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Tech Tips Showcase: The Engine Builders Association’s (AERA) Shop Kinks Contest

Engine builders know as well as anyone that necessity is the mother of invention. On a weekly basis, engine builders find themselves in need of ways to make the rebuilding process more efficient, easier and more accurate.

With this motivation, many shop owners and workers invent, modify or recycle shop equipment that can aid in making their shops some of the best in the business. Better yet, they’re willing to share that information with you through the Engine Builders Association’s (AERA) Shop Kinks contest. Sponsored by AERA’s Vanguard and Martin Wells Valve Seat Company, the annual Shop Kinks contest showcases these innovative ideas and offers first, second and third place prizes. The winners were announced at AERA’s Expo 2001 in Orlando, FL, June 23.

The first place winner received air fare to Orlando, three nights hotel accommodations and $750 cash. Second place received $200, and third place won $100. Each person who submitted a qualified entry received either a Team AERA hat, pocket T-shirt or a rod and piston key chain. Included here are just some of the submissions, including the winners, and the descriptions of the entries in the words of those who submitted them. Space does not permit us to print every Shop Kinks submission, but here are some of the best.

First Place Winner
Submitted by Russell Rogers, Harry’s Machine Works, Inc., Dodge City, KS.

Wrist Pin Bushing Installation Tool
Rogers has devised a method of installing connecting rod pin bushings for larger diesel connecting rods that are tapered on the top. Rogers created tooling that holds and locates the oiling hole of the bushing while the rod rests on specialty contoured holding plates. Larger connecting rods are somewhat cumbersome and require working with multiple pieces at the same time. Using these tools has sped up the task of installing tapered piston pin bushings and has made it much easier with Rogers’ bushing driver and rod holding fixtures.

Second Place Winner
Submitted by Jim Iwanchuk, Canada Auto, Winnipeg, Manitoba, Canada.

"Catch All"
Iwanchuk’s "Catch All" consists of magnets taken from old, burnt-out heater motors which are then placed in a valve refacer coolant tank to catch grinding particles. Iwanchuk advises that the rebuilder should remove the magnets every so often and clean them. The result is clean coolant all the time.

Third Place Winner
Submitted by Don Fedak, RPMS Engineshop, Brantford, Ontario, Canada.

Flywheel Imbalancer
Flywheels and harmonic balancers for externally balanced engines are engineered with a specific built-in imbalance. To check, balance or duplicate an imbalanced flywheel or balancer, we mount the part after rotating it 180 degrees with a similar component that has the proper imbalance, spin the two-part assembly and remove material from the subject part until the assembly is balanced. This procedure has proved to be an economical, quick and useful method for producing either an imbalanced spare or an imbalanced part from a balanced part.

Cutting Corners
Submitted by Don Fedak, RPMS Engineshop, Brantford, Ontario, Canada.

1990-2001 2.2L GM and 1994-2001 GM truck cylinder head castings tend to leak coolant from the corners on the exhaust side. To correct the problem, GM has modified its head gasket three or four times, with limited success. Meanwhile, all engine shops that service GM dealers have enjoyed the steady demand for warranty claim leak testing and machining of these heads.

Cylinder head specialists Jacques Giard (Motrex, Quebec City, Quebec) and Paul Lotey (Mr. Cylinder Head, Toronto, Ontario) are typical of many AERA shop owners. They do not enjoy dealing with comebacks that are due to OEM engine design problems. Paul and Jacques realized that the OEM casting design makes coolant leakage from the corners of the head gasket inevitable. Because the corners on the exhaust side of these heads include a step and large coolant passages, hot coolant is very close to the outside of the head. Their solution is economic, fast and exceedingly simple.

They reduce the possibility of coolant leaks by filling in the corners and reducing the size of the water passages. This increases the area of gasketed surface, contains the coolant and extends the service life of the head gasket. And, while they are doing this, they also add aluminum to strengthen the castings in the crack prone areas along the casting seam above the spark plugs for cylinders 1 through 3.

These two simple modifications enable them to supply reverse engineered cylinder head castings that never fail to perform in the same way as the original equipment part.

Rocker Stud Height Gauge
Submitted by Edward Talley, TSI/Pronto Auto Parts and Paint, Winchester, VA.

This is used for replacing pressed-in type rocker arm studs to obtain correct height. Cut a universal valve guide (11/32˝ or 3/8˝, whatever will slide over the stud) to the length of the stud before you remove it. Talley has several labeled for different engines. When you insert the new stud, slide the cut guide over it and press until you touch the guide. This is easier and more accurate than "sighting" it.

Oil Filler Tube Removal Tool
Submitted by Bob Burns, Weir Auto Parts, Osawatomie, KS.

To remove the oil filler tube from Oldsmobile V8 engines, clamp a discarded small engine connecting rod around it. This rod was from a Kohler engine and fit the tube perfectly. This gave a good area to strike with a hammer with no distortion to the tube.

Repairing Loose Fitting Rod Bolts in Connecting Rods
Submitted by Ed Shuman, Shuman’s Automotive and Machine Shop, Blandon, PA.

If new bolts or outside knurling of the bolts does not work, Shuman separates the cap from the rod and uses a 3/8˝ knurler to repair the bolt holes. Start from the inside of the connecting rod and knurl downward to repair the rod bolt hole. This way works best if used by hand. This enables you to custom fit the rod bolt either by reaming to 3/8˝ or not.

The entry for Shuman’s Automotive and Machine Shop was a video entry, and pictures were not available for print.

Long and Large Crankshaft Polisher
Submitted by Peter Burrows, Motive Parts Co. Inc., Port Washington, NY.

Problem: Polishing long and large crankshafts. Solution: Convert an align boring machine to polish crankshafts. Burrows’ set up was to purchase two stock tooling holders, 2˝ by #4 MT (Morse Taper), turn both ODs (outside diameters) to 45 mm and one unit to 1˝ drive size. Machine two aluminum thrust washers to slip over units to carry the thrust load of the centers. A plain dead center with an integral driving dog is used on the drive end. A live ball bearing #4 MT center is used at the other end.