First (second really) 5 main aluminum block.

[Tod]

OK, here we go with the first aluminum 5 main block just out of the sand. After talking to the foundry, it sounds like I need to provide for chilling a few spots, but for the first attempt in a new molding and pouring method, I think it looks pretty good. Can only get better from here on.


Tod

[rotorwrench]

Welcome to the 21st Century 200 CID Ford. What a jewel. That's going to be the cat's meow for the hot rod 4-banger guys.

[The Master Cylinder]

Very Kool, Rod.

[Tod]

Originally Posted by rotorwrench

Welcome to the 21st Century 200 CID Ford. What a jewel. That's going to be the cat's meow for the hot rod 4-banger guys.

Aluminum and 5 main blocks are just an aside for me (although I have dozens of people wanting these already). My main focus will be 3 main A and B journal blocks that people can use parts they already have to build. I did this just for more 5 main fun and to test my new aluminum foundry out. I think they did well. I assembled the mold Saturday morning, they poured it shortly thereafter, and Monday they had that to show me.



Tod

[motordr]

Great stuff!

[Jw]

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have you considered moving the water port back by cylinder number 4 to increase cooling

[Seth Swoboda]

That's pretty amazing. I can't imagine the cost it takes to get this endevour started let alone to a final product that is marketable.

Have you considered an aluminum flathead V8 block?

[Tod]

Originally Posted by Seth Swoboda

That's pretty amazing. I can't imagine the cost it takes to get this endevour started let alone to a final product that is marketable.

Have you considered an aluminum flathead V8 block?

Cost is negligible given that I do pretty much everything myself. Don't be impressed. It is more time consuming than difficult. I've made castings that make engine blocks look like child's play. Finding time is my largest problem.



I have an 8BA model almost finished. Probably stick with iron on that, though.


Tod

[Tod]

Originally Posted by Jw

have you considered moving the water port back by cylinder number 4 to increase cooling

No.

[rotorwrench]

Ford delt with cooling in the last of the flatheads by opening up the cylinder head in the back and forcing more coolant to flow back there. I don't know if I'd worry about it much. The 24 stud V8 engines all had the coolant pushed in from the front and they seemed to survive it OK. When they opened up the 8BA block in the back it was due to the larger heavier vehicles they were being used in and they did OK as well as long as all the core wire and casting sand was removed.

With the starter motor back there, it might make more problems. I'd say keep it simple.

[Tod]

I stopped by my iron foundry today while I was running some errands to look over the 3 main block they recently poured. They have not run it totally through the grinding room yet but, WOW, does it look good for an unfinished casting! I can't wait to get at machining it and getting these things into the hands of waiting customers and builders.


Tod

[Lawrie]

Good work .
Cant wait to see the 3 main iron ones.
Lawrie

[Tod]

Originally Posted by Lawrie

Good work .
Cant wait to see the 3 main iron ones.
Lawrie

I knew you would like that. You will love what you see. I will email you pics first.


Tod

[Jw]

very impressive!

[Jw]

question. is the blocked sleeved or like the Vega blocks?

[Tod]

Originally Posted by Jw

question. is the blocked sleeved or like the Vega blocks?

Aluminum use ductile sleeves. The iron blocks obviously do not use sleeves, not for another 50-75 years, anyway


Tod

[DBrer]

Great, I'm sure your efforts will pay off.

[Tod]

A picture of the 3 main A block we just cast before getting rid of the parting line flashing and gating residue. Can't wait to machine this one. Yes, that is a B head sitting next to it. Also a couple of iron Winfield heads on that skid.


We will grind off flashing etc... and then final shot blast. Then I get it here to the shop and machine it.



Tod

[Tod]

Just got back from picking up some castings at the iron foundry. B heads, Winfield heads, and a 3 main A block.


Tod

[Russ/40]

Tod, I see the head gasket in photo 4. Are you an advocate of that type gasket?

[Tod]

Originally Posted by Russ/40

Tod, I see the head gasket in photo 4. Are you an advocate of that type gasket?

That is just for checking. I hear horror stories about these.


Tod

[Tod]

The first iron B head all machined. 7:1 compression ratio.


Tod

[motordr]

That looks great!

[Tod]

I found out from my iron foundry that 12 Winfield heads I assembled molds for and the first iron OHV sample were cast the other day. I will post pictures as soon as I can.



I have 4 engine blocks in house that I am machining and 1 aluminum block will be sent to a builder soon to be put together and run around some.


Tod

[bphillips]

Fabulous work! I’d love to be a fly on the wall in your shop as I’ve always been fascinated by pattern making

[Ernie Vitucci]

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Good Morning Tod...Have you worked up pricing for your three main block as yet? Ernie in Arizona

[Tod]

Originally Posted by Ernie Vitucci

Good Morning Tod...Have you worked up pricing for your three main block as yet? Ernie in Arizona

I don't have final pricing fixed yet, mainly due to uncertainty of sales. The more blocks I can make the less the price will be. Right now, people are having to pay more because I am not being asked to make large runs of castings. My machining costs are pretty fixed. Casting cost is the moving target until I can place orders in large numbers.


Tod

[Russ/40]

Originally Posted by Tod

I don't have final pricing fixed yet, mainly due to uncertainty of sales. The more blocks I can make the less the price will be. Right now, people are having to pay more because I am not being asked to make large runs of castings. My machining costs are pretty fixed. Casting cost is the moving target until I can place orders in large numbers.


Tod

Tod, what are you considering "large numbers" ? Perhaps we who are waiting could pool our requests.

[Tod]

Originally Posted by Russ/40

Tod, what are you considering "large numbers" ? Perhaps we who are waiting could pool our requests.

Probably runs of 20 at a time.


Tod

[Flathead]

Will any iron Winfield heads be for sale?

[Tod]

Originally Posted by Flathead

Will any iron Winfield heads be for sale?

Yes. I should start machining 14 of them this week. I believe at least 10 are already spoken for.


Tod

[Mart]

Excellent work Tod. just seeing those pics make me feel lazy. Mind blowing stuff.
Mart.

[Tod]

Originally Posted by Mart

Excellent work Tod. just seeing those pics make me feel lazy. Mind blowing stuff.
Mart.

Thanks. This is much easier than many of the things I have made. But, this gives me more of a sense of satisfaction because I did all the CAD work, all of the foundry tooling/mold design, mold assembly in the foundry, all the machining fixture design, machining programming, and machining (except for builder finishing where necessary).



Before CAD systems, which make anyone look like they know what they are doing, I would have made all the tooling by hand. I wish I had pictures of the M1A1 tank transmission and transfer case that I made for Allison Transmission back in the early 1990's. If you think this is impressive, you should have seen that tooling. So many memories.



Tod

[old31]

Tod what would the approximate, ballpark, cost be?

[Tod]

Originally Posted by old31

Tod what would the approximate, ballpark, cost be?

On the 5 main aluminum I am aiming at mid-to upper $2000 range. They need cylinder sleeves and valve seats installed here. There is also the need for insert bearings and possibly lifter bushings. I am working with a couple of builders to iron out a smooth process.



Tod