Upping the compression ratio with light weight pistons

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Andy335Touring
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Post Thu Jun 01, 2006 9:56 pm

Sorry this might not be totally the right section for this but it's where all the modifyers hang out :)

Ok, say the rest of my engine stays the same(cam/ported head/Emerald ECU/etc) but the pistons are changed for some light(ish) weight/high comp' ratio pistons that increase my compression from 9.0:1 to about 10.0:1

What kind of gains could i expect to see ?

Obviously i'm not expecting masive gains but i'd be interested to hear what you guys think.
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Post Thu Jun 01, 2006 10:04 pm

Be interested to hear this too actually.

There was that thing in PPC a while back by Dave Vizard which talks about gaining 7bhp for every thou' of squish clearance reduction (I think)

Can ya get off the shelf forgies for the M30 then, or would you need to spec them yourself?
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Post Thu Jun 01, 2006 10:07 pm

better mpg, more tractable engine, maybe 10bhp if mapped to suit

engine will obviously rev up quicker due to lesser rotating mass
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Post Thu Jun 01, 2006 10:22 pm

Turbo-Brown wrote:Be interested to hear this too actually.

There was that thing in PPC a while back by Dave Vizard which talks about gaining 7bhp for every thou' of squish clearance reduction (I think)
Shame i haven't a clue how big a thou' is, metric is the way forward with fine tolerances, mind i'm a mixed up bloke that still likes feet/inches/miles depending whats being measured :oops: :)
Can ya get off the shelf forgies for the M30 then, or would you need to spec them yourself?
Nothing too fancy/expensive, second hand items
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Post Thu Jun 01, 2006 10:24 pm

Jhonno wrote:better mpg, more tractable engine, maybe 10bhp if mapped to suit

engine will obviously rev up quicker due to lesser rotating mass
This is along the lines of what i was thinking 8)
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Post Fri Jun 02, 2006 9:50 am

Jhonno wrote:better mpg, more tractable engine, maybe 10bhp if mapped to suit

engine will obviously rev up quicker due to lesser rotating mass
yeah this is true-engine will accelerate faster, but how much torque will you lose? I assume lightened pistons would have a similar effect to a lightened flywheel?

I dont know what you think andy, but i wouldnt want to lose the "ballsout laziness" of the m30 :D
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Post Fri Jun 02, 2006 11:55 am

320Touring wrote:
Jhonno wrote:better mpg, more tractable engine, maybe 10bhp if mapped to suit

engine will obviously rev up quicker due to lesser rotating mass
yeah this is true-engine will accelerate faster, but how much torque will you lose? I assume lightened pistons would have a similar effect to a lightened flywheel?

I dont know what you think andy, but i wouldnt want to lose the "ballsout laziness" of the m30 :D
that is a total misunderstanding.. how much an engines internals and the flywheel weigh has nothing to do with the torque produced. Torque is the force exerted onto the crank from the pistons due to the ignition of the fuel. its a measure of how much force an engine can exert, bhp is how powerful it is ie the rate at which it is able to produce the torque (rpm)

all a flywheel does, and consequently the rest of the rotating mass in the engine, is to store energy already produced. balls out lazyness (if im understanding what it meant by that correctly) of an m30 would imo be improved due the amount of torque the engine has in a car the weight of an e30, meaning the fact less energy will be stored in the flywheel will have little or no effect on goin up a hill etc. weight loss on rotating mass particularly in the engine makes a significant improvement in the ability of it to accelerate, particularly in lower gears. then engine has to do less work to accelerate the heavy ass pistons and crank/flywheel combination

end of the day, there isnt alot of room to save weight in a piston - we're talkin 100g maybe most. crank and flywheel are where its at for significant effect winkeye
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Post Fri Jun 02, 2006 12:06 pm

got "ballsout laziness" spot on dude :D

as for the torque thing-sounds good to me, i must be confuzzled.

Just wonderin about the effect of reducing mass within the engine would have on engine performance "under load" eg up hill etc?
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Post Fri Jun 02, 2006 1:40 pm

The mass of the rotating components makes no difference to the steady state performance of an engine i.e. up hill.

Imaging we're driving up a perfectly even grade of 1in10 and have been for 5 minutes at 30mph. We won't have to change the throttle opening at all to maintain that speed because we've reached a steady state of load on the engine which is producing enough power to overcome wind resistance and gravity.

Now imagine that we kill the power and coast to a halt (ignoring engine braking) giving rise to a transient condition. The distance we travel without power will be a function of the vehicle mass and the rotating masses and the retarding forces on the vehicle like wind, friction, gravity etc.. If we had a massive flywheel we'd go on for quite some time. With a tiny flywheel, we'd most likely stop in much less time.

Another (more real world) example:
Say we're driving at 30mph on the flat. We'll have say 5% throttle opening to maintain our speed. Now we approach our mythical hill which means to maintain 30mph, we'll need to open the throttle to say 10%. This is where our rotating mass comes into play:

With a light fly etc, we'll need to get on the throttle pretty soon after starting up the hill to avoid losing speed, with a massive heavy fly, we've got a little more time to open the throttle. Once on the hill though, the throttle openings will be exactly the same at 10%.
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Post Fri Jun 02, 2006 1:51 pm

Turbo-Brown wrote:The mass of the rotating components makes no difference to the steady state performance of an engine i.e. up hill.

Imaging we're driving up a perfectly even grade of 1in10 and have been for 5 minutes at 30mph. We won't have to change the throttle opening at all to maintain that speed because we've reached a steady state of load on the engine which is producing enough power to overcome wind resistance and gravity.

Now imagine that we kill the power and coast to a halt (ignoring engine braking) giving rise to a transient condition. The distance we travel without power will be a function of the vehicle mass and the rotating masses and the retarding forces on the vehicle like wind, friction, gravity etc.. If we had a massive flywheel we'd go on for quite some time. With a tiny flywheel, we'd most likely stop in much less time.

Another (more real world) example:
Say we're driving at 30mph on the flat. We'll have say 5% throttle opening to maintain our speed. Now we approach our mythical hill which means to maintain 30mph, we'll need to open the throttle to say 10%. This is where our rotating mass comes into play:

With a light fly etc, we'll need to get on the throttle pretty soon after starting up the hill to avoid losing speed, with a massive heavy fly, we've got a little more time to open the throttle. Once on the hill though, the throttle openings will be exactly the same at 10%.
:cool: :clap:
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Post Fri Jun 02, 2006 2:00 pm

Turbo-Brown wrote:The mass of the rotating components makes no difference to the steady state performance of an engine i.e. up hill.

Imaging we're driving up a perfectly even grade of 1in10 and have been for 5 minutes at 30mph. We won't have to change the throttle opening at all to maintain that speed because we've reached a steady state of load on the engine which is producing enough power to overcome wind resistance and gravity.

Now imagine that we kill the power and coast to a halt (ignoring engine braking) giving rise to a transient condition. The distance we travel without power will be a function of the vehicle mass and the rotating masses and the retarding forces on the vehicle like wind, friction, gravity etc.. If we had a massive flywheel we'd go on for quite some time. With a tiny flywheel, we'd most likely stop in much less time.

Another (more real world) example:
Say we're driving at 30mph on the flat. We'll have say 5% throttle opening to maintain our speed. Now we approach our mythical hill which means to maintain 30mph, we'll need to open the throttle to say 10%. This is where our rotating mass comes into play:

With a light fly etc, we'll need to get on the throttle pretty soon after starting up the hill to avoid losing speed, with a massive heavy fly, we've got a little more time to open the throttle. Once on the hill though, the throttle openings will be exactly the same at 10%.
alex (for I think tat is your name?)

spot on dude-got it sorted in my head thanks. :cool: :D

jhonno, thanks for your insight too :D
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Post Fri Jun 02, 2006 2:22 pm

no worries dude, thats what tinternet forums are about.. sharing info

didnt mean to sound harsh in my reply if i did, just had my last exam for the yr and was in a rush
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Post Fri Jun 02, 2006 2:35 pm

Jhonno wrote:no worries dude, thats what tinternet forums are about.. sharing info

didnt mean to sound harsh in my reply if i did, just had my last exam for the yr and was in a rush
dude, I was the one soundin like a thicko-no offence taken at your post dude :D

hope exam went well :cool:
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Post Fri Jun 02, 2006 6:31 pm

yeah, nice read chaps 8)

Just found the actual comp ratio with these pistons, it will go from 9.0:1 to 10.6:1

It's only a small differance to what i said before but i thought i'd say it incase it will make much differance ?
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Post Fri Jun 02, 2006 6:36 pm

I'd say that CR would be spot on Andy.

take the early M20 vs late M20 CR, the early car is certainly livlier and has more HP and torque, can only be a good thing mate

what CR do ALpina quote on the N/A B10 , with your cam and the Emerald you shoul be well into their league dude, not to mention the huuuuge TB winkeye
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Post Sat Jun 10, 2006 4:37 pm

Ok, this is defo happening, i have bought an Alpina B10 bottom end that touch wood i'm hoping to fit next Sunday with the assistance of some of some top e30zone members, thanks guys ! :cool:

Any way, this means as said before nothing else is being changed in the rest of the engine except the C/R is going to increas, so the question is what is this going to do to my AFR's ?

As this increas in C/R will gain me a bit of extra power i'm guessing i will have a slightly weaker fuel mix ?

Is it going to be so weak as to cause me running problems ?
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Post Sun Jun 11, 2006 2:15 am

wont make your mixture weaker, but you may hav to richen it to avoid pinking depending on fuel quality and timing..
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Post Sun Jun 11, 2006 10:01 am

Agreed Jhonno


the higher CR will require a tiing tweak to control the burn, it will burn faster and hotter due to the increased CR, possibly have to add a little more fuel due to the increased HP target

with the monster TB this could be well be a completely new Map Andy, :cool: worth the effort for sure though.
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Post Sun Jun 11, 2006 2:45 pm

Cheers for the info guys, i might revert to the orginal map as i had leaned it off under 3k with light trottle, may be i'll rescale/decrease my injector size by about 4% to trick the ECU to fire 4% more fuel in ? All most like an overall fuel adustment.

Which way should the timing be adjusted, i guess i should retard the timing but how much and where(RPM/Throttle angle) ?

I guess i could use some high octain fuel like that stuff from Tesco's or optimax as a stop gap fix if it pinks/knocks ?

I just want it drivable and above all safe for a while until i can fit that TB as it will need changing again.

I'm resisting the temptation to fit the TB at the same time as the new bottom end because i want to keep things as simple/problem free as possible so i can get back on the road. Once on the road i can tweek it to get it running as well possible with the new bottom end then put the TB on later.

I don't know if it will help but heres a screen grab of my ignition table/map

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Post Mon Jun 12, 2006 2:41 pm

a note on ignition advance,

think about it as cylender filling = torque ,
torque = cyl charge temp
cyl charge temp = ignition advance possible before detonation

cylender filling = ignition advance

the more air the less you can advance it, i.e if your at the limit and raise the charge temp(more air or higher compression) you need to back off the ignition advance

if your raising compression I would only back the advance off in the high torque sites, and then move back in after to get optimum advance
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Post Mon Jun 12, 2006 3:17 pm

Gunni wrote:a note on ignition advance,

think about it as cylender filling = torque ,
torque = cyl charge temp
cyl charge temp = ignition advance possible before detonation

cylender filling = ignition advance

the more air the less you can advance it, i.e if your at the limit and raise the charge temp(more air or higher compression) you need to back off the ignition advance

if your raising compression I would only back the advance off in the high torque sites, and then move back in after to get optimum advance
Cheers, that make sense. 8)

I think the way they map the ignition if you have acess to a RR is advance the timing until you get max power at the load site your working on, check the fueling as you tweek it and then back it off a tad to give a margin for error for bad fuel ect to stop it pinking.

Shame i've not got a RR to use :( :)
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Post Mon Jun 12, 2006 4:26 pm

Andy335Touring wrote:
Gunni wrote:a note on ignition advance,

think about it as cylender filling = torque ,
torque = cyl charge temp
cyl charge temp = ignition advance possible before detonation

cylender filling = ignition advance

the more air the less you can advance it, i.e if your at the limit and raise the charge temp(more air or higher compression) you need to back off the ignition advance

if your raising compression I would only back the advance off in the high torque sites, and then move back in after to get optimum advance
Cheers, that make sense. 8)

I think the way they map the ignition if you have acess to a RR is advance the timing until you get max power at the load site your working on, check the fueling as you tweek it and then back it off a tad to give a margin for error for bad fuel ect to stop it pinking.

Shame i've not got a RR to use :( :)
your right, when you have a rr or a dyno as I like to call them,
you can fine tune the ignition alot more, and remove any and all
iregularities or dips in the curves at diffrent loads,

I wish I had a dyno myself :P
but it´s about 4years until that happens
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Post Tue Jun 13, 2006 9:35 pm

I got the Alpina engine today but what with the rain i haven't been able to do much with it yet, i need to dummy fit a head and old head gasket because i've got a feeling the pistons will hit the head because of the shape of them and they stick out the block a bit more :(

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Old standard piston

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The areas inside the red lines are where i think the Alpina pistons might hit :?

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Post Tue Jun 13, 2006 10:01 pm

What can you do to get round this ?

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Post Tue Jun 13, 2006 10:03 pm

Plate between the block and head? or new lightweight pistons in the shape of the ones before
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Post Tue Jun 13, 2006 10:26 pm

It might need the combustion chambers fettling by some one who knows what they are doing, i.e not me :)

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Post Tue Jun 13, 2006 11:55 pm

Alpina ones look alot like stock m20 ones but cant be cos they different bore sizes, maybe you could try rest head on block with head bolts with tops cut off and turn it over slowly to see if it touches and maybe try put some putty in there to see how much thickness it leaves there is if doesnt touch then you know if you got a safe clearance, if it touches see what the thickest MLS gasket you can get is and shim it up by that much and if it still hits them you know the combustion chamber needs some work. The combestion chambers are quite similar to M20 aswell, tho im not sure they are quite that shallow at the edges
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Post Wed Jun 14, 2006 12:54 am

thats odd... it should be the same should it not, dont think they should protrude - that would indicate a different stroke/rod length possibly

Alpina's used standard heads yeah?

Might have to be careful with your higher lift/duration cam also to avoid piston - valve contact (dont know the clearances/specs involved)
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Post Wed Jun 14, 2006 8:21 am

Think I'd go with the putty idea to check the piston to head clearance.

Looks like they're only, what, .25mm out of the bore or so? What's that, 10thou less clearance odd, surely Alpina didn't mod the heads to miss their pistons did they?
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Post Wed Jun 14, 2006 12:25 pm

Im not too sure thats going to work. Those new pistons look like they have a totaly different head casting to go with them, like someone else pointed out they look M20 almost.

H/C is good you will yield more torque and HP !!!

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Post Wed Jun 14, 2006 1:16 pm

E28->34 M30 heads have a diff part number so something must have changed, the early 3.5 has diff bore/stroke ratio too iirc ?

Dummy bulid is certainly the way forward here Andy.
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Post Wed Jun 14, 2006 9:27 pm

The engine is supposed to be from a E34 B10, it has the upward pointing oil filter housing which again points to it being from an E34 but it's in no way concluesive.

Well, it wasn't raining when i got home today so i cleaned the block face up and dummy fitted it with an old H/G and a bare scrap e34 head, it doesn't quite get to TDC and locks up :?

I'm hope fully going to get some pictures of the 'pina head tomorrow to confirm the combustion chamber shape, but it's fairly obvious when you see it in the flesh that it's going to need some shaping. I don't think it will need much taking off at the mo' but i will have to wait and see.

But this brings other problems like measuring what will be the new squish band and taking off the same amount of metal and shape/angle through all six C/Chambers.

So i need to know where to get some suitable putty/plasterseen(sp?) to measure clearances and how much squish clearance should i aim for ?1mm ? 0.75mm ? 0.50mm ?

I also think to do a proper job i will have to measure the CC's of each C/C.

I've read some where that the way to do it is to smear a little grease on the valve seat to help sealing, insert the valves and springs. Cut a square of clear plastic with 4 bolt holes and a small hole to put the water in. Another smear of grease on the cylinder head face and secure it with 4 bolts/nuts and add water with a syringe(sp?) and measure/keep note/grind some more and repeat. Sound's like fun ! :mad: :)

So much for getting back on the road by this Sun/Mon :cry:
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Post Wed Jun 14, 2006 10:39 pm

Andy335Touring wrote:The engine is supposed to be from a E34 B10, it has the upward pointing oil filter housing which again points to it being from an E34 but it's in no way concluesive.

Well, it wasn't raining when i got home today so i cleaned the block face up and dummy fitted it with an old H/G and a bare scrap e34 head, it doesn't quite get to TDC and locks up :?

I'm hope fully going to get some pictures of the 'pina head tomorrow to confirm the combustion chamber shape, but it's fairly obvious when you see it in the flesh that it's going to need some shaping. I don't think it will need much taking off at the mo' but i will have to wait and see.

But this brings other problems like measuring what will be the new squish band and taking off the same amount of metal and shape/angle through all six C/Chambers.

So i need to know where to get some suitable putty/plasterseen(sp?) to measure clearances and how much squish clearance should i aim for ?1mm ? 0.75mm ? 0.50mm ?

I also think to do a proper job i will have to measure the CC's of each C/C.

I've read some where that the way to do it is to smear a little grease on the valve seat to help sealing, insert the valves and springs. Cut a square of clear plastic with 4 bolt holes and a small hole to put the water in. Another smear of grease on the cylinder head face and secure it with 4 bolts/nuts and add water with a syringe(sp?) and measure/keep note/grind some more and repeat. Sound's like fun ! :mad: :)

So much for getting back on the road by this Sun/Mon :cry:
method of CCing is spot on, use the flat surface (clear plastic bit) to prevent meniscus of water. i use sand too to verify on pistons, but you have a nightmare cleaning everything up. i use blue tac as the plastercine stuff. you will def have to check impact on CR and measure CC of all combustion chambers. is it gonna be worth it? how far is the increase in CR going to be mitigated by the increased volume of the C/C? (btw haven't read thread in detail, just last post).
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Post Wed Jun 14, 2006 10:59 pm

I should be going from 9.0:1(standard M30) to 10.6:1(alpina pistons/bottom end)

I am going to try to copy the 'pina head, although i will be increasing the the head volume slightly the pistons protrude more in to this space so i should still have acheived a C/R of 10.6:1

Blutack seems a little rubbery, if you squeeze or pull it, it want's to pull back to shape a little, not ideal stuff to use i'd have thought ?
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Post Wed Jun 14, 2006 11:17 pm

Andy335Touring wrote:I am going to try to copy the 'pina head, although i will be increasing the the head volume slightly the pistons protrude more in to this space so i should still have acheived a C/R of 10.6:1

Blutack seems a little rubbery, if you squeeze or pull it, it want's to pull back to shape a little, not ideal stuff to use i'd have thought ?
oh yeah, that figures. how much are you talking about increasing the chamber size by? do alpina do the same on their heads? how much clearance are you going to leave between the piston and the chamber on the bits where the piston protrudes?

blu tac works ok for me, i understand what you're saying, but you're gonna have to use something that deforms/compressed obviously, once compressed by the valve it doesn't look like its pulled up back into its pvs shape at all. just played with some to check, it seems fine and not spongey/elastic (for want of better words!)- honest! used it on the dry build and testing of my M42 to do this, found it good because it doesn't stick to the valve, you can easily cut away a bit from the piston and then measure. mb give it a go, see how you find it?
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