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"Maxi Micra" project....by EBBdude.
- Thread starter EBBdude
- Start date
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On my list over DIY modifications i have done, with this level in the Maxi Micra set up, the inlet manifold and high-compression pistons can be checked out.
Inlet manifold =
more capacity DIY FINISHED
Pistons =
Higher compression / lighter. DIY FINISHED
Camshafts = DIY FINISHED
More lift.
Cylinderhead = DIY
-more capacity
-valvelifte modification , shimless
-valvespring , harder
-valves , bigger
OEM Ex-manifold
-more capacity
4-2-1 Ex-manifold DIY
So the next im going to dig into is a nice cylinderhead for the Maxi Micra.
It will be a long trip but worth every step of the way for both me and possibly for the wiever of the thread.
Any engine that you are trying to increase the performancelevel of will benefit from a complete and thorrow work process regarding the cylinderhead and the accompanying other steps involved.
The amount of details put into it will often dictate the direct result you will get as you in the end hammer down the pedal too the metal.
What each cylinderhead need is a individual thing and so is the need for the Maxi Micra.
I have done a full analysis and calculated through my flowbench work and engine analyzer what the necessary steps will be.
But enough talk , lets dig into the practical stuff.
This 1,3 engien will be the donor of a cylinderhead to the project.
Lots of work will be put into it and I will try to show you some of it.
The head is fully dismantled and put through a machine wash
Then I pull out all the valves and the rest of parts inside it.
( as i didnt have a picture of that i just show a ga14 instead )
More update coming soon….
Inlet manifold =
more capacity DIY FINISHED
Pistons =
Higher compression / lighter. DIY FINISHED
Camshafts = DIY FINISHED
More lift.
Cylinderhead = DIY
-more capacity
-valvelifte modification , shimless
-valvespring , harder
-valves , bigger
OEM Ex-manifold
-more capacity
4-2-1 Ex-manifold DIY
So the next im going to dig into is a nice cylinderhead for the Maxi Micra.
It will be a long trip but worth every step of the way for both me and possibly for the wiever of the thread.
Any engine that you are trying to increase the performancelevel of will benefit from a complete and thorrow work process regarding the cylinderhead and the accompanying other steps involved.
The amount of details put into it will often dictate the direct result you will get as you in the end hammer down the pedal too the metal.
What each cylinderhead need is a individual thing and so is the need for the Maxi Micra.
I have done a full analysis and calculated through my flowbench work and engine analyzer what the necessary steps will be.
But enough talk , lets dig into the practical stuff.
This 1,3 engien will be the donor of a cylinderhead to the project.
Lots of work will be put into it and I will try to show you some of it.
The head is fully dismantled and put through a machine wash
Then I pull out all the valves and the rest of parts inside it.
( as i didnt have a picture of that i just show a ga14 instead )
More update coming soon….
@Frank
The biggest botleneck is not in the head but in the inlet manifold.
That is why i did the inlet manifold first to get the flow numbers out of that before i started working with the head.
OEM cylinderhead can support quite a punch , even in stock form but i would say that it is as everything else ; whats your preference.
I want to make a hard pulling engine , with as good as NO new parts bought at all for increased performance and that leaves me with no choice.
I have to get many small details to work better and that is also the case with the cylinderhead.
Want the gearchanges in the 8500 rpm range with full power and Nm all the way up toward 7000-7200 rpm. ( yes in the 1,3 engine )
Will show you some more details as i go along
The biggest botleneck is not in the head but in the inlet manifold.
That is why i did the inlet manifold first to get the flow numbers out of that before i started working with the head.
OEM cylinderhead can support quite a punch , even in stock form but i would say that it is as everything else ; whats your preference.
I want to make a hard pulling engine , with as good as NO new parts bought at all for increased performance and that leaves me with no choice.
I have to get many small details to work better and that is also the case with the cylinderhead.
Want the gearchanges in the 8500 rpm range with full power and Nm all the way up toward 7000-7200 rpm. ( yes in the 1,3 engine )
Will show you some more details as i go along
As i want this cylinderhead to be spotless before commencing works on it I will remove the end-plugs in the oil-gallery.
That’s very important as sludge and other stuff is easily left in there and will collect grinding dust etc as I machine the head.
Drilling out the oem oil gallery plugs like this
Then setting some 6x1mm with a tap
Using my DIY built puller
Pullingo ut the plugs easily
I`ll measure them and store them till i have made some new later on when all work is done
Now the head is partially clean
That’s not good enough for me so ill do some more work and now I am satisfied
Now it is spotless , 100 % clean in all the oil-channels and the critical end aereas of them behind the removed oil-plugs.
Not to shabby i have to say
These OEM valves will now be stored for something in the future,,,another project of some sort…you never know !
Now I am ready to so my work on the “ Evo “ Maxi Micra cylinderhead and there will be lots of details put into it
Who wants to see more ?
That’s very important as sludge and other stuff is easily left in there and will collect grinding dust etc as I machine the head.
Drilling out the oem oil gallery plugs like this
Then setting some 6x1mm with a tap
Using my DIY built puller
Pullingo ut the plugs easily
I`ll measure them and store them till i have made some new later on when all work is done
Now the head is partially clean
That’s not good enough for me so ill do some more work and now I am satisfied
Now it is spotless , 100 % clean in all the oil-channels and the critical end aereas of them behind the removed oil-plugs.
Not to shabby i have to say
These OEM valves will now be stored for something in the future,,,another project of some sort…you never know !
Now I am ready to so my work on the “ Evo “ Maxi Micra cylinderhead and there will be lots of details put into it
Who wants to see more ?
@shaun
Thank you for looking
Here is more on the Evo head build :
This cylinderhead will have some differences from a OEM one after i am finished.
All will be done in full DIY style.
Bewfore i start some heavy work i will need to log some valve heights to ease my work later on.
The valvestems height from the springs pedestall area will be of importance
To be able to get a reference measurement i will need to make i little gizmo from Alu-axle.
Run the bolt in my lathe and work it a bit
Set my desired inner dia , lenght and dia
Looks like this when finished
With this little gizmo i can now get a reference height for the protrusion of the valve stems from the base of the valve spring pedestall aerea.
Then i just scribe down the numbers on a A4 sheet of paper and keep it for later.
Finally I can start developing a better and more efficient cylinderhead for tha Maxi project.
Have made a plan of what I want to do to reach my finally target.
First challenge is to create a more efficient combustion chamber to give me more turbulens for more efficiency it higher rpms , higher torque and also giving me a higher compression ratio,,,,all this without any sacrifice of total flow potensial needed.
Easy...?
To be seen...
Thank you for looking
Here is more on the Evo head build :
This cylinderhead will have some differences from a OEM one after i am finished.
All will be done in full DIY style.
Bewfore i start some heavy work i will need to log some valve heights to ease my work later on.
The valvestems height from the springs pedestall area will be of importance
To be able to get a reference measurement i will need to make i little gizmo from Alu-axle.
Run the bolt in my lathe and work it a bit
Set my desired inner dia , lenght and dia
Looks like this when finished
With this little gizmo i can now get a reference height for the protrusion of the valve stems from the base of the valve spring pedestall aerea.
Then i just scribe down the numbers on a A4 sheet of paper and keep it for later.
Finally I can start developing a better and more efficient cylinderhead for tha Maxi project.
Have made a plan of what I want to do to reach my finally target.
First challenge is to create a more efficient combustion chamber to give me more turbulens for more efficiency it higher rpms , higher torque and also giving me a higher compression ratio,,,,all this without any sacrifice of total flow potensial needed.
Easy...?
To be seen...
Here is more of the cylinder head build :
Lay down some machinist blue around the combustion chamber and put the head gasket that i am going to use on top of it.
Then i scribe the area to get an idea of how the actual chamber where the combustion will find place will look like.
Testing out different designs in the chamber with modelers clay
Running flow-test between in the Flow-bench to find best suited solution.
I need to get to my desired level without giving away any of the flow potencial for maximum estimated power level.
Have made up my mind and prepare the cylinder head for Tig-welding
Running a warm up cycle first and then it is just a matter of welding in material.
To be opdated soon…
Lay down some machinist blue around the combustion chamber and put the head gasket that i am going to use on top of it.
Then i scribe the area to get an idea of how the actual chamber where the combustion will find place will look like.
Testing out different designs in the chamber with modelers clay
Running flow-test between in the Flow-bench to find best suited solution.
I need to get to my desired level without giving away any of the flow potencial for maximum estimated power level.
Have made up my mind and prepare the cylinder head for Tig-welding
Running a warm up cycle first and then it is just a matter of welding in material.
To be opdated soon…
Its getting close to Christmas so i have to hurry up a bit on the Maxi Micra project.
Have more projects waiting to work on...
Here is more cylinderhead stuff.
Now the job with machining the cylinderhead starts and they will give me my desired dimensions on the different ports and chambers.
Here the machining of the exhaust ports has started and using the milling machine on a program set up by me.
It works in several steps inward the exhaust runners.
Inlet runners being done in same way , step by step
Then lots of hand work with different tools follow.
Exhaust
Inlet
Adjusting the inlet manifold gasket here
Runners and chambers are now done and i will commence the work on some used , bigger valves , from another jap car that i am going to put in there.
More in a bit…
Have more projects waiting to work on...
Here is more cylinderhead stuff.
Now the job with machining the cylinderhead starts and they will give me my desired dimensions on the different ports and chambers.
Here the machining of the exhaust ports has started and using the milling machine on a program set up by me.
It works in several steps inward the exhaust runners.
Inlet runners being done in same way , step by step
Then lots of hand work with different tools follow.
Exhaust
Inlet
Adjusting the inlet manifold gasket here
Runners and chambers are now done and i will commence the work on some used , bigger valves , from another jap car that i am going to put in there.
More in a bit…
Thanks for looking again all
@Liio
I belive the right term is ; Blood , sweat & tears...
Just kidding. This is actually quite rutine stuff but it might be new for some of the enthusiasts here in the Micra community , i dont know.
But i like to show it so that everyone can see what it takes to go from one level to the next and so on.
@Liio
I belive the right term is ; Blood , sweat & tears...
Just kidding. This is actually quite rutine stuff but it might be new for some of the enthusiasts here in the Micra community , i dont know.
But i like to show it so that everyone can see what it takes to go from one level to the next and so on.
Thanks for looking again all
@Liio
I belive the right term is ; Blood , sweat & tears...
Just kidding. This is actually quite rutine stuff but it might be new for some of the enthusiasts here in the Micra community , i dont know.
But i like to show it so that everyone can see what it takes to go from one level to the next and so on.
Haa yes i bet there has been hard times. It is very good that you are doing what you are, as you said it gives an insight to others, and for others to know what can be achieved etc. Good on you mate
(Y)
Not so hard times,,,more fun times knowing how much more interesting the Maxi will be with this done to it
Interesting it will be, im just enjoying seeing what you have up your sleeve :grinning:
Here is more on the valves:
The upper ones is the OEM 1,3 engine valves and the lower ones the 1,6 mm bigger valves that I am going to modify to go into the Evo head for the Maxi Micra.
The valves are bigger , longer and will provide more potencial in my complete build.
They are not my perfect choice but as they are free and were laying around in a box in my garage ill use them as best I can.
My new valves will be modified in every direction possible but the first I need to do is to grind the valve seat area in them
Doing that in my valve grinding machine like this
The lot together on the shelf waiting for more work
Since these valves are longer I need to adjust the height and set a new position for the valve stem groove for the 2 halves that locks the valves to the retainers.
A dab of machinist blue
Then I mark the new valves on the stem for the height of the new groove. The OEM valve to the right has been the model for the new height on the new valves.
Transferring height by scribing a line with the diy tool
Turning a new groove in the stem using my lathe
When I am done I will control the fit of the locks and retainer very thorrow
it needs to be 100 % perfect to hold the valves at my expected 8500 + rpms without risk of dropping the valves…
Even more update soon…
The upper ones is the OEM 1,3 engine valves and the lower ones the 1,6 mm bigger valves that I am going to modify to go into the Evo head for the Maxi Micra.
The valves are bigger , longer and will provide more potencial in my complete build.
They are not my perfect choice but as they are free and were laying around in a box in my garage ill use them as best I can.
My new valves will be modified in every direction possible but the first I need to do is to grind the valve seat area in them
Doing that in my valve grinding machine like this
The lot together on the shelf waiting for more work
Since these valves are longer I need to adjust the height and set a new position for the valve stem groove for the 2 halves that locks the valves to the retainers.
A dab of machinist blue
Then I mark the new valves on the stem for the height of the new groove. The OEM valve to the right has been the model for the new height on the new valves.
Transferring height by scribing a line with the diy tool
Turning a new groove in the stem using my lathe
When I am done I will control the fit of the locks and retainer very thorrow
it needs to be 100 % perfect to hold the valves at my expected 8500 + rpms without risk of dropping the valves…
Even more update soon…
B
blobbletec
Guest
Great work again ebb, i still don't understand how you achieve higher lift on the cams without adding material to the extremes of the cam lobes..? great work, homegrown engineering at its best..:grinning:
It's all to do with the difference in height from the base circle of the cam and the peak, because the base circle is now smaller the difference between that and the peak of the lobe is now bigger! hence the greater lift.
and rather than fitting shims to make up for the difference we now know he is going to make up the difference with the longer valves, so what has been taken away from the cam base circle will be added to the length of the valve.
B
blobbletec
Guest
I hear you brother.. now i get it.. simples really.. thanks
and some secrets i think?
@stani
the inlet valve is not normally able to cope with the heat as often htere arer different materials in the In and Ex valves.
On some engines it can be done thoug.
@blobbltec
Good that you now understand.
@R-reg
Not to many secrets in this i think , just knowledge
It is a esy way yeah...
the inlet valve is not normally able to cope with the heat as often htere arer different materials in the In and Ex valves.
On some engines it can be done thoug.
@blobbltec
Good that you now understand.
@R-reg
Not to many secrets in this i think , just knowledge
It is a esy way yeah...
I have now my modified cylinderhead , my used and bigger , longer valves form another Jap car and my homegrinded camshafts.
I now need some link between the camshafts and the valves so I will then , in a DIY fashion , modify my old OEM valve lifters that used to have shims , to a shimless type.
Here are my OEM lifters and i have removed all the shims
Shims = dead weight and i dont need that at 8500 + rpms
Well , i ll just put the lifter into my lathe and remove this edge and adjust the height as i want it to be.
Almost done here now
Grinding a nice radius at the top of the lifter
Here is the finished result , LHS is OEM and RHS is mine without shim.
Does it work ?,,,,,have a look later and find out.
Ready for action
The weight of 1 shim
Weight of one lifter before i start working it
Weight of modified shimbucket
Doesnt look like much but put all the shims at the scale and it is another ballpark
Low weight on these parts in the valvetrain is very good and at the same time i dont need to worry about shims coming loose / dropping out at my anticipated 8500+ rpms gearshifts.
Controlling the ” footprint ” of the cam-lobes after process
DIY lifters , shimless and valves to be used
Here are all the DIY details that will help providing more powa` in the future in the Maxi Micra
Now there are a bit fewer things remaining in the cylinderhead job so have a look in later dudes !
I now need some link between the camshafts and the valves so I will then , in a DIY fashion , modify my old OEM valve lifters that used to have shims , to a shimless type.
Here are my OEM lifters and i have removed all the shims
Shims = dead weight and i dont need that at 8500 + rpms
Well , i ll just put the lifter into my lathe and remove this edge and adjust the height as i want it to be.
Almost done here now
Grinding a nice radius at the top of the lifter
Here is the finished result , LHS is OEM and RHS is mine without shim.
Does it work ?,,,,,have a look later and find out.
Ready for action
The weight of 1 shim
Weight of one lifter before i start working it
Weight of modified shimbucket
Doesnt look like much but put all the shims at the scale and it is another ballpark
Low weight on these parts in the valvetrain is very good and at the same time i dont need to worry about shims coming loose / dropping out at my anticipated 8500+ rpms gearshifts.
Controlling the ” footprint ” of the cam-lobes after process
DIY lifters , shimless and valves to be used
Here are all the DIY details that will help providing more powa` in the future in the Maxi Micra
Now there are a bit fewer things remaining in the cylinderhead job so have a look in later dudes !
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