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Volvo Redblock Cylinder Head

by Ceravyn, published

Volvo Redblock Cylinder Head by Ceravyn Nov 14, 2015
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7976Views 2494Downloads Found in Mechanical Toys

Summary

Inspired by the Toyota 4 cylinder engine found here http://www.thingiverse.com/thing:644933 I thought it'd be cool to have more different kinds of these available for download. So.

This model is based on 8-valve cylinder head found from Volvo's 2.0 - 2.3l "Redblock" engines (B200-B230). It uses singular overhead camshaft operating the valves without rockers. Volvo has made these with various configurations, different camshafts etc as it's standard head found in both turbocharged and non-turbo redblocks. These heads don't have bearings for camshaft either, it's simply locked in place with the collars and constantly lubricated with oil channels running around the cam mounts. Super simple.

This isn't meant to be an exact replica: measurements were taken using non-digital caliper so some of them are pretty surely off, intake/exhaust channels are very basic (straight to the valves) and coolant channels are completely missing.

However all the mechanical stuff works and it provides good view of OHC head operation. Files marked as SCALED are ready to print, 40% scale and checked with netfabb.

SCALED files also include some features for easier assembly: places for 4mm x 2mm disc magnets to attach rocker cover and, possibly in the future, the head to the block. Tolerances have been checked for easier assembly, but some can still be pretty tight and require sanding/drilling (depending on printing quality). Like the Toyota engine, this isn't an easy assembly to complete either and does challenge your printer and nerves.

List of parts needed to print:

  • Head x 1
  • Rocker cover x 1
  • Oil cap x 1
  • 1st shaft collar x 1
  • 2-4 shaft collar x 3
  • 5th shaft collar x 1
  • Camshaft x 1 (or camshaft split 1 and 2)
  • Valve intake x 4
  • Valve exhaust x 4
  • Cam sprocket x 1
  • Valve cap x 8
  • Valve spring retainer x 8
  • Retainer holder x 8

Video: https://www.youtube.com/watch?v=kX2LNHgHR7c

I had to rotate camshaft to wrong way in the video due to my drill being broken :p the real engine rotates cam in clockwise direction.

Firing order is 1-3-4-2, with 1 closest to the timing belt sprocket.
Wiring order for distribution cap is therefore 4-3-1-2 (left to right, looking from front)


NOTE: If you are printing, make sure you pick the SCALED files, the original ones are in REAL SIZE.


Update 24th Nov 2015: Replaced head_SCALED.stl, rocker_cover_SCALED.stl and valve_cap_SCALED.stl to fix some tolerance issues found after test print. Removed "Work in progress" stamp as the test print turned out pretty good.


Related Things:
Distributor: http://www.thingiverse.com/thing:1133141
Thermostat: http://www.thingiverse.com/thing:1133322
Additional non-mechanical components: http://www.thingiverse.com/thing:1176179

Print Settings

Printer Brand:

RepRap

Printer:

i3 variant

Rafts:

Doesn't Matter

Supports:

Yes


Notes:

Supports required for Head and Camshaft_T (or camshaft split 1 and 2).

Camshaft can be printed in 2 parts if your build platform height isn't sufficient. The split versions can be joined together with glue and 4mm stud, and feature small alignment marks near the cut surface to help with proper alignment.

Rocker cover features some long-ish bridging but I was able to print it without supports, use your own thinking with this, it may or may not require supports depending on your printer.

Rest of the parts can be printed without supports.

For layer heights I used 0.1mm for smaller parts and 0.2mm for the rest.

Post-Printing

Assembly instructions

VALVES:

  1. Insert valve to its seat from the bottom of the head.
  2. Drop a spring around valve stem from above, spring should be long enough to reach at least the washer groove on the valve stem.
  3. Insert spring retainer to the valve stem and compress the spring a little bit.
  4. Lock the retainer by inserting the holder washer to the groove in the valve stem. Release the spring from compression.
  5. Drop the valve cap on top of the valve stem. It should sit a couple of mm above the head surface, and the valve should move smoothly down and back up when pressing it.

CAMSHAFT:

  1. If you printed the cam in two parts, insert a short 4mm stud to either part's cut surface. Align the parts by the small mark on the cut surfaces and glue together.
  2. Once you have camshaft completed, drop it in its mounts on the head and apply some silicon grease for smoother operation.
  3. Glue and/or screw the cam collars to hold it down. (1st collar to the front, 2-4 in the middle, 5th to the rear)
  4. Insert timing belt sprocket and glue and/or screw it to the front end of the camshaft.
  5. Rotate camshaft, testing all valves open and close smoothly.

Rocker cover can be installed either by screws or by 4mm x 2mm disc magnets.

You can use silicon grease to further smoothen operation by applying it to the sides of the valve caps, to the cam lobes etc.

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Awsome design! Why not make a egine block too :) ? And crank sump etc :)

Thank you! ^-^
Engine block is mounted in my car which makes it a lil difficult to take measurements :( head I had indoors for repairs so it was easy to get the dimensions for that. But hopefully I'll find a way someday! I'd love the whole engine miniature on my own desk too ;)

Comments deleted.

Thank you for this awesome design!
Really cool that you are incorporating LEDs to visualize the spark.

it would be cool to see a turbo

I do have the stock Mitsu TD04 somewhere so maybe :)

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