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I'm a bit worried about using these malleable iron plugs.

Because I'm relocating the three studs that normally stay in place, I've drilled them for tapping 3/8" BSPT to fit the plugs.

I've also plugged two of the other stud holes because of a cock-up on my part.

These plugs are as soft as sh*t. Hence I'm worried about the studs pulling under stress.

I've fitted a stud and placed a head on, then torqued the stud at 50 lb ft without problem, but the thread has pulled a bit.

The other problem is that at 15mm tapping drill size, you cannot go very deep without breaking though into areas that you do not want too. I've already had to braze up a couple of holes after inadvertantly joining water and oil ways. So there is only about 8-9mm of depth of plug/thread, because you cannot get the taper thread tap in far enough.

Before going any further I'm comtemplating using 5/8 UNF parallel plugs cut from steel bolts. These could be tightened into the bottom of the hole that could be tapped all the way down.

Is it worth carrying on with the malleable iron or should I use steel instead?

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

If the malleable plugs are pulling already without any expansion from heat I would ditch them!

I would of thought mild steel would be better as its a little harder.

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www.fusionfabs.co.uk



1/4mile in 13.2sec @ 111 terminal on 15psi

Paul, when I first got interested in this conversion I researched it a bit, I found out that cast iron machinery cracks are repaired using a thing they call a stitching pin. These are basically threaded inserts like yours, but made of the appropriate material for the repair. They drill a hole on the crack and screw in one of these pins, then another hole and pin, and so on, and then they come back and do more holes and pins in the spaces between the previous pins, until eventually the crack is replaced by entirely new metal from the pins. I found a company selling the pins, and the drills here ...
http://www.locknstitch.com/StitchingPins.htm
I called and discussed the project with them and they said moving studs in a cast iron block would be easy. They sent a training video tape (awesome repairs!), nowadays I see they have DVDs available. I ended up purchasing their recommended pins and taps. I never throw anything out, I will find them tonight and post the part numbers tomorrow.

Edited by scooperman on 1st May, 2008.

I'd be interested in those pins and taps as well.

That's interesting. I'm familiar with this as a method of repairing large castings.

Problem is that the holes are already drilled 15mm whih is bigger than their largest plug.

Good thought though.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

how about this from the same firm

http://fulltorque.com/plugs.htm


seems like these are made for this purpose

That sir, is not rust, it is the progressive mass reduction system

http://aseriesmodifications.wordpress.com/

Hi,
Those look just the job. I had a crack in a diesel head repaired with the locknstitch, worked for years after :)
Cheers,
Gavin :)

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My Mini build diary

I think you are right, the fulltorque plugs do look like the best thing, I think this is a newer product than what I bought. I found my box of stuff, the receipt shows I got these in March 2002, about a year or so after I started trying to find BMW heads and engines to match up with my pile of ancient A series lumps. I had forgotten how expensive they were. For each size of pin, there is a special drill bit, a piloted spotfacer to create a shoulder for the pin, and special taps. The pins are not expensive but of course the special tools cost a pretty penny. I got 25 of the C3A pins for $37. The C3 tap set was $200, the C3 spotfacer was $55, the C3 drill was $13. I got 25 of the C4A pins for $86, the C4 tap set was $354, the C4 spotfacer was $91, the C4 drill was $28.

ouch that is expensive. its cheaper to get a machine shop to make the plugs and do it for you.

Thanks for the advice guys.

Some expensive options there.

I've decided that the plugs are hard enough, but the problem is the depth of the thread and the thread form. The plugs don't go in far enough and the recommended 8mm tapping drill is a tad too big.

So I'm going to get another tap and cut a few mill off the end so that I can get a full 1/2 inch of plug in the hole. That will then be as deep as the length of thread on the stud.

I'm then going to use a 7.5mm tapping drill to get a full thread form.

Wish me luck.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

How is this going now?

Ground to a halt whilst I sort out the 998 Efi Turbo.

I'll pick it up again in the Autumn.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Out of interest how much do you reckon you've got to deck the block by? my maths makes it around 4mm unless you want to run the pistons down the bores or use longer rods. And do you reckon there's enough meat in the deck to remove that much?

I'm taking 2.75mm off, I think.

4mm is the difference in the crank throw, but I will be running the pistons down the bore.

I'll be using the thinnest SC gasket.

The deck is thick enough in the critiical areas around the stud holes. The rear studs sit above the tappet chest wall, the front studs are in the ususla place with plenty of depth to the casting.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Are we going to dry deck this?

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

On 11th Jan, 2010 sturgeo said:
Well we have a choice of 5

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

In a non sexual way, give me one!

If something is worth doing, it's worth doing half of.

i'll take one too!

If needs be, you can always put this engine in my mini.

Paul did you ever finish this build?

I remember you saying to me when I got carb off you but didn't know if you finished it

thanks
Stephen

What a waste of time :(

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Ahh how come?

Long story.

Back in 2008 I was struggling with the 5 port injection and this project engine was really a fall back option. Good for pub points if nothing else.

In 2009 I got the injection sorted and that then opens up a lot of potential for 5 port development.

In my opinion, the 5 port is a much better engine for a road going turbo, particularly with fuel injection and optimised runner lengths.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Ohh right fair enough :) well your 5 port work is amazing!

your engineering is top on this and other work though