Speaking of the Jesel Custom OHC Followers ...
Overhead Ed 101
http://www.nmradigital.com/2011/02/17/overhead-ed-101/
NO PUSHRODS? LOOK NO FURTHER…
Last month we talked about pushrod camshaft design parameters, and
what it takes to make one of those camshafts perform properly under the
intense conditions found inside many of today’s top runners. This month,
we’ve decided to delve into the Modular powerplant; a chance to get
together and discuss technology with some of the best and brightest in
the industry was one that we didn’t want to pass up. We’ve built many
project engines over the years, and have never gotten too deep into the
technology behind the overhead-cam revolution, but that’s about to
change. Between this article and some others we have scheduled for the
upcoming pages of this very magazine, we hope to be able to share with
you the speed secrets you seek for your Modular machine. Ford’s Modular
powerplant and all other overhead-cam engines share many design
features. When compared to a pushrod design, the advantages of the
overhead-cam layout are many, and the downfalls are few. All overhead
valve (OHV) designs feature a single, centrally-located camshaft that
drives pushrods, which in turn actuate rocker arms, which move the valve
tip to open and close it – meaning that there are four moving parts for
each valve. An overhead cam (OHC) design like the Modular has fewer
parts – typically a camshaft and a follower much like a rocker arm are all
that’s needed to create the valve motion. Fewer moving parts equals less
mass, which in turn means a higher-revving valvetrain and reduced stress
on the moving parts. However, the drive system gains more complexity
over the single timing chain and gears of the OHV setup. Although at least
two timing chains (or four in a dual-OHC setup) and the associated
tensioners and bracketry add extra cost on the front end, the improved
engine breathing afforded by the OHC setup becomes well worth it to the
enthusiast. Read on as we consult with the experts on what it will take to
make your Modular rev-worthy…>>
REV IT UP
One of the inherent advantages to the Modular (OHC) engine design is its
improved breathing capabilities over the years-gone-by pushrod design.
Why is this, you ask? It’s not necessarily because of the improved
cylinder port layout that is a result of moving the camshafts atop the
cylinder heads, but mainly the reduced mass in the valvetrain assembly.
As we talked about in last month’s pushrod-based camshaft article,
anytime you can reduce mass in the valvetrain a corresponding gain in
RPM is the result. Dave Crower of Crower Cams and Equipment explained
at that time, “Every gram of weight that you can get off the valve is a
25RPM improvement. We’ve seen 1000RPM increases in a pushrod-style
engine by swapping to a titanium valve in a race application.” That’s where
the OHC Modular design excels – with no pushrods in the mix to add weight
(and flex), and a follower that’s half the weight of the typical OHV rocker
arm, the Modular has a leg up on the competition before the flag’s ever
dropped. The stock SOHC Modular powerplant in a ’99-’04 Mustang was
good for 6000RPM before giving up the ghost and the DOHC Four-Valve
Modular carried a 6500RPM redline from the factory. The OEM camshafts
were designed to make plenty of low-end torque, as the small 4.6L
displacement needs all of the help it can get, but modifications to the
entire engine can be made to take advantage of the Modular’s highrevving
capabilities. Even though there is less mass in the valvetrain, don’t let
that fool you into thinking that stock parts are good enough to spin your
Modular to the moon. As Jesel Engineering’s Bob McDonald explains,
“Regardless of what you do, you need to stabilize the valvetrain – it all
depends on how much you want to rev it. If you’re trying to get to
10,000RPM with it, the stock valvetrain just isn’t going to do it. You need
something with a roller tip on it so that it’s not skidding around on the
valve. Also, lighter weight helps out a lot – the same basic properties of
what you’d need to do with a pushrod engine still apply, even though there
aren’t any pushrods in these engines.”
Jesel’s steel roller followers have been on the market for a number of years
and perform admirably; in fact, we selected them for our Two-Valve
project engine build. They offer both a hydraulic- or solid-lash-post
design.
In a typical pushrod engine, valvetrain geometry is a huge issue; without
the correct pushrod length the valve will not open properly and too much
(or too little) of a rocker ratio will affect engine performance. These
issues are in the past with the Modular engine platform. As McDonald told
us, “With a Modular there are no geometry issues – the follower is wedged
between the cam and the valve. The main problem we faced when
designing our roller follower was getting the parts to last, as many of the
stock pieces we had seen were cracked between the tip and the roller.
There are no angles or heights or anything else to worry about like you
would have to with a pushrod-style application.” One of the ways that
Jesel engineered their product around the limitations of the package was
to use proven components. “We replicated a stock follower in terms of
dimensions, but engineered it to last and perform well. We used all of the
same materials we use in our other rocker-arm assemblies that last well in
high-RPM engines—the same nose wheel, the same kinds of bearings, the
same materials,” McDonald explained.
TIMING IS EVERYTHING – ESPECIALLY ON THE NEW STUFF
The ability to turn more RPM is one of the main advantages of the OHC
design, and the last several years have been incredible for anyone who
makes a living tuning on cars with one of these engines. According to
Comp Cams’ Billy Godbold, “Any time you advance the cam, the intake
valves get closer to the pistons, and any time you retard the cam the
exhaust valves get closer. With the stock 3V cam phasers changing the
cam timing by as much as 60 degrees, that really limits how much cam
you can put into the engine if your goal is performance. Say you took a
Three-Valve Ford and put a big old cam into it and didn’t do anything else,
you’d crash all the exhaust valves into the pistons. It really puts you into
a box in terms of what cams you can put into a Three-Valve engine
because you have to follow the original exhaust lobe profile to keep from
banging valves into the pistons.” However, there are a number of ways
around this problem, mainly the use of a phase limiter, offered by several
different aftermarket companies. Since the camshaft is moving around a
ten-degree range of retard under full throttle (the rest of the swing is
during part-throttle operation), using a limiter of some sort helps quite a
bit with maximizing available power on the dragstrip—as with any other
performance parts, you need to determine what makes the most sense for
your program.
Ford’s ingenious use of oil pressure to control camshaft timing has made
the Modular-style engine a heavy-hitter despite its lack of displacement.
Having computer control over this most-important engine parameter was
unheard of even ten years ago.
A conversation with noted tuner Ken Bjonnes of DiabloSport revealed more.
“The Three-Valve is pretty unique as compared to the Two- and
Four-Valve since you have variable cam timing and the charge motion
plates. This brought the need to get very complicated in the timing
requirements for the different cam positions and whether the plates where
opened or closed. Of course, many modified Three-Valves will delete both
of these items (VCT and the plates) so at that point you have to address
the timing tables. Not only do most people delete them, but I personally
recommend it on the 3v, as I don’t feel the VCT system is robust enough.
The problem is, many people put lockouts in, and in stock form oftentimes
the lockouts put the cams in a less than desirable position, but it’s a
compromise due to the cost of the lockouts versus adjustable cam gears,”
said Bjonnes. Dez Racing’s Mike Dezotell also weighed in by explaining,
“Tuning on these is actually not all that much different from tuning on a
pushrod, but the Modular powerplants do require different timing curves,
with the Four-Valve accepting more timing due to its open chamber and
better spark plug location.” Dezotell’s years of tuning experience has
taught him to recommend removing the Three-Valve phasers if you plan
on spinning past 7000RPM, and he also recommends using a chassis dyno
and knowledgeable tuning specialist to help unlock your car’s
performance.
The Three-Valve cam phasers allow up to a 60- degree swing in timing
during part-throttle operation, which is great for emissions. Locking the
phaser during operation allows performance modifications to be made
without the fear of engine damage.
We also cornered Phil Elliott from T&D Machine Products, who explained
how his company got involved in the Modular market after years of making
shaft rocker systems for pushrod engines. “Kyle Carrothers from Roush
Performance approached us about making these for a Super Stock
program he’s part of, when they couldn’t keep the OEM followers alive
under hard use. We were hearing that the stock investment-cast pieces
were just disappearing under hard loads – not cracking, but actually
turning into the powder from which they were derived,” he recalled. After
conversations with some of the top engine builders in the country, the
T&D gang set out to build a product that would last for their customers.
The realization came quickly that there were design limitations; in other
words, there was no way to make a roller follower adjustable due
operating limitations, so they had to focus on longevity and strength, two
features built into all of their other products. “We cut our followers from a
single piece of billet steel, then we heat treat them for more rigidity. They
have tool steel axles, captured needle bearings, a roller tip, are fully
rebuildable, and are available for each of the Modular engine types. With
all of these improvements, there hasn’t been someone to be able to
destroy the parts – it has stayed with all of our various customers that
are pushing them incredibly hard. Our customers have been breaking
records with these followers,” said Elliott.
T&D has worked very closely with Kyle Carrothers of Roush Performance to
develop their Modular follower systems. Available in 4130 chromoly, these
will stand up to just about anything you throw at them.
Whenever you modify an engine to make more power and turn more RPM,
there are also concerns that have to be taken into account in the
interest of longevity, a factor each of the experts we spoke with
reinforced heavily. Do your research, work with your engine builder, and
above all, ask questions. An engine build that’s done correctly the first
time will be far more enjoyable than a build that needs to be re-done a
second or third time due to corner-cutting. Figure out what you can
afford to build (and maintain) and get cracking—your Modular awaits!
Sources:
COMP Cams
www.compcams.com
Crower Cams and Equipment Co., Inc.
www.crower.com
Dez Racing
www.shopdezracing.com
DiabloSport
www.diablosport.com
Jesel Valvetrain Innovation
www.jesel.com
T&D Machine Products
www.tdmach.com
Written By: Jason Reiss
Terry