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Detailed Duratec Build Up

Entries in this blog

Fitting the Head

So the next job is to fit the head to the block. Start off by fitting the oil restrictor to the block. It is critical this this has the tapered hole towards the top to ensure that it will align up with the head regardless of the casing position. Next the ARP studs are screwed into position. These need to be cleaned spotless with brake cleaner, and I use an airline to ensure no foreign bodies are in the block threads. Once this is done they are coated with ARP Ultra lube and screwed hand tig
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Building up the head

So building up the head. In this case starting with a nice fresh ported SBD head. After marking all the valves to ensure their position is kept identical then removing them to allow fitting the valve stem seals. These can be fitted with GREEN on the inlets and BROWN on the exhaust. These need to be pressed on straight. I use an oversize long reach socket to press them firmly against the seats. Now each of the valves, spring seats and caps can be put into place. These should all be spot
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EWP Conversion - Part 2

So with the Electric Water Pump conversion I need to blank the back of the pump. Previously I have put a plate from SBD over the thermostat / take off location, but this leave a big area full of static water so instead I have aimed to create a plug to fit in the back of the water pump area. So I started with some bar billet in the lathe and made up a top hat to fit in the hole. I then machined in a groove to take an O-ring to form a seal. I wanted to retain the bung in place so fitted
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Pistons and Rods

Ok so now onto the pistons and rods. In this case I am using SBD supplied steel rods and slipper piston kit. So the rods come individually wrapped and at present come with no markings on them. In future I believe they may come laser etched. The important thing is not to mark them with anything that might introduce stress into the rods. So I use a paint marker and put lines 1 4 onto one end of the rods so that not only is the rod identified, but also the cap will be maintained the right way
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Waterpump Conversion to EWP - Tonights Job

So tonight to wind down after work I decided to tackle the conversion of the water pump on the duratec engine to a water inlet from the electric water pump. So to start off with I took the water pump off the engine and stripped off the O-ring. Using an angry grinder cut off the impeller and pulley mounting off the pump. once this is don't the pump body can be put into the lathe and the front face lathed down to within an inch of its life. Once this is complete the shaft and bearing can be stri
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Bottom End

Ok so onto the build up of the bottom end mounted on the engine stand. In this case I am using ARP main studs from SBD which are reusable compared to the OEM bolts. Because I will be using a dry sump pan that fits tight under the Main Bearing ladder I need to shorten the studs to prevent fouling as can be seen in the pic below. I do this by putting each on one the lathe and taking off around 4-5mm. Once this is done the studs are completed with the bench grinder followed by a thread file to
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Introduction

So anyway I was building up a duratec engine and thought I would snap a few pics along the way to create a bit of a reference for anyone else building up a Duratec engine. So I plan to use this blog to run through the build up process in as much detail as possible. In this engines case its an all steel engine with a lot of SBD bits, but the main principals will remain the same. Feel free to comment, discuss and disagree with some of my techniques. Ive been assembling engines since I was little,
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