok I get it now

 

[YorkshireKyle]

If you wanna know this stuff then watch the vid ETCG did with Kalvinator engines. They explain everything to do with measuring bore/compression/cc

Same with the TSF and John, they did a vid too. The vid might be an hour-long but it feels like 10 mins when you're engrossed haha

 

[incy-spider]

This pic makes my eyes go funny!


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[Dr HMS Derv Destroyer]

View attachment 1467806
This pic makes my eyes go funny!


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In the fact there’s a smiley face on the floor ( looking directly between the crank )

 

[NorthloopCup]

Lockdown update #3

Had a spare hour this afternoon after the wife took over from daddy daycare, so went in the garage to get the block pulled apart.

Here you can see the oil squirt delete better, and we also have some improvements to the block in terms of reducing crankcase pressure.

And a couple of randoms.

Angle grinder fun coming up soon as the block needs modifying for the dry sump setup.

More to come.

 

[NorthloopCup]

Lockdown update #4

Block attacked with the angle grinder and the dry sump setup now fits like a charm.

More to come.

 

[Chambers_RS]

Lockdown update #4

Block attacked with the angle grinder and the dry sump setup now fits like a charm.
View attachment 1468612View attachment 1468613View attachment 1468614View attachment 1468621View attachment 1468626View attachment 1468627View attachment 1468630View attachment 1468634

More to come.

I want!!

 

[NorthloopCup]

I want!!

Good luck. The kits are incomplete and that means either sourcing the oil pickup pipe, or fabricating one.

 

[Hazza462]

Awesome work so far, very jealous of the engine spec was speaking to Tom the other day about it.

Is that external machining of the block the only 'modification' required to fit the dry sump setup then, or is there more internal work needed like blocking off galleries etc? Reading this has made me want to get mine fitted!!

 

[NorthloopCup]

Awesome work so far, very jealous of the engine spec was speaking to Tom the other day about it.

Is that external machining of the block the only 'modification' required to fit the dry sump setup then, or is there more internal work needed like blocking off galleries etc? Reading this has made me want to get mine fitted!!

Cheers mate. Lol I don’t think there’s a day that goes by that I don’t speak to Tom tbf!

Yeah there’s a hole or 2 that needs blocking off mate, but I’ll be covering that through the build process. At least people will be able to see what the craic is when fitting one.

 

[Hazza462]

Cheers mate. Lol I don’t think there’s a day that goes by that I don’t speak to Tom tbf!

Yeah there’s a hole or 2 that needs blocking off mate, but I’ll be covering that through the build process. At least people will be able to see what the craic is when fitting one.

Perfect that was gonna be my next question haha, look forward to seeing those thankyou very much!

 

[Eddie555]

Cheers mate. Lol I don’t think there’s a day that goes by that I don’t speak to Tom tbf! [emoji23]

Yeah there’s a hole or 2 that needs blocking off mate, but I’ll be covering that through the build process. At least people will be able to see what the craic is when fitting one. [emoji1303]

I know for sure that the pipe coming out of the water pump will need modification as it will be obstructed by the oil pump shaft. But you may already know that clever clogs.

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[numbers_]

I have to ask after seeing it a few times now, why do you want to block off the oil squirters? I would have thought the cooling would have been beneficial

 

[NorthloopCup]

Long time since any updates on this! There’s been a lot of stuff going on that’s needed custom parts, but I’ll go into that in a bit more detail later on. For now it’s a few pics - everyone likes pics.

King race main bearings

Graphogen loveliness

King big end bearings

original oil feed in the block blanked off

New cam sensor mount finalised and 3d carbon printed

Head stud kit fitted

Will be updating through the day with pics and waffle.

 

[NorthloopCup]

More pics:
Secondary injectors and rail

Cam sensor mounted to check fit

EGT probe bulkhead mount design

and 3d printed

aluminium coil on plug spacers

various sensors

water pump prepped for the new smaller pulley

More to come.

 

[frayz]

NIce to see someone still using some old school Graphogen and not that awful Torco s**t people seem to use these days.

 

[R3k1355]

You use graphogen in place of assembly lube? Do you find it does a better job?

 

[NorthloopCup]

New ECU Master components and the Maxx Race ECU. (Tom is a dealer for ECU Master - if you need owt speak to him )

Time to get the party started and do a bit of dialling in the cams

And in the next exciting instalment there will be a lot of disappointment, swearing and very large dose of me getting very annoyed. Lol