posted on February 07, 2011 00:23
Back in August 2010, I spent some time sectioning a 4G63 cylinder block and cylinder head so that Tyler, Clayton, Lyon, and I could get a detailed look at the structural integrity of the components. We weren't able to get CAD models from Mitsubishi so we had to do it the old fashioned way. This study came about because we had to solve the head to block interface issue for Sierra Sierra. This was not a drag engine that had a total life span of 15 miles at 1/4 mile intervals in 10 second sessions. These 800hp engines have to last for many hundreds of miles in approximately 12 miles intervals in 10 minute sessions. The Sierra Sierra engines had never had a component failure so we knew the Cosworth internals were plenty good. This study was the initial investigation of what was going on inside of the factory castings.
The 4G block was too tall to fit into our band saw so I asked Martin if he could mill away some material. The part of the block below the crank centerline was not the part we were interested in anyhow. Martin chucked the block up in the CNC and wrote a quick program to cut the block down.
Here's what Martin ended up at couple hours later. Now it was short enough to chuck into the band saw. This was just an EVO 8 block from a completely factory engine that we had sitting around with a spun main bearing so it was a perfect candidate for sectioning.
After sectioning the block, I noticed there was some sand in the crevices of the block. I took a flat screwdriver and was able to chip some of the iron/sand mixture away. It's difficult to see in this image, but it is a very hard and crusty matrix of iron and sand that is semi attached to the block. When I say semi, I mean that the factory did not intend for this sand/iron matrix to stay behind after the sand cores from the casting tooling were broken away. It is the result of old school sand casting tooling and methods. Remember that the 4G63 is the younger brother of the G32B that was born in the early 70's.
Underneath the iron/sand matrix is loose sand and plenty of iron particles. This particular cluster here is at the bottom of a water jacket in between cylnders, but some of this was present in oil passages as well. While none of this caused a problem in the engine's approximate 40,000 miles of usage in a completely stock EVO 8, I wonder if some of it could have broken off and caused a problem in the lubrication system of a race engine that is subjected to far more vibration. Every production sand cast cylinder block built by Cosworth spends a considerable amount of time in ultrasonic cleaners so it isn't a concern for Cosworth built engines, but seeing this crap break off with the simple flick of a screwdriver makes me worry about blocks that aren't ultrasonically cleaned.
Monday, February 07, 2011 2:18 AM
Magnus Motorsports did this back around 2001 or 2002 with the 4G63 as well.
Monday, February 07, 2011 3:37 AM
Wow. I've never seen that done before. Pretty cool! Thanks for sharing.
Monday, February 07, 2011 4:26 AM
Magnus is a 4g63 leader. They may not have the media connections but they have the HP... :)
Monday, February 07, 2011 7:47 AM
Hey, its that my old motor that came out of Shawn's car?
Monday, February 07, 2011 11:36 AM
Does the last article line mean there are there more pictures to come?
Monday, February 07, 2011 11:56 AM
Gotta love ultrasonic cleaning. I use a small cheap US cleaner when I rebuilt my R/C engines. It's amazing what comes off when you toss a part in one of those. Neat look inside an engine, what other engines has Cosworth done this too?
Monday, February 07, 2011 12:15 PM
Magnus has been building 4G63s forever. I met the Magnus guys a couple times back in the day when we used to drag race FD RX-7s against each other. Cool guys. This was when I with XS Engineering. If they sectioned a 4G63 in 2001, then it must not have been an EVO engine. Cosworth has only been building 4G63s since 2006. I'd have to say we've developed the 4G63s to an extremely high level in a relatively short time.
Mike: No, your engine is on the 4th level of a pallet rack just outside of the build shop. We did not chop your block up.
Fabrik8: Yes, just as soon as I get them together later today.
8595: Ultrasonic is the only way. I cannot believe I used to do it without ultrasonic cleaning.
Monday, February 07, 2011 12:29 PM
I hope those sectioned pieces ended up as a display in someone's showroom or Garage Mahal. Would be a shame to waste them!
Monday, February 07, 2011 1:24 PM
Super sweet ! Thanks for sharing Eric.
I can't wait to see more in-depth pics.
Monday, February 07, 2011 1:48 PM
So you've shown us some pics, but what have you found? Is there room for improvement and, if so, where? Obviously this is an EVO engine, and I have not heard of too many failures due to specific issues. About the only mod I see people making is the Kiggly oil pressure valve in the head. (beyond full builds) Are there any "cool" things Mitsu did that builders or manufacturers could learn from? I'm a big fan of the 4G63 and I'm even swapping one into a Datsun 510, albeit a non-EVO motor.
Monday, February 07, 2011 7:15 PM
8595: Usually we don't need to do this kind of sectioning because we have CAD models for other engines.
vanilla: Unfortunately the parts will sit on a shelf above the dyno until they are needed again. It's kind of like that warehouse in the Raiders of the Lost Ark above the dyno. There are engine parts and random race engine stuff from the late 70's.
jeffball610: I did not know I was required to inform you of what we found. I thought perhaps sharing images of something like this might be enough. There is room for improvement with this block, but our findings and what we learn from the study will stay within the walls of the building. We are not a university or a public knowledge base. We are a profit center owned by a venture capitalist. I am not at liberty to share our findings so thanks for understanding. As it is I am probably crossing the line already.
I did not get a chance to get the images together today, but I'll put them up tomorrow.
Monday, February 07, 2011 10:13 PM
Been lurking on this site for a while but never posted. Wanted to say thanks for the pics and insight.
Monday, February 07, 2011 11:37 PM
Hahahaha @ Eric's response to Jeffball610.....sorry, not trying to be mean.....just the way Eric answered.
Tuesday, February 08, 2011 5:13 AM
Come on Eric, why so stingy? Just because Cosworth has put in the time, money, man and brain power, doesn't mean you can't help an Asian Brother out. It's simple. You do all the work and give us the results for free. You have my words as a China-man that I won't tell anybody, especially my family at TinDuck Racing China.
Tuesday, February 08, 2011 10:07 AM
I take no offense to Eric's response. I understand the secrecy involved in these things. I guess I'm just used to finding so much "free" knowledge on the internet that I just wanted more. I appreciate the article and look forward to more in the future.
Tuesday, February 08, 2011 11:40 PM
I am glad that people can enjoy stuff like this. Damn, I'm busy during the days. I hope to get more pics up tomorrow.
Wednesday, February 09, 2011 7:08 PM
Eric, you are also a journalist working for a publication, the business of which is to make relevant technical information available to the public. I understand if your other business precludes you from publishing Cosworth's findings, but I don't understand the defensiveness when someone asks you to act like a journalist.
Wednesday, February 09, 2011 7:39 PM
There is a very clear line between a topical coverage of the basic technical findings and divulging the hard-won results. This is no different than covering the highlights of a racecar without giving away the myriad secret details that are proprietary to a specific team.
The reply might have been slightly heavy handed in the delivery, but I don't see anything wrong with the message. Eric doesn't work in the company press office, which means he's not as practiced at gracefully deflecting overstepping questions. That said, I'd rather read Eric's technical articles than those written by a press office employee, so I'm fully willing to overlook the occasional journalistic foible..
Wednesday, February 09, 2011 9:17 PM
Eric a journalist working for a publication? Where did you get that idea? Last I heard Eric wasn't getting paid to move his personal blog over to Motoiq. I think the defensive response was appropriate for the offense question.
"So you've shown us some pics," = So what.
Obviously I was not the only one who interpreted it that way.
Wednesday, February 09, 2011 11:50 PM
Jeffball610 asked what he wanted and I explained why I didn't write what he wanted. No harm, no foul to me. I didn't think I was defensive and I didn't think Jeffball was too offensive.
Daewoo, let me clarify my presence on motoiq.com: When Motoiq first started, they needed a boost in traffic. At the time my personal blog was ranked 122,000 in the world and motoiq was not even ranked 1,000,000 in the world yet. I moved my personal blog to motoiq to boost traffic. Beyond the Dyno is actually no longer my personal blog since I just don't have the time to write about random personal shit everyday anymore. So when I do write, it is usually car related whereas before it was about anything that was literally "beyond the dyno". To those who do not know, I may come off LIKE a journalist working for a website, motoiq.com, but in actuality:
1. I am not a journalist.
2. Where Mike and the others are interested in educating the automotive enthusiast public, I am not. It would be great if you got something out of what I write, but it's not my main purpose in contributing to motoiq.
3. I am writing for your entertainment. Its something to read when you're having your morning coffee while looking over at the stock ticker occasionally. Whether or not you enjoy the entertainment is up to you. I don't mind if you don't like it.
And I hope that clears things up.
Fabrik8: well said
Thursday, February 10, 2011 5:21 PM
Thanks Eric for posting the pictures up. I'd say its very interesting though it in no way benefits me. I'd definitely love to see more as I love Evo's in general.
I did notice that you haven't been posting entries much to Beyond the Dyno. Its a bummer cause I enjoy reading them, but I understand your actual work to pay for the roof and the meals are more important. I'm also glad work is becoming busier for you which means the racing and tuning scene isn't going to die anytime soon as some naysayers are propagating.
PS: You heavy-handed reply was quite amusing, though I won't want to be on the receiving end.
Monday, February 14, 2011 11:57 AM
How does one get spots of casting sand/rust in the oil passages; those passages are drilled into the block. Unless of course there's been some mixing of oil and coolant somewhere along the line.
Tuesday, February 15, 2011 5:28 PM
Leon: One of these days I'll start writing again regularly. I think the racing and tuning scene is fine, but unfortunately the street scene may be the segment of the industry that is getting smaller.
Street: Not all of the oil passages are machined in. An example would be drain back passages from the cylinder head to the crankcase.
Thursday, February 17, 2011 10:43 AM
Aaaah din' think about those!
Wednesday, November 09, 2011 11:48 PM
Eric: Any chance you could send me a message?