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That is an amazing amount of work , the hours of head scratching and work involved would be staggering . It would be nice to see the project completed.

Walter,

On all the picures it only shows one head on one cilinder:are the heads going to be individual or one head per cilinderbank?
Who's going to make the camshafts and rockers?

Keep up the good work!

Edit:I saw the pictures on the Boxergasse Fb-page-individual heads eh..one cam per side?

Individual heads, equal length headstuds, one cam per bank (two heads).
I have made no cont(r)acts as to who will manufacture the cams or rockers.
You volunteering?

So the cam runs out of one head into the other-with seals of course.Do you think uneven expansion of the heads/cilinders could cause binding of the cam?If I have to make you a camshaft the valves will be open for the whole duration...or closed haha!

Hi Arnoud,

The heads on one bank will be rigidly connected by a thick plate, see picture



But only live testing will be proof of course

I haven't been here in some time, glad to see you're still working on these, making progress..

Tom

Tnx Tom!
It does give energy to slowly see the pieces fall together. If all goes well, coming weeks might see machining of the core parts of the molds. And after summer could see the first cores being cast.

After a lot of work behind the scenes, the newly made casting molds yielded a milestone result: the first (test) castings!
To say I am very happy would be an understatement





Top two ones are the new castings, below one of the original heads which has been made some 40-45years ago with wooden molds (!)


The quality of the casting surprised me because I had not thought the divider fin inside the intake port would be this nice. Its exactly as we drew it!


Next job will be to machine the first head, so we can see if all measurements line up.

Make no mistake though: Lots of parts still have to be made, but this is very encouraging

they look are great looking castings , not sure if its been raised before but what style of cooling system are you planning on running ?

Looking very good! Are the new castings also heat treated? Keep up the excellent work!

Niceeee…
Multi valve and cross flow... should be easy making 100HP/L .
And smooth running engine..

Richie wrote: ↑Sat Jun 12, 2021 11:58 pm Looking very good! Are the new castings also heat treated? Keep up the excellent work!

Good question, in fact the foundry asked the same one. But heat treating came with a warning that some edges (fins?) of other parts may droop or have different sizes afterwards... I didn't want to risk that at this stage so for this first one(s), it will just be as cast. If lateron it may found to be benificial, we can always try it in a later batch.

wreck wrote: ↑Sat Jun 12, 2021 11:33 pm they look are great looking castings , not sure if its been raised before but what style of cooling system are you planning on running ?

Don't know yet tbh, it seems less important at this stage with so many other jobs still. Suggestions?

Eddie010 wrote: ↑Sun Jun 13, 2021 12:54 am Niceeee…
Multi valve and cross flow... should be easy making 100HP/L .
And smooth running engine..

The book says it should do 115hp/ltr, so I shoot for that goal first and see if 40+ years of (EFI) technology may help it even a little more.
Fingers crossed

Super cool! Will follow along eagerly.