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Oldsmobile 324 Engine - Rocket Power!: Part 2Machine Work and Balancing From the February, 2009 issue of Rod & Custom By Dan Kahn
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Last month we kicked things off on our Rocket Power Olds buildup by carting a grimy, but all-original, 324 four-barrel mule motor over to the engine gurus at Taylor Engines in Whittier, California, for a thorough inspection and teardown. After stripping the mill down to a pile of parts, we discovered that the 324 had lived a fairly easy life, as the original pistons, bearings, and other internal parts were still in place and looking pretty good. We also ran some numbers and discovered that the '56 324 was a decent little performer in its day, utilizing a cast-iron four-barrel intake manifold and a 9.25:1 compression ratio to make 230 hp and 340 lb-ft of torque. While these numbers may not sound staggering by today's standards, that was serious power back when the biggest passenger car engine available from Chevrolet only displaced 265 cubes, and the Blue Oval boys were just sorting out their new Y-block. Since the Rocket Power Olds will eventually be nestled between the framerails of Riz's Budget Beater roadster pickup--which will likely be driven all over the country for years to come--we knew it had to be extremely reliable. When it comes to tire-melting grunt, there's no such thing as too much, so a little extra power would also be nice. By the time we moseyed on over to Taylor Engines this time around, they had taken all of our reusable hard parts (crank, rods, heads, block, caps, etc.) and cleaned them thoroughly, then inspected everything for cracks or other unusual wear. Everything looked good, so the next step in the buildup process we're going to cover here is the machine work and prep necessary prior to assembly. The machine work on the block should be a familiar sight to anyone who has followed an engine buildup, as the boring, decking, and align-boring are common to just about every type of engine out there. Since we want this engine to live as long as possible, Jay Steel and his crew at Taylor decided to really go the extra mile with the reciprocating assembly, which means the rods were polished and shot-peened, then fitted with high-strength ARP bolts. The forged crank was ground, shot-peened, and polished, and the entire setup was carefully balanced and blueprinted. Egge Machine supplied pistons, bearings, rings, gaskets, and just about everything else necessary to assemble the engine, and we were thoroughly impressed with the quality of Egge's cast piston line. Even more impressive is the fact that they offer slugs for even the rarest and strangest of motors, from Buick straight-eights to Cadillac V-12s. The Olds pistons they supplied allow for a full floater pin, which is a much more high-performance way of attaching the rod to the piston than the standard pressed-pin setup. If this all sounds confusing, relax. It will be explained. Follow along and we'll detail every step in this interesting process. Next issue, we'll tackle the assembly process, where all of the parts we've been working on and hoarding will finally come together. We'll also discuss how to rebuild an old harmonic balancer, where to find a high-performance cam for an old mill like this one, and how to properly set up a shaft rocker arm system. In the meantime, soak up the info on the following pages about how to machine a block the old-fashioned way.  When it comes to machining...  When it comes to machining the block (boring, decking, etc.) all measurements are taken off the mains, since the saddle for the machine is centered where the main bearings would normally go. Therefore, the first step in the process is to cut the main caps, grinding off .010 inch of material to provide a fresh, flat surface. Once bolted back on, the circular hole in the main journal is now oval-shaped because of the material removed.  Once all the caps are surfaced...  Once all the caps are surfaced and bolted back onto the block, there are two ways to open the holes back up again. An align-hone machines all five caps at once, which works great on engines where all five main journals are the same size. On the Oldsmobile, however, the rear main journal is larger, so a line-bore machine is employed, which machines each journal separately.  You can see the cutting bit...  You can see the cutting bit in the picture. The line-bore will shift the hole about .002 inch down into the block, opening up the hole back to normal size and cutting into fresh metal. The machinist must be careful not to move the hole too much, or the timing chain will be loose because the crank will be too close to the cam.  With the main journals bored...  With the main journals bored fresh, the next step in the machining process is to square and deck the block. Making a block "square" necessitates measuring the deck, or cylinder head mounting surface, from the centerline of the crank (the center of the journals we just bored) and ensuring that the measurements of both sides are equal.  The surfacing wheel spins...  The surfacing wheel spins at low rpm and uses a cutting bit to take a small amount of metal off the top, leaving a fresh surface. When decking, it's important to only surface the minimum amount necessary to clean up the metal. Our first pass took off .002 inch, which knocked down the high spots and allowed us to see how distorted the block is. A second pass took off .006 inch, which left a clean surface like you see here.  The machine that opens up...  The machine that opens up the cylinder bores is called a boring bar. It uses three fingers that extend from the tool to center the cutting bit in the hole, then the actual bit spools up and slowly takes away the designated amount of material. Since this block has never been bored, it has what's called a "ridge" in the top of the cylinders, which is a step at the very top of the cylinder where the rings cannot touch and therefore have not ground away any material through wear over time. We used this ridge and the very bottom of the cylinder, where there also has been no ring wear, to center the block on the machine.  Next, the fingers center the...  Next, the fingers center the actual cutting tool in the worn part of the cylinder bore, ensuring that the material taken off is even all the way around the cylinder. Since we are opening up the bore .030 inch, the cutting tool actually only takes off .015 inch of material per side, so when the circular bore is measured across, it totals .030 inch.  Our Olds came with quite a...  Our Olds came with quite a few good parts from the factory, including a forged steel crank. Taylor Engines likes to smooth down the counterweights on each crank to help relieve stress and prevent cuts during the assembly process.  Once the weights on the crank...  Once the weights on the crank have been de-burred, the snout is masked off with duct tape to prevent damage and the crank is sent out to be shot-peened. Essentially, that means that metal shot will be blasted into the fillets, or throws, of the crank, rearranging the molecular structure of the metal and relieving stress. This could prevent a cracked or broken crank at high rpm or under heavy load.  Another popular trick for...  Another popular trick for relieving stress and preventing internal breakage is what's called "polishing" a rod, which essentially involves using an 80-grit belt sander to remove the casting flash from the sides of a connecting rod, leaving a smooth finish.  When polishing the side of...  When polishing the side of a rod, make slow, even passes, and only remove just enough material to make the sides of the rod smooth. Take off too much, and the rod can be weakened. Once polished, the rods will also be sent out for shot-peening, and when they come back, they will be about as strong as possible for a stock rod.  After being shot-peened, the...  After being shot-peened, the rods will look smoother, with a dull gray finish. Some engines use what's called a pressed pin, which means the end of the rod is heated up, a pin is inserted through the piston and rod, and, when it cools, the pin is stuck so the piston cannot be removed. In this case we went with a more high-performance setup, by inserting a brass bushing into the rod and using "floater" pins that can move.  The rods were also fitted...  The rods were also fitted with high-strength ARP rod bolts. Bolt failure is one of the most common reasons for a stock engine to come apart at a speed, and using ARP bolts should take that possibility out of the equation. The guys at Taylor figured out that big-block Chrysler rod bolts will work perfectly in the 324 Olds.  Once the brass bushing has...  Once the brass bushing has been pressed into the small end of the rod, it can then be honed to size.  While the small end of a rod...  While the small end of a rod gets honed, the big end is bored. The caps are ground down in a similar process to the one described in caption 1. Then the rod is put back together with its matching cap and the bolts are torqued to spec. The hole is then bored back to size, leaving fresh metal for the bearing to seat on.  Finally, the bushing is chamfered...  Finally, the bushing is chamfered so the pin can be inserted easily.  Now that the rods are prepped,...  Now that the rods are prepped, the next step is to balance the rotating assembly. The big end of a rod is called the rotating end; the small side is the reciprocating end. All of the rods are measured by hanging the reciprocating end as shown and weighing the rotating end.  The weight of the lightest...  The weight of the lightest rod is noted then all other rods are lightened to match. To lighten the rotating end of a connecting rod, material can be taken off by sanding the pad as shown. Go slow and only take off a small amount at a time, as it's always easier to take off more material than to try and put some back on.  All eight rods were matched...  All eight rods were matched so that the rotating end weighed 531 g. Next, the entire rod was weighed, and the lightest one weighed in at 801 g.  By subtracting the weight...  By subtracting the weight of the rotating end (531 g) from the overall weight of the rod (801 g), we can conclude that the small (reciprocating) end of the rod should be balanced to 270 g.  Egge Machine provided all...  Egge Machine provided all the new internal parts going into the engine, including these beautiful new cast pistons and full floater pins.  A set of eight pistons was...  A set of eight pistons was provided, and while all were weighed before leaving the factory, it's important to weigh each piston an pin individually so they can be matched to each other and added into the overall balancing equation.  All of the bearings weighed...  All of the bearings weighed the same, so we only needed to weigh one set. The weight, 55 g, will be taken into account on the balance sheet.  Next, the rings for one piston...  Next, the rings for one piston are weighed as well. All of this information is recorded on a balance sheet, which will be given to the crank balancer, who will figure out the total weight swinging on one journal of the crankshaft (two rods attach to each of the four journals).  Finally, all of the pistons...  Finally, all of the pistons are weighed, and once again, the weight of the lightest piston is noted.  Since a few of the pistons...  Since a few of the pistons were a touch heavy, we lightened them by cutting off a small amount of material on the lathe. A 4-5g variance is acceptable, but for balancing reasons these pistons will be matched to within .5 g. The excess metal was removed from the inside base of the piston, where structural integrity and shape are not an issue.  As you can see on the balance...  As you can see on the balance sheet, all of the measurements we just took are marked down, along with a 5g "oil balance," which allows for the weight of the oil coating everything during normal engine operation. The rod and bearing rotating weight were doubled because there are two rods on each journal, but the rings and pistons do not because they are reciprocating. The total weight of 2,314 g will be measured out on a "bob weight," which will be used on the crank during the balancing process to simulate the reciprocating/rotating assembly. Once the crank is balanced, the assembly process can begin.
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Egge Machine
11707 Slauson Ave.
Santa Fe Springs
CA
90670
5-62/-945-3419
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Taylor Engine Rebuilding
8145 Byron Rd., Unit D, Dept R&C
Whittier
CA
90606
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