The Elio Engine

[DAVID BROWER]

I've been a bit concerned with the all-aluminum engine. Not only bad experience with an early '70's vehicle with aluminum heads but a dozen years as a machinist and now twenty-five years as a mechanical designer cause me to worry a bit. Cast iron sleeves in an aluminum block don't ease my worries any.

SURE , SOME ALUMINUM ENGINES WERE FIRST CLASS DISASTERS , THE VEGA BEING CHIEF AMONG THEM .
DONE RIGHT , THEY HAVE DONE FINE FOR NUMEROUS MANUFACTURERS FOR AT LEAST 75 YEARS .

THE ONLY BUGABOO BEING THEY ARE MORE EASILY DAMAGED WHEN OVERHEATED
BUT I WOULD CALL THAT ABUSE , NOT USE .

ELIO HAS GONE TO GREAT LENGTHS TO DO THE MOTOR RIGHT .

 

[DAVID BROWER]

Yeah, the old VW engines were the bomb! That's why most folks who owned a VW
kept a spare engine sitting on their workbench ready to swap out with the one in their car.

THE CASES ON THE OLD AIR COOLED VW MOTOR WAS MADE OF MAGNESIUM , NOT ALUMINUM .
THE AFTERMARKET DOES SUPPLY ALUMINUM CASE$ THESE DAYS & THEY ARE QUITE BULLETPROOF .

 

[Frim]

Recently watched a show on Velocity channel showing the build of a new Lamborghini 12-cyclinder engine. They exposed the cast iron sleeves to liquid nitrogen before inserting them into the block. As they returned to ambient temperature they expand slightly. Very tight fit. These engines are proven technology and in some of the most expensive cars in the world. Go Elio!

I used this technique to replace a valve seat in a Toyota B-210 engine head. It worked.

 

[Frim]

Yeah, the old VW engines were the bomb! That's why most folks who owned a VW
kept a spare engine sitting on their workbench ready to swap out with the one in their car.

THE CASES ON THE OLD AIR COOLED VW MOTOR WAS MADE OF MAGNESIUM , NOT ALUMINUM .
THE AFTERMARKET DOES SUPPLY ALUMINUM CASE$ THESE DAYS & THEY ARE QUITE BULLETPROOF .

The old mag cases are quite delightful when placed in a camp fire.

 

[Ekh]

I have experience with pressure welding of this sort. In my youth I used to shoot a muzzle-loading cannon with a private horse-drawn artillery regiment. (Don't ask, it's complicated). The barrel was made of alternate pipes whose inner and outer diameters equalled each other. Warm the larger, chill the smaller in dry ice -- slide 'em together and wait. Presto, perfect welds. Built up a barrel about 8 inches thick this way, then machined it and threaded the back for the end plug and cascabel (that's the knob at the back) which was screwed in then welded. This was done at the model shop of Pratt & Whitney during a summer hiatus. We shot beer cans full of cement, back when they had rims. Had to run 'em through a sizing die and grease them before they'd go down the barrel, but by golly that gun won competitions all over New England. Amazing accuracy.

 

[CrimsonEclipse]

I have experience with pressure welding of this sort. In my youth I used to shoot a muzzle-loading cannon with a private horse-drawn artillery regiment. (Don't ask, it's complicated). The barrel was made of alternate pipes whose inner and outer diameters equalled each other. Warm the larger, chill the smaller in dry ice -- slide 'em together and wait. Presto, perfect welds. Built up a barrel about 8 inches thick this way, then machined it and bored it. This was done at the model shop of Pratt & Whitney during a summer hiatus. We shot beer cans full of cement, back when they had rims. Had to run 'em through a sizing die and grease them before they'd go down the barrel, but by golly that gun won competitions all over New England. Amazing accuracy.

There's not a single part of this post that i don't love.

 

[electroken]

I have experience with pressure welding of this sort. In my youth I used to shoot a muzzle-loading cannon with a private horse-drawn artillery regiment. (Don't ask, it's complicated). The barrel was made of alternate pipes whose inner and outer diameters equalled each other. Warm the larger, chill the smaller in dry ice -- slide 'em together and wait. Presto, perfect welds. Built up a barrel about 8 inches thick this way, then machined it and threaded the back for the end plug and cascabel (that's the knob at the back) which was screwed in then welded. This was done at the model shop of Pratt & Whitney during a summer hiatus. We shot beer cans full of cement, back when they had rims. Had to run 'em through a sizing die and grease them before they'd go down the barrel, but by golly that gun won competitions all over New England. Amazing accuracy.

There's an urban myth around here from a long time ago about a guy who sank a buoy near Norwalk Harbor with a cannon and concrete-filled can. I'm starting to think it's not a myth.

 

[Horn]

I'm thinking that Elio realized they wouldn't be able to build their own engine and Linamar stepped in and said basically "We'll get you started and build some for you till you get the hang of it but we want to sell the motor to other markets." Perhaps they agreed to pay a bit per motor as well.

I'm curious as to what other markets. Don't get me wrong, a small 3 cylinder engine is simple and awesome, but it limits your market. For example in the U.S., it won't go in any other cars.

Overseas, they have such fuel efficient cars that I don't think this engine would do much for them. Possibly other types of off road vehicles?

Look at the Suzuki G10 (3 cyl) engine. You really don't see those anywhere other than in Suzukis/Geos....

 

[Sethodine]

I'm curious as to what other markets. Don't get me wrong, a small 3 cylinder engine is simple and awesome, but it limits your market. For example in the U.S., it won't go in any other cars.

Overseas, they have such fuel efficient cars that I don't think this engine would do much for them. Possibly other types of off road vehicles?

Look at the Suzuki G10 (3 cyl) engine. You really don't see those anywhere other than in Suzukis/Geos....

The G10 had some experimental aircraft builds, and the better low-end torque of the Elio engine would suit that purpose even better

 

[WilliamH]

I'm curious as to what other markets. Don't get me wrong, a small 3 cylinder engine is simple and awesome, but it limits your market. For example in the U.S., it won't go in any other cars.

Overseas, they have such fuel efficient cars that I don't think this engine would do much for them. Possibly other types of off road vehicles?

Look at the Suzuki G10 (3 cyl) engine. You really don't see those anywhere other than in Suzukis/Geos....

You seem to be all about limitations where as Elio is about possibilities.
You appear to be about why it can't be done where as Elio is all about working to get it done.
Somehow I don't think you are the one I would share forward looking plans with.