Mark Anderson

As someone who has reproduced the 911 case I'm sure you have a very good idea on what it takes to reproduce and market a 928 block. Are the 911 cases in production now?

Catorce

The prototypes are mostly done, and I just opened my own machine shop to do them. The 5 axis just got delivered 3 days ago, so no, production has not started. I want to point out that the 911 case is very different and somewhat more challenging to make than any block, but having said that, my machine (Haas UMC-1000) has a 40x25x25 work envelope so yes, I could machine a block on it.

I'd be looking for someone to scan a 928 block and come up with a solidworks file, however. I don't have any time or resources to do that part. However, if some enterprising dude had a good file that we could use to machine, heck yeah I'd clamp a hunk of billet in the machine and go to town.....

SwayBar

That is quite an offer!

GregBBRD

Trust me, we've thought about this and discussed it, more than once!

Catorce

Why don't you guys develop the model, and I will make it then. I know very little about the 928 block other than the generalities. If you guys were to come up with the "killer design" and a model I could use to create a tool path, we could make a few assuming there was demand. We can figure out the machining, all you need to do is come up with a solidworks model of what the ideal block looks like.

Then we can machine it from a piece of 6061 and it would crush the stock block.

GregBBRD

Yes, the stock blocks are certainly the limitation of making power. The silicon alloy is very brittle. A chunk of 6061 with some Nicosil liners would be...very nice.

With what you must have on your plate, that is an amazingly offer.

I'll talk to some solidworks people and see what is involved to do this.

Strosek Ultra

Alusil liner blanks.
http://www.pierburg-service.de/ximag...199_en_web.pdf

Honing of Alusil cylinders.
https://www.sunnen.com/NewsDetails.aspx?NewsID=11

Åke

Catorce

Yeah we are super busy but the reason I suggested it is that we *may* have some downtime soon. The foundry has thus far been making prototypes here and there, and there will probably be a delay for them to spool up to full production for us to get started, so I bet I will have pockets of time where this could be accomplished, but I definitely don't have the time to design the thing and even if I did, you're the 928 expert so.....

This is what you need to do:

1. find your best block to use as a model
2. Have it scanned
3. Import that scan into solidworks
4. make all your proprietary changes, mods, improvements, whatever
5. Send that to me, where we will then create the toolpaths necessary to mill it.
6. We then mill it.

Obviously lots of little details between those steps, but you get the idea.

V2Rocket

the big holes are 122mm apart on centerline.
there's 8 of them 90 degrees to each other.

fire up the mill...what more do you need

GregBBRD

Just need to figure out how to get an air supply to my die grinder and it will be done.

merchauser

^^^^^^^^^here is a good air source; can you get it done later today?^^^^^^^^

V2Rocket

have you ever looked at a 928 block and a Chrysler 440 block side by side?

some similarities, even the bore spacing is nearly identical.
maybe one of the existing alum. 440 block manufacturers could be per$uaded to adjust their files for 4 head studs instead of 5/6, etc.

hacker-pschorr

If my memory is correct, the bore spacing between a 928 engine and big block chevy is off by .030"

There is a bonneville racer that manged to put 928 heads on a BBC.

GregBBRD

We've been talking about this, since the first high horsepower 928 block cracked, so there is enthusiasm for this project.
Rob Edwards wants to scan one, this weekend....to get it rolling.

​​​​​

GregBBRD

Pretty sure I still have my parents old Polaroid Camera for the scanning part. This seems easy.