Playing with the gating system is an art form in itself.   The latest solid modeling software makes it much easier, but an experienced patternmaker can usually solve the problems. So many things are going on at the same time when pouring metal, it was always amazing we got what we wanted !!!!   Several of our smaller parts needed the gating design changed for summer and winter!  Iron doesn't flow the same when the mold is cold in winter as it does in 140 degree sand in the summer.   Same for AL3.   We cast small compresser parts for Fridgidare and the Detroit Diesel truck I6 and V8 blocks.   Lots of other parts in between with volumes measured in tons/hr.  Good old days, and I'm glad I'm retired!!!

DON"T GIVE UP

J

I have to second all the that.



Having some machine and casting knowledge; I have a slight clue of what John is going thru.

One would think it is easy just to copy the stock heads and put them on the market. Oh no this is not same animal as a sbf or a sbc head.

John has basically re engineered this animal.

Joe, thank you for your insight. The particular machine we have has a Centroid controller. Although it is not the most common we wanted it for 2 reasons. First, it is "conversational", which means it has has a fill in the blanks type format available as opposed to being G-code and M-Code only. It can be programmed in G and M code for the people that are familiar with it. I am not.



Secondly, it is the same controller found on most CNC porting machines. I don't know if we will ever get to the point where we can afford one (135-190K) but if so we will be familiar with the controller.



The downside of this controller is that there are very few in the area and the closest rep is 120 miles away.



We did cut up the first head shown in the pictures. There were areas that needed to be changed. I think these problems have been addressed. I'm quite happy with the shape of the ports etc, all the issues now are in gating and risers. I think we have found the source of the problems with the last 2 castings. The foundry has ordered 10 sets of cores which should be in next week. Unfortunately, the foundry is only able to make cores in heated aluminum core boxes while mine are wood/plastic.



I'll post some updates if we get to cast a head or 2 next week.



John

http://ford-y-block.com 

20 miles east of San Diego, 20 miles north of Mexico

John - I am a retired wood and metal patternmaker who spent over 30 years in a very large foundry's machine shop.   I fully appreciate the magnitude of your undertaking in developing and improving new parts and making them fit an existing application.   Prototyping in the industry used to take several years, and we had the full co-operation of the foundry at our disposal.  Many preproduction samples were cast and then sawed up for evaluation before small runs of castings were even machined and assembled to run on test engines.  It takes time and a great deal of perserverance to work through all the issues.  Can't imagine what it would be like to fight all the normal issues and then have to deal with the problems of a struggling foundry.

We went through the learning curve of programming CNC machines.   Tons of programs and software companies are available.  All are good, some are better.  Only bit of wisdom I can give are to start with a major provider of software, and not get overwhelmed with all the bells and whistles.  Learn how to do the minimum required for the task at hand and in time the advanced features will come in to play.   Large software suppliers have tech help and instructors who come to your shop.   They want to make you happy so you stay with them!   Every programmer has their preferance of software and controllers for the mill.  Many vocational and tech schools also have programming classes.  Several of our pattern makers/machinists also worked part time to assist other small shops (or had their own) to help the learning curve.  Perhaps there is a machine shop in your area you could get help from.  

Its a huge investment, not just in money, but time and energy as you well know.

Keep up the good work!

J

Hey John!!   WOW!!!   Thank you for not giving up!!   Also thank you for coming on the site and sharing you vast knowledge, that's what is so wonderful about this forum, everyone willing to share so we can all learn!!!   God Bless you and your family--   Eddie

Eddie

Lake Forest, Ca. 92630

Thought I'd add a pic. Will probably cause more questions than answers. As with the spark plug clearance in another thread please remember that this is a prototype. There will be changes and issues resolved. If you can see a problem from the pics, we've probably already seen it too.

http://ford-y-block.com 

20 miles east of San Diego, 20 miles north of Mexico

Thanks John and Glen. I'm trying to add a spec sheet for the heads but site is NOT cooperating.

CASTINGS: Cast at local foundry in El Cajon, Calif USA

CASTING NUMBER: ECZ-G in original location 3/8" letters

COMPATIBILITY: All stock location externally. Will accept stock intake manifolds, exhaust, rocker arms, valve covers. Roller rockers will require different spacing due to altered valve spacing.

EXTERIOR APPEARANCE: As close to original as possible. Horizontal parting line like mid-1959 and later heads. Non-negotiable.

VALVE SIZE: 1.94" X 1.50 to 1.54". 11/32" single groove keeper, 45 degree seats.

AIR FLOW:  Sample test head that ports were copied from: 255cfm intake  179cfm exhaust. Out of box est. 230int 170 ex.

DECK THICKNESS: .600"

HEAD BOLTS: 7/16". ARP bolts & washers supplied with heads. Modifications up to purchaser. Use of original head bolts will void any and all warrantees.

VALVE SPRINGS: 1.44" diameter 115# seat, chrome moly retainers, hardened & machine keepers, hardened spring cups

VALVE SEATS: Exact material to be determined. Ductile iron, powdered metal or ?

SPARK PLUGS: 14mm 3/4" reach. Moved .400" closer to exhaust valve centerline (away from intake valve).

COMBUSTION CHAMBER: approx 62-64cc. It is impossible to determine from the pattern. Only a fully machined casting can be checked. As pointed out earlier in this thread aluminum heads actually need a higher CR than iron heads due to heat loss. When feasible large chamber heads will be made available.

BARE CASTINGS: Will be available. Guide sizing and valve job un-finished.

ROCKER OILING: Stock. Haven't figured an easy way to oil stud mount rockers

WILL ANSWER QUESTIONS AS THEY COME UP

http://ford-y-block.com 

20 miles east of San Diego, 20 miles north of Mexico

I don't think that most of us realize all the problems than can crop up with a project of this magnitude not too mention the expense. I know that Frank had foundry problems with his products and with the economy being like it is I understand as I am sure others do. But please be aware that we all appreciate your efforts and I for one steer newcomers looking for parts and information your way. I am holding off on a intake until you let us know that it is ready for shipment. And once again welcome to the site.

Glen Henderson



Freedom is not Free

Letohatchee, AL

John:

Thanks for the update.  I'll bet Pegleg is about the only guy here who truly understands what you have gone through.

John - "The Hoosier Hurricane"

I know that many are (im)patiently waiting for word on the aluminum heads. It's hard to believe that its been nearly a year since we cast the first head shown in YBM. There have been so many set backs in the last 12 month that I don't know where to start.

The foundry told me last October that they were going out of business. However, they were able to downsize both in square footage and payroll and keep the doors open. They were basically OOB for nearly 6 weeks.

We have cast a few heads this year and it appears that we have identified and corrected the problems we encountered.

While all this was going on I also took on making castings of a new valley cover, alternator bracket and intake manifold. When we got a quote to machine the manifolds and extrapolated what the cost of machining the heads would add to the bill it seemed logical to buy a machine center and do this in house. I then found a 6 month old machine with a 4th axis on epay. It was a repo and only 100miles from our shop. Too good to be true! Purchase and delivery were arranged and the rep came and set it up. The 4th axis unit was still in the crate, never installed. The rep connected it while it was still in the crate and felt that it was drawing a little more current than it should but felt it would free-up with a little use.

Since the center line of the horizontal 4th axis was too low to swing an intake manifold, spacer blocks needed to be built to raise it approx 2.5". A tail stock was made from an import rotary table. All is going well! The day came to install the spacer blocks, 4th axis and tailstock. It won't fit in the machine's cabinet. It wouldn't even fit without the spacers! So the enclosure of the 4th axis and the spacers needed to be modified to fit.

Once again we are back on track! Install everything and the 4th axis won't even run! The rep says its now out of warranty being over 1 year old. So, a couple of days of messing with it and it seems to work okay.

Then comes the fun of building fixtures for alt brackets, valley covers and the intake. This consumes the next 4months. There also is the small issue of learning how to program a cnc machine, something I have no clue how to do. Earn as you learn.

Please realize I'm writing this to bring you up to speed, not just sing the blues. Just so you understand that no one has given up on the head project. There have just been many more obstacles. More than I'm saying here.

Your patience is appreciated!   John

http://ford-y-block.com 

20 miles east of San Diego, 20 miles north of Mexico