DIESEL PERFORMANCE: DIESEL RACE ENGINE SCENE AN AERA INTERNATIONAL QUARTERLY PUBLICATION JULY-SEPTEMBER 2011 Diesel Engines GALE BANKS ENGINEERING DURAMAX DRAG RACE ENGINE FOR SIDEWINDER S-10. PHOTO COURTESY OF GALE BANKS ENGINEERING. Diesel Engine Machining Alternatives B Series Cummins Light-Duty Diesel Engine Casting Repair engine professional WWW.AERA.ORG/EP 1 CONTENTS VOLUME 4, NUMBER 3 PUBLISHER 4 FROM THE PUBLISHER AERA - Engine Builders Association 500 Coventry Lane, Suite 180 6 INDUSTRY NEWS Crystal Lake, IL 60014 Welcome to new AERA members, 815-526-7600 815-526-7601 fax calendar of events, news and views Chairman of the Board 10 DIESEL PERFORMANCE David Bianchi Seattle, WA By Mike Mavrigian First Vice Chairman An overview of the diesel race engine scene Dwayne Dugas New Iberia, LA 26 GUIDE-LINERS FOR DIESEL 26 APPLICATIONS Second Vice Chairman Ron McMorris By Pim van den Bergh Maple Ridge, BC CANADA 34 5 MINUTES WITH AN Treasurer Dean Yatchyshyn AERA MEMBER Cumberland, MD By Jim Rickoff President John Goodman 38 IN TOUCH By Jim Rickoff EDITOR Free Tech & Skills Conferences John Goodman [email protected] 40 REPAIRING DAMAGED ASSOCIATE EDITOR LIGHT-DUTY DIESEL 40 Jim Rickoff ENGINE CASTINGS [email protected] By Gary Reed TECHNICAL EDITORS 48 CONFERENCE RECAP Dave Hagen [email protected] By Steve Fox Steve Fox Sunnen and MAHLE Clevite Regional Conference [email protected] at Hendrick Motorsports a huge success Mike Caruso 50 B SERIES CUMMINS [email protected] Gary Lewis By Dwayne J. Dugas [email protected] 60 DIESEL ENGINE MACHINING Mike Eighmy ALTERNATIVES 50 [email protected] By Steve Gettelfinger COMPTROLLER Ellen Mechlin 68 TECH BULLETINS [email protected] GRAPHIC DESIGN Maria Beyerstedt [email protected] ADVERTISING SALES Jim Rickoff [email protected] Hal Fowler [email protected] 60 PRODUCTION Jan Juhl [email protected] Engine Professional®magazine (ISSN 1945-7634) is published quarterly by Automotive Engine Rebuilders Association. CIRCULATION Copyright 2011, Automotive Engine Rebuilders Association. Karen Tendering Subscription rates: $70 per year, outside the United States $90, single copy $20. Publication, editorial and business office: [email protected] 500 Coventry Lane, Suite 180, Crystal Lake, IL 60014. Editorial: 815-526-7600, Advertising: 507-457-8975, INTERNATIONAL LIAISON Circulation: 815-526-7600. Send change of address to the above. Yolanda Carranza The opinions, beliefs and viewpoints expressed by the various [email protected] authors in this magazine are those of the individual authors and not of the Automotive Engine Rebuilders Association, which CHIEF TECHNOLOGY disclaims all responsibility for them. ARCHITECT Richard Rooks [email protected] 2 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION engine professional WWW.AERA.ORG/EP 3 FROM THE PUBLISHER BY JOHN GOODMAN, AERA PRESIDENT High Performance Diesels have arrived My first experience at the Bonneville Salt Flats was common rail diesel engines are plentiful in the EU in 1964 for Speed Week. Anyone who ever visited and are beginning to take hold here in the United Speed Week was treated to the wildest array of States. This new breed of diesel is quiet, clean racing machinery ever assembled in one place at burning and powerful. Fiat, VW, Audi and Mercedes the same time. If you build it, there is a class to Benz all have their version of small bore diesels race it so this environment fosters large amounts of aimed at the US market and some could be creativity and personal opinion on how to go faster considered hot rods even by gasoline standards. than anybody has ever gone before. It was at These diminutive turbo diesels can rival Bonneville where I first saw a diesel-powered performance of gasoline engines with much larger streamliner and as a teenager wondered why displacement. There will be compelling arguments anyone would build such a car powered by, of all in favor of these engines as consumer things, a diesel. What transpired over the week was understanding grows. to see that diesel liner set a new speed record in class. Truly an amazing accomplishment and Generally, when an OEM market gains popularity, should have sparked some curiosity in me as to the aftermarket follows suit and provides customers why that car owner chose diesel power over all with performance parts. We are beginning to see other gasoline engines. this happen with diesel engines as well. Although there have been pioneers like Gale Banks who was My next trip to Bonneville wasn’t until 1993 when I one of the first to recognize benefits of high visited Speed Week once again but this time with performance diesel engines, it has taken time for my own car. Once bitten by the Salt, you never fully the US aftermarket to offer diversity and choice of recover so there I was, standing on this ancient components. Engine Professional Magazinewill lake bed staring out at this pure white expanse explore this new era of high performance diesel and thinking how blessed I was to be there. But how give the reader a glimpse into what is going on and things have changed. There were no fewer than four highly modified Kenworth, Peterbuilt and Mac how a diesel engine builder approaches trucks out to set fastest time of meet in class and performance enhancement. Given a trend toward maybe take home a world record for the effort. A diesel engines for performance, the high mix of superchargers and turbos powered these big performance aftermarket may just have new diesels to speeds in excess of 200+ miles per hour! frontiers to explore and our engine shops new profit One such truck out of Oregon used a four potential as well.(cid:1) turbocharged diesel to set a new class record over 232 MPH only limited by tires. I never would have believed it possible for a truck of this size and weight to go this fast. Here again, something in this experience should have told me there is real speed potential in these diesel engines but alas, it did not. Around this same time, Audi was developing the R8 diesel powered endurance road racer that eventually changed how unlimited endurance road races were done. From six to 24 hours, the R8 was untouchable. This too should have been a clue to Prior to becoming president of AERA, John Goodman was director of the Advanced Technology Center (ATC) speed potential of diesel power but only a few were for Micromatic-Textron. The ATC focused on actually looking closely. manufacturing honing solutions and studies for OEM engine manufacturers. Testing of traditional and unique Fast forward to 2011 and we see the fruit of all honing abrasive systems, coolants, fixtures, tools and these years of diesel development. Small bore, software were primary responsibilities of the ATC lab. 4 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION engine professional WWW.AERA.ORG/EP 5 (cid:1) industry news calendar AUGUST 16 AERA welcomes • RPM Machine, assembly but teaches and TECH & SKILLS new members Cedar Valley, UT reinforces what a technician REGIONAL • SRC of Lexington, may already understand about CONFERENCE ACTIVE Lexington, KY his or her chosen profession. Hosted by Jobbers • A Extreme Transmission, • Strasburg Automotive, David leads the way for Warehouse Supply Tallapoosa, GA Lindon, UT many other dedicated engine Minneapolis, MN machinists interested in proving www.aera.org/conferences • Baltimore Head Works, • The Hot Rod Shop, what they know. AERA Eldersburg, MD Cayce, SC currently has 21 technicians in SEPTEMBER 30 • Brazier Race & Machine, • USA Racing Engines, the online training program. If TECH & SKILLS Winnipeg, MB CANADA Houston, TX interested in adding to your REGIONAL • C Smith Automotive, • Valley Automotive, resume of engine experience, CONFERENCE Hosted by Rottler Wooler ON CANADA Winchester, VA contact AERA at 815-526- Kent, WA • C & T Automotive, • You Do Engines, 7600, extension 202 and ask www.aera.org/conferences Orem, UT Middleville, MI for Karen Tendering — or email • Carquest Auto Parts, [email protected]. Karen can NOVEMBER 1-3 Arden, NC ASSOCIATE answer all your questions and AAPEX SHOW • Charlie’s High Performance, • Euromarketing Ltd, when ready, register you to Sands Expo Center begin the program.(cid:1) Las Vegas, NV Tracy, CA Auckland, NEW ZEALAND www.aapexshow.com • Comardo Racing Engines, • Nanak Crankshaft Grinders, In memory of Oscar Scott Edgewater, FL Nairobi, KENYA NOVEMBER 1-4 Oscar Scott of Don Gross • DC Cylinder Head, • PA Performance, SEMA SHOW Sales Company died Clayton, WI Boyertown, PA Las Vegas Convention Center, unexpectedly on Monday, June • Deluxe Auto Machine, • Preto Metals Recycling, Las Vegas, NV 13, at the age of 59. He is AERA Booth #21760 Phoenix, AZ Statham, GA survived by his wife Faye and www.semashow.com • E&N Body & Machine, daughters Kirsten and Kailey. Sevierville, TN MEMBERGETTERS Oscar has worked in the NOVEMBER 28-30 • Eliminator Products, • Dave Monyhan, automotive industry for over 30 ADVANCED Auburn Hills, MI Goodson Tools & Supplies years. He began his career at ENGINEERING • Gerlach Performance, Hopper Shop Equipment and TECHNOLOGY CONFERENCE (AETC) Eagle, CO then at West Coast Engine Orange County Convention Rebuilding in the Los Angeles • HRT LLC, Durham, NC Center, Orlando, FL area before landing a job at • MTP Drivetrain Services, www.aetconline.com Don Gross Sales Co. in 1980 Many, LA where he remained an integral DECEMBER 1-3 • Matts Motorsports, part of the company until his PRI SHOW Melbourne, FL passing. Dan Gross noted the Orange County Convention • Metal Crafters, pleasure he had in working Center, Orlando, FL Stevens Point, WI with Oscar traveling half the AERA Booth #4377 AERA congratulates world… ”He became like a www.performanceracing.com • Montoya Machine Shop, San Antonio, TX David Roland, the first brother to me. The passion he • Nut Cracker Racing, to hold a Cylinder Head showed for his work, for his DECEMBER 8-10 family, and for life was inspiring. IMIS SHOW Salisbury, NC and Engine Machinist He will be missed.”(cid:1) Indiana Convention Center • Olive City Auto Parts, Certificate Indianapolis, IN Corning, CA The Legend of Joe www.imis-indy.com David Roland, a professor of • Partens Auto Supply, Automotive Technology at Mondello Continues DECEMBER 8-10 Omak, WA Macomb Community College, Calvin Hill tapped as general TECH & SKILLS • Performance Motorsports – was first to complete the AERA manager of Mondello Tech REGIONAL Asia, SIP, CHINA online training course for CONFERENCE Center’s High Performance • Quenby Auto Center, Cylinder Head and Engine Hosted by AERA at the Machine Shop Albemarle, NC Machinist certificates. Mr. IMIS Trade Show Roland did it in record time by CROSSVILLE, Tenn. – Despite Indianapolis, IN • R & B Automotive, completing stringent Joe Mondello’s recent passing, www.imis-indy.com High Point, NC requirements in less than four the crew at Mondello Tech • Rectificado Motor Val, months. Center in Crossville, Tenn., is Cucuta, COLOMBIA Mr. Roland expressed a committed to carrying on the • Ricks Repair & Machine, strong desire for this type of legacy of their founder. Calvin Mooresville, NC meaningful program that not Hill has been named general • Roman Machine Shop, only tests one’s knowledge of manager of the company’s high Juana Diaz, PR engine machining and performance machine shop 6 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION (cid:1) industry news and brings with him a renewed to lead the company and to performance cylinder heads Operations/Engineering for dedication to building carry on Joe’s legacy. Joe was and engine components, will Dura-Bond Bearing Company performance engines and their well respected in our industry launch its “Head to Vegas” (A Melling Company). components. for everything he accomplished promotion on July 1, 2011. The In his new position, “I’m so pleased to have and he certainly left big shoes grand prize winner will receive McBroom will lead the Dura- Calvin as part of our team and to fill. I’m excited about the a seven day, six night trip for Bond efforts to oversee to know that he’ll carry on ‘The challenges and the possibilities two to attend IMCA's Duel in engineering, production, Mondello Way,’” said Mary and can’t wait to get started.” the Desert event at the Las environmental, new product Mondello, owner of Mondello The high performance shop Vegas Motor Speedway in development, new production Tech Center. “Joe was a at Mondello Tech Center November. processes and maintenance mentor to Calvin, as he was to specializes in engine and For complete contest rules activities. He will lead a so many of the people Joe cylinder head development and and to enter EQ’s “Head to experienced team to facilitate knew throughout the years, features superior workmanship Vegas” promotion, visit for future growth of the and I know Joe would be with the latest technology, www.enginequest.com/headto company. Dura-Bond has seen proud today.” including the SuperFlow NSCR vegas. The promotion ends on strong growth in the Hill, owner of Hill 902 dyno cell. For more September 30, 2011.(cid:1) aftermarket during the last two Performance in Lakemoor, Ill., information, please visit them years. has a strong background in online at www.mondello.com.(cid:1) Bob McBroom Bob has been with Dura- cylinder head and port promoted to VP Bond for over 27 years. He development and carved an EngineQuest® 2011 Operations/Engineering developed the popular Dura- impressive niche in the Pontiac performance community. Upon IMCA “Head to Vegas” for Dura-Bond Bond High Performance Promotion accepting the position, Hill CARSON CITY, Nev. – bearings widely used by the stated, “I’m honored that Mary LAS VEGAS, Nev. – Bob McBroom, formerly racing industry today along and the team at Mondello Tech EngineQuest® (EQ®), a leading Engineering Manager, has been with many other engineering Center has put their trust in me supplier of stock and appointed Vice President of achievements.(cid:1) 8 JULY-SEPT 2011engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION