I should make a thread for this stuff really, but in the meantime, here’s the latest on the big bore N42. With the first chamber pretty much done, I’ve duplicated the design and measurements along the head with a mixture of a cutout template and a set of french curves to try and get the most exact replication. My OCD and caution dictates I then mask off the head face to protect against any rogue carbide moments.
The principal tools are a set of 6mm shank carbides for aluminium in a power drill. The drill is actually much more stable and controllable, being a relatively weighty two-handed tool. I also have a set of 3mm Dremel-size carbides for detail work in certain areas. These are more tricky to use and require more care. However, they are sidelined for the moment as my Dremel’s long flexible extension broke earlier.
I will work along the head shaping the “scoops” into the valves opposite the spark plug holes, and then turn the head around and do the sections either side of the holes. Once the carbide work is done, I will switch to sanding rolls and flap wheels to smooth the carbide texture out. This will be followed with hand-sanding with wet and dry paper moving through the grades from 240 to 2500 grit. Then some Autoglym metal polish, either on a Dremel felt bob or by hand.
The chamber I’m working on gets its seats protected with a pair of sacrificial valves, which are actually BMW E46 valves. These have 8mm stems and are 46 and 38mm, i.e. the same as the race size L-series valves.
The chambers will be cc’ed before the sanding stages to get as close to 34cc as possible.
TBH, I’ve got well into this whole headwork thing, and will be doing an assortment of different L-series heads going forward. I’ve got it in mind to build a flow bench so I can really do some fine tuning down the line.