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Discussion Starter · #1 ·
I am planning on the following engine mods this winter once it gets too cold to ride regularly (mid to late November):

Remove engine and pull it down.
Connecting rods - polish and shot peen/nitride, balance, and coat with oil shedding coating.
Pistons - balance, coat skirts with low friction coating, coat tops with ceramic reflective coating.
Crankshaft - balance, aero shape the throws, and coat with oil shedding coating.
Head - Get stock flow numbers, port and bowl clean up, dimple low velocity areas, cut for added compression, get modified flow numbers, ceramic (reflective) coat chambers, valves, exhaust ports.

Possibly add crank scraper to reduce windage - need to look at this in detail.

Since I am doing most of this myself, the cost is low.

Custom header

Custom cams will follow at a later date - stage 3.

I will post photos and measurements as this progresses.
 

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I live in a condo. I'm just happy to have a garage to keep my S3 in. My planned mods for the winter include reading all about what others are doing and wishing I had the talent/know-how/tools/equipment to do the same. Can't wait.
Fred
 
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Discussion Starter · #4 ·
Stage 2 of this development work is not going to be for everyone. But even so, I think some will find it entertaining, if nothing else.  ;D
 
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Discussion Starter · #5 ·
I am debating about installing oil squirters in the block to spray oil on the bottom of the pistons to keep them cool. This is for the potential forced induction I am planning.

I have the turbo and soon a supercharger, air-to-air and air-to-water intercoolers, and more. But at this stage of the game, this is a possible stage three mod in place of aftermarket cams.

As always, plans far exceed current time.
 
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Discussion Starter · #6 ·
Hey Dev take your time.

I get this feeling once you "do it all" you will go find another project possibly not an S3 and leave us all alone! lol :D

Make your next project a RSVR Mille preferably 2002 model. :p

Mark
 

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That's awesome, devi!

Coating everything with stuff... what is it supposed to do? Why is does it do what it does?

I would love to take my engine apart too! Too bad I propably couldn't get it back together! :D
 
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Discussion Starter · #8 ·
There are MANY different types of coatings. In fact, the D675 has the piston skirts and ring lands coated with a VERY low drag coating called Diamond-Like Carbon (DLC). I have used DLC and it works VERY well - reducing friction by more than half.

Low friction coatings reduce friction is high load areas like piston skirts, some types of bearings, cams, etc. This frees up power at higher rpm.

Oil shedding coatings on the crank, rods, sump, etc. and a crank scraper, reduce oil build up on these parts and reduce windage - the added weight of oil, and its tendancy to foam when beaten by the rotating parts. These coating work best in high revving engines like cycles.

Reflective coatings on piston tops, chambers, and exhaust ports are used to improve thermal efficiency. They keep the heat in the chamber (not lost to the cooling system), which makes more power. They can also be used on the valves to prevent the intake valve from getting hot and transfering this heat to the incoming air/fuel charge. They also reduce the tendancy for hot spots in the chamber (and exhaust valve) to form and reduce the chance of pre-ignition and detonation. This is especially true at lower rpm when heat in the chamber has more time to soak into engine parts.

Depending on the engine design, the coatings used, and the rpm the engine sees, I have seen improvements from 3-5% in peak power, and even more lower rpm torque improvements when the engine is modified and tuned to take advantage of these coatings.

Lower friction, better efficiency, improved throttle response ALL can be had with coatings. Many OEM's are starting to take advantage of this technology, and racers have been using it for decades.

Also, cryo-treating the pistons can greatly increase the lifespan of the skirts and ring lands - keeping the bore seal better for up to 50% longer.
 
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Discussion Starter · #9 ·
If you pick up a couple of percent more power with coatings, a couple more with some head work, a bit more with a custom header, a little more with better ring seal, more with increased compression/better squish and quench, a slight bit more from a better balanced engine, and soon it all adds up to a consideral improvement. AND you improve the engine life and mileage in the process - IF you do the right mods.

Like I said above, it is not for everyone, but can be entertaining. If someone learns something in the process, even better. Especially if it is me.
 

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Devious - I think it's gonna be time for you to start a custom tuning shop.....  For all of us who lack the space/skill to tweek our bikes in this manner.  Until then keep the posts coming!  I may be getting smater..... Who'd've thunk it! ;D
 
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