Warped Cylinder Head Straighten Resurface in the GARAGE DIY
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- čas přidán 5. 05. 2021
- Just as good as a machine shop to within .0005in with basic shop tools!
WHAT TOOLS ARE A MUST?
Precision Straight edge around $20 : amzn.to/3eZjaCH
Feeler Gauges down to .0015in around $9 : amzn.to/3xPf7S1
Aluminum oxide sand paper(doesn't have to be sticky stuff I used) amzn.to/3eWNuxK
OXY Acetylene or OXY Propane a MUST. A Mapp gas and high btu torch like the ts8000 amzn.to/2PXnsSE may work but you have to be careful. A propane tank/torch will not work.
PROCESS:
First, your metal high school ruler is NOT straight and should not be used( I tested around 20 that I had with some .010 out over a foot). Buy a precision straight edge for $20, it will come in handy over the years. Use the straight edge to measure the top and bottom of the cylinder head. If you have a cam that inserts vs lays on top like mine you will just be able to measure the valve cover mounting surface but this will give you a great idea of how straight your cam journals are. You can use a shop press instead of bolting it down but be careful as a shop press can easily over bend it. Even if your block is warped, you're better off using it and a bunch of shims to compensate(read below about warped block). Heat and check. Just do a little at a time until it's straight on top. Now, use this straight edge to find a flat surface for sanding/resurfacing. I prefer the engine block but that is not always an option. Just an FYI glass is rarely flatter than .002-.005 over a 18" spread and it is also super flexible and will contour to whatever you put it on. The flattest surface I have found is 3/4in MDF and Melamine(plastic coated MDF). Yes a woodworking plywood type product. Cut it and make it double or triple thick so it doesn't deflect. If you have a cast iron block it is likely straight enough to use like I did. I started with 120grit and you should use this until it just touches the lowest spot/depression. Then I went to 220 and that should suffice, but I finished with 320. You could also start your first passes with 60 or 80 grit if you have .004+ to take off. Wet sand paper is not needed.
What if my block is warped as well?
Does it match the head with the same contour? If both have a .003 bend the exact same way you could likely just slap them back together and be happy unless you are pulling them apart due to a blown head gasket, then something needs to be straightened. First straighten your cyl head like I discuss above. Then you can use sand paper on your head to flatten your block. Or if you used a MDF block you can also cut it down to fit inside your engine bay and do your engine block. Word of caution: plug all your oil ports and cylinders with towels and grease the edges of the cyl walls to catch any sanding grit from falling in. The grease allows easy wipe up/cleaning. You don't want sand in your engine.
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You know, Ive been doing this for almost 50 years. And Ive never seen another shop do this kind of straightening. In fact, numerous shops years back outright attacked me for doing it. Screaming and crying why the head needed machining. Ive seen the same kind of people on youtube. When you mill a head, IT DOESNT REMOVE THE FREAKING WARP!
Not only will the camshaft will be off, but now you have thin and heavy areas of the head AT THE WATER JACKET! AND you have combustion chambers that will be smaller where more material was removed and larger chambers where material wasnt, which will cause additional tuning and performance imbalance. You will raise the compression ratio in 2 of the cylinders where the most material was removed. The list of issues immediate and long term are too long to list. All because of milling a warped head.
That's fantastic, I'm glad I'm not the only one that sees it this way!
You make some very good arguments, for not machining it straight, I’ve always wondered aboutThose issues that you talked about
Iv never seen this method how cool Iv had to use shims on diesel heads because of machining I'll have to try this method
Machine shops must hate you😆
The way I was told at the engine shop I worked at, the head is warped so the cam bearings are now subject to heavy wear because the cylinder head is probably shaped like a Pringles potato chip.
Shave the head , the cam bearing area is still warped and then it's all downhill from there.
Straighten it first , and then shave it ,and you're only gonna shave enough to get a clean surface.
I had an unwarped vw head like this ,and we cut the surface with the block grinder because of the hardened prechambers.
Thumbs up for adding metric measurements.
Thanks Man
I used this method tonight on a 2.4 Ecotec engine and it worked great the head was out .013 I cannot fit a .003 feeler gauge under the straight edge now!!! Thank you for helping me get the wife's cylinder head back within factory specs!
Omg a guy that actually fixes things instead of replacing. Well done sir!
remove your temostat you dont need to do this job anymore...in hot weather-
if cold comes is easy cover your radiator.. hi five..
I’m impressed. I’m sure a machine shop foreman will shake his head. Obviously this method needs care to detect and avoid lateral warping. Well done.
Thanks.
I like seeing Old School Backyard on the Farm Machining
Hey thanks
People think it can't be done without huge machines, but lathe beds on the very best lathes are scraped flat by hand with a scraper and dye.
Never thought about measuring the camshaft and that the whole head is bent! This is brilliant! Also the explanation why it bends makes totally sense! Thanks a lot!
LOL I'm proud of him . whoever taught him that tech must be super old school . 👍
I am 43 and I had a classmate in my auto-mechanics shop class in high school who had a 4 cylinder Mustang and he warped the head when he overheated the engine. Well, he brought the head to school and was outside one day on the concrete driveway sliding this cast iron head back and forth. In amazement, I asked what he was doing, to which he replied, “I’m shaving the head because it was warped”. I don't know just how warped it was or just how straight he got it in the end but I do know that he ended up putting it back on the engine and it ran fine. As far as I know he never did take it to a machine shop.
Yeah buddy 👍🤠
This is remarkable skill for a DIY head calibration job, I enjoyed this! Learned quite a bit
Hey thanks Man
You do some great work with very basic tools. My dad helped me grind a crank using a pack of over-sized bearings and valve grinding compound. We were 30 though out of round and I didn't have the money for the machine work. The guys in the shop (on a military base) said it wouldn't work but the crank came in true with only about 200 turns of the connecting rod on the journal. Put it together and I drove it for about 15K miles before I sold it. Keep up the great work.
That's an awesome story.
@@sixtyfiveford Should do a myth buster on that !
I've never seen anything like that before. Brilliant. 👍
this is why I sub! alternative DIY methods to crazy expensive regular tasks
Hey thanks, I'm glad you liked it.
It's not about saving money on this job, rather it's about balancing the heat cycle stresses in the head. Quick and dirty repair is to machine the head... BUT like he says, that leaves the cam bores not parallel with the bottom of the head.
This is one of those jobs where you get better at it the more often you do it. For the first time, take it easy and slowly get it straight.
Nicely done Bud!! It don't get any better than that!!☺
Cast iron is better 🤣
Titanium is better
@@Freekniggers
Some would say that “ELECTRIC” is better.
To that I say, “aww go screw yourself!!! Nobody wants an electric powered vehicle around here!!!”. Not to mention the fact that I love the smell of gas and oil burning!!!
#LongLiveCombustionEngines!!!
You sir, have officially been crowned "King of Frugality".
This is actually the recommended way to straighten an ohc head , so you don't wipe the cam bearings out.
Much love for the VW idi diesel too, great engines.
I have often wondered if machine shops took into consideration the parallelism of cam journals,glad to know someone e is paying attention.
Blown away bud. Genius!! Ive used precision ground stones super fine takes forever. Heating the head to relieve tension tho genius! So impressed.
Dave Rebello told me how to do this decades ago. Never tried it and it's nice to actually see it performed. Very cool!
Very educational on entire job. I learned so much and love when all jobs can be done in house.Thank you!
Very intelligent. I will never, in all my life, do this, but I really enjoyed watching it anyway.
I came back to this video to watch it again. We are lucky to have your channel !
Hey Thanks.
I'm very impressed as a fabricator by trade I've never attempted to flame straighten engine parts before nice job brother
That was excellent tutorial on straightening the head. So many are done wrong. That’s the correct way and easy. Nice!
A good day, thanks for sharing that God-given genius of yours with us. Way old-school . Did not know they made that special sanding paper. Going to have to obtain some! No Shop should be without it after seeing this. You are the man!!! have always expressed the more you do it the more you learn. Thanks again have a beautiful day look forward to more. Jim
This is a great way to keep budget builds in check ive never tried heating them before but I certainly will be giving this a go I use a similar method for sanding as well!! Great video thank you!!
Thanks man, you're awesome!
I have sanded heads but i like this idea more. Thanks again for the fun and knowledge.
WOW! That was some serious good-looking job! I hope you are proud of it, to say the least. Congratulations!
Your method improves upon other DIY techniques I've seen. Well done!
Hey Thanks.
I've been wrenching for 20 years and I've never seen this.
Thank you for very educational video.
Thanks, I'm glad you liked it.
Glad to see you put on them shades when the torch came out. I will turn off others torches on a jobsite if the idiot is brazing or cutting without spectacles. Thanks for sharing the info!
This is a nice informative video. In the 1980`s this was common practice prior to machining. I can remember doing Toyota cylinder heads it seemed like every one that had a over heat had cam alignment issues. In the Machine shop i started in every OHC head was straitened before resurfacing. Not exactly this method but same idea. One thing you did not mention is the absolute need to line hone the cam journals to restore cam alignment. Aluminum heads twist as well as warp. Straightening takes out cam journal height issues but dose not fix journal alignment issues. I misaligned cam journals can cause excessive journal wear, Low oil pressure, premature camshaft failure. Just as straightening is just one part of a repair to a warped head (always resurface after straightening) line honing cam journals should never be overlooked.
Thanks for sharing more priceless information👍 so far I've been lucky in that the only multi-cylinder heads I've re-used have been cast iron and were well within spec! I almost never check single cylinder heads or brand new aluminum units. So far so good. Your method makes perfect sense, if not more sense than milling if purely for the purpose of truing the surface!
Thank you!
Nice job Ginger. I mean sixtyfiveford a money saving tip 👍. I say all those tricks over the years you owe me one bag of treats 😉.
She got me good. I thought I could run into the post office for 90 seconds and not tell her to leave it. That's my mistake and she caught me and deserves it.
@@sixtyfiveford now, I don't have to tell Bear to leave it, he's been taught from a pup, even if I put a piece of bacon on his nose, it doesn't go in his mouth till I say "take it". I would have got back to the truck to find him laying with one paw and his chin on the bag, looking at me like "see dad, I saved it from having an escape... Can I have one now?" ;)
I've straightened a lot of stuff with heat and shrink methods. I never would have thought of straightening a cylinder head. I'll sure try it if I have a warped cylinder head.
Yeah I've seen this done before with a half inch glass plate sitting on a steel table with sandpaper taped to it. Great video and good tips as always
Thanks!
That is an artist at work , you truly understand the processes , fantastic share thank you 😊
Amazing you you know exactly where to heat it, pro mechanic tip right there
That is awesome. I have never taken an engine apart (Man Card Status: Under Investigation) and have great respect for all who have and possess a wealth of knowledge.
Hey thanks. It's not as fun as it looks. The fun part is when it starts for the first time and that could be enjoyed by anyone.
You’re expertise in so many different things is amazing. 👍🏻🎥🏴☠️❤️👨🏭
Hey thanks
Awesome Video! I've done a few Subaru heads by flat sanding. Have to try the torch method on the one I have coming up. Makes perfect sense. Thanks!
Very interesting, this method and your directions certainly give me confidence to try and straighten the next head I have that is bowed. Thanks for posting.
Thanks Man.
That baby looks like my old 1’6. Diesel. VW . I did the exact same job , but sent the head out to a machine shop .nice motor to work on . I did notice the cam has a groove in the end for the cam gear but no key . Just bolted on to the tapered end . PS I think that pic up has a lot of potential and very economical .
I actually looked for a more powerful engine to swap in it as everybody says they're slow as molasses. But I think I'm okay with that if it gets as good as mileage as everyone says it does.
Excellent instructional video thank you for sharing your knowledge 👍
Great trick for resurfacing ! Great video . thanks!
GREAT JOB, I NEVER SAW THIS FIX BEFORE, I WOULD HAVE TAKEN IT TO A MACHINE SHOP, VALUABLE LESSON LEARNED, FOR THIS OLD DOG..!!!
Oh my I would've never have thought of that! Did you come up with it yourself? This is the quality content ive subbed for
1st. Of all I commend you for this tutorial, it is a fine example/ demonstration of machining/mechanical expertise. Would I be right in assuming that you started out in a machine shop ? Seeing you using the gauges , shims and all brought back very good memories of my working in a couple of machine shops/factories, reading blue prints, machine center set ups all . Keep up the good work ! 😎
Never would have thought of this. Makes sense though.
Thanks Robert.
I dig all your videos buddy, everyday shit with everyday answers. No machine shop or custom stuff just everyday solutions.
Outstanding. If you could find a nice sized chunk of slate from an old pool table, that'd work perfect for the sanding stage, assuming a warped block...
Great technique. Looking forward to more VW videos.
You're awesome, thanks man
Uh oh! Doggy is in trouble 😂 Great video!
Great video and procedure, thank you!
Slick trick, Moe. You always amaze me.
You're awesome, thanks George.
I remember seeing this on Faye Hadley channel as well pretty awesome
I would have never thunk it lol awesome work as always!
My mind is blown, thanks for sharing
You're awesome, thanks Man
I've had to do that to the cylinder heads before on cars and lawnmowers. People thought i was crazy till they seen it actually work without having to take the heads to a machine shop
Awesome.
I learned it from a lawnmower shop also
We did this technique in a engine shop and it works great but we still surfaced after straightening👍
Great point!
I've seen using a piece of glass but using the oxy acetylene tank to take out most of the bow is an excellent idea that way you're only taking off as little as necessary
I tried a piece of glass years ago and found out they aren't really that flat. They also just bend to the workbench when you put 40# of cyl head on it. I had a 3/8in thick piece that I could get to bend .010+ without too much effort and thinner sheets 1/8in bend was easy. I then went and pickup up a piece of 1in+ thick granite and it was also .005 out of flat but didn't bend at all. Finally I found MDF and Melamine MDF and it was near flawless flat over 24in. I used that with great success.
nice to see you know how to do that my dad had a chrysler 2.2L was knowing to warp the head like that the speed shop he know did that then mill .20 off and never had a problem after the. I did a head job on a chevy 3.4L the head was warp the other way and just heat it up and thaw it back on still have no problem with it its all was better to heat and fix the warp before milling
Nicely done!
Very cool!! I must have missed the truck. I’ll look for it now.
Thanks Brad
Cool Tech Moe. I saw the latest video then came to watch this.
For sanding heads, I use a lab certified granite block that is 3' x 4' with the kind of sandpaper used to make floor sander paper before it has been cut. Works great for both aluminum and cast iron because I can get about two feet of movement on the head.
I actually picked up a granite slab years ago to do this and found that it was about .005 out. Of course it wasn't lab certified. I then looked at a bunch of glass up to even 1/2-in thick and that wasn't flat either. Also the biggest problem is glass is super flexible and just bends to whatever surface you place it on. The flattest stuff I could find which was under .0015 was 3/4" MDF and melamine MDF.
@@sixtyfiveford never would've guessed MDF out of those materials!
@@sixtyfiveford they can be re flattened to .002 which is fine work it would probably cost about a $1000 to have it reground and yes they do that by hand with diamond dust.
@@sixtyfiveford Tool & Die maker 45 years we used granite surface plates ground to .002 had a surface plate tech every year to come to shop and regrind all plates to this spec.
Learned something. Thank you!
Glad u Ford guys know how to keep your trucks running w/o breaking the bank
The vw gas engines like the 1.8 where bad for warping heads too. Always used to leak water and oil. New gasket. Head surfaces checked. 6 months later starts leaking again.
Such a smart dude man. I've learned a ton from you, and the way you explain your projects is so easy to comprehend thanks for your contribution sixtyfiveford
Wow, thanks Jason. -Moe
Ingenious! You know a lot about the details. May i ask you for tipps tricks and opinion on oils greases and dry lubes? Future video? MoS2 grease on ballbearings did a astounding job in preventig wear. I am interested in bicycle, home and car topics.
Well .... straightened a lot of stuff, chrome shaft, circular saws ect ect, never even considered doing this...of course it works, why would it not? Bloody brilliance.
i always walk away from your videos a little bit wiser. great tip
Hey thanks! And for watching!
That was awesome...good job 👍🏻
Thanks man
I like it. Hey I was watching your bolt extension video. Can you show us how to harden all thread to make long bolt. Right on love the VW series.
dude im impressed.thank you for sharing👍
Thanks, I'm glad you liked it.
You make things dead simple. Thanks
Thanks man
very impressive! thanks for sharing
I'm not a great mechanic, just a pretty good backyard mechanic that's troubleshot a lot of problems. All your videos make perfect sense to me, thanks for posting them!
And I'm guessing someone had a taste of jerky recently. 🤔
Hey Thanks, I'm glad you like them.
Clever! Great work bud! The kind of old school ingenuity lost on a generation.
Glad you liked it! Engine has a few thousand miles on it since I did this.
We used this method too. You have to be very careful as head can bent side ways too
Great job Moe. Perhaps next video you can show how to splice a broken winch cable together..or really I need to shorten my trans shifter cable, which has braided steel cable inside, as my engine swap needs one 1ft shorter. I thought of you when I needed to do this, no help on youtube or google!
Great video. I do simular. I have acces to a press. so I just shim ends and pres it. For people not use to deal with aluminium. be very careful when heating. when you break through the oxide scale. Alu melt around only 700 degree c.
That's awesome.
Thinking outside the box. Excellent for me this would be overkill, but it's a job well done!
I recognized the Vw diesel from the thumbnail and had to watch.
Hell yeah dude.
Much love for mk1s.
Nice idea you can use grease pencils for every different heat range to not have to eyeball the temps from the weld store
Great tips. Thank you
Nice work man👍
It seems to me like it needs heated as a full unit after that technique to release the i internal pressures to prevent re-warping and/or cracking.
Great job.
Never would have thought of doing that. Ingenious!
Ginger..."but you still love me, right?"
This video blew my mind and I love it!! I'm rebuilding my first car engine, a 93 Accord 2.2L F22A6, and the donor engine head has right at .005" warp in the middle going upwards like yours. I'd really love your advice. Placing it on the block without a head gasket, then barely hand tightened the middle two head bolts only, makes the warp disappear. Cam journals appear straight and cam spins smoothly. Should I just go for a light resurfacing with sandpaper then run it, or should I heat up the mating surface and try and get a bit more of the warp out? Thanks for the amazing video!
Very nice job. I learned alot! TY
Hey Thanks.
Paint that bump side cab lol Ferd tough great vid
That is a cool trick, thanks!
Hey Thanks.
thanks for showing this
Good technique on the straightening. My only question is how do you keep that grit out of the engine, or is that what the oil filter is for?
Awesome, good old school trick
Thanks Man.
Thanks for the metric conversions for the whole rest of the world!
Or, as Jeremy Clarkson once said, " In Roman Catholic ".
Nice work! Thanks!
You're awesome, thanks Jack.
so those heads are prone to cracking between the valves , inspect this area closely , i've welded more than a few up and reinstalled new seats .
also a head stud kit makes it much easier to get a slightly twisted head to seal up .
a thicker head gasket can help seal a twisted head , but going from a 1 hole to a 3 hole head gasket also screws up on how the diesel burns in the combustion chamber and it will run with more black smoke .