2ZZ-GE engine build/design for competition

[Julius Jodelė]

There are not too many aftermarket parts available to build a real race/competition Yamaha 2ZZ-GE engine. The ones that are available are just generic parts adapted to the 2ZZ. The 2ZZ engine seems to be a great starting point in that the block is made from MMC and therefore lighter, more compact and stiffer than a "conventional" cast block.

Would this be the place to post custom designed and made parts for the 2ZZ engine? If not, can this post be moved to the appropriate place?

And, is there any interest in the results?

[Julius Jodelė]

I wanted a longer connecting rod for the engine, so we ordered custom titanium connecting rods Crower in the USA. And this is what they look like

I looked at a lot of pistons, Cosworth, Wiseco, OEM, etc. and I didn't like any of them. So I've designed my own crown and 3D printed a piston to check valve clearances and to measure combustion chamber volume and then to flow bench them to check how they flow during the crossover phase.

When we were happy with the design, we had Omega build us a set.

and I think they came out very well...

Edited September 27, 2017 by Julius Jodelė
added weights of connecting rods

[Bibs]

Nice! This isn't your first go at this I assume! 

[Julius Jodelė]

Thanks...

I have done individual pieces/components, but never all at once and all together. I'm liking how it is progressing...but it's taking so much longer than I had hoped. But that's how it usually goes, especially with such comprehensive projects.

[Julius Jodelė]

So, an intake manifold got printed up...and installed on the mule engine...

Another angle...

And the throttle body...

We want to check out if the carbon printed manifold will hold up to the vacuum of an atmo engine first.

 

Edited October 25, 2017 by Julius Jodelė

[Julius Jodelė]

I had to redesign the manifold for the new material...finally finished!

Edited June 23, 2018 by Julius Jodelė

[Julius Jodelė]

And here is how the intake assembly will look

[IgEvo400]

How are things progressing? Superb work, impressive attention to detail, I can’t wait to see how this thing is going to perform.

[Julius Jodelė]

I can't wait either. As all new things, It's not going as fast you would like/wish. I still had apprehensions with the last material found and finally found a material that I'm completely happy with. It can even be manufactured the way it was designed to be manufactured. This new material is even stronger than the last one, so to save money, I'm redesigning it again to take into account the better material properties.

Meanwhile, the bottom end is being assembled and flow benching of the head is being done. I've designed intake port to improve flow.

[Julius Jodelė]

I finally got the engine block back after Nikasil'ing the bores and silver powder coating of the block.

[Steve V8]

On 23/06/2018 at 09:53, Julius Jodelė said:

And here is how the intake assembly will look

Wow this looks fantastic from the outside, those veins look rather intriguing I'd be more interested in what's going on on the inside??? 

[Julius Jodelė]

1 hour ago, Steve V8 said:

Wow this looks fantastic from the outside, those veins look rather intriguing I'd be more interested in what's going on on the inside??? 

I'll just say that there are full trumpets on the inside. The injectors point straight to the back of the valves. The volume of the plenum is 2.5x the working volume of the engine. Those ribs on the outside are for structural rigidity. Under full vacuum, the plenum only deflects 0.15mm! The plenum weighs 1.5kg.

[Julius Jodelė]

I've finally gotten the design to the point where I like it. It meets my criteria for loads. It is 10x as strong as it needs to be and only weighs 1.48kg.

And the max deflection is only 0.158mm at the red spot. You can also make out some of the interior design features.

OK...some movement on this project!

Edited August 19, 2018 by Julius Jodelė

[Julius Jodelė]

And no stress analysis is complete without a check of the principal loads.

principal compression loads are highest, no surprise because I put a 1 bar load.

maximum tensile loads.

 

[Julius Jodelė]

That 76mm throttle body looks huge...

[C8RKH]

Wow!  :)

[silverfrost]

Amazing, the work looks stunning,  cant wait to see the results and hope they go way past your expectations, fantastic work and a pleasure to read and veiw the cad      

[Julius Jodelė]

Top view

 

Side view

 

Bottom view

 

Front view

 

Back view

Edited April 15, 2019 by Julius Jodelė

[Julius Jodelė]

with the AN fittings... :D

[Julius Jodelė]

I thought I'd tease you with a couple of section views...just so you can see how much work went into this project.

[Julius Jodelė]

This is what forged, ceramic coated pistons look like for a 2ZZ-GE...

[powersteer]

How's your build coming along? We are keen to know how the engine is running 🙂