The Elio Engine

[Kuda]

Snipped: I personally don't think any all aluminum engine should be built without studs instead of head bolts.

How about Stainless Steel Helicoils?

http://www.jeepforum.com/forum/f8/helicoil-aluminum-673054/

 

[ArthurKent]

No lack of ignorance about aluminum engines around here, I see.

 

[skygazer6033]

Helicoils really don't work that well on high stress applications. Any given point inside a helicoil is only strenghtened by the corrisponding point in the parent metal. There is a fix called a TimeSert which looks like helicoil but is actually a flanged stainless steel tube threaded inside and out. This is an approved repair for the Northstar V8.

 

[ArthurKent]

Anyone who has qualms about aluminum engines should stop worrying. Any bad experiences with aluminum engines that occurred over to years ago are obsolete. Today's die cast aluminum alloys are twice as strong as the old aluminum alloys used in years past and are stronger than cast iron, do not corrode or rust anywhere near as much as cast iron, dissipate heat far more efficiently and are much lighter and more durable than cast iron. I wouldn't want anything but an aluminum engine in my Elio. Nothing else makes any sense.

 

[skygazer6033]

I totally agree. A well engineered aluminum engine is almost a work of art. However there are factors that are a little different than dealing iron engines. Not necessarily better or worse just different. From what I've learned about the Suzuki G10 they are as tough and durable as a bush ax. With a small bore and a long stroke inline 3 makes a very light weight compact engine that should run 250,000 easily with proper maintenance. Using an updated version of the G10 is genius.

 

[wheaters]

I

I totally agree. A well engineered aluminum engine is almost a work of art. However there are factors that are a little different than dealing iron engines. Not necessarily better or worse just different. From what I've learned about the Suzuki G10 they are as tough and durable as a bush ax. With a small bore and a long stroke inline 3 makes a very light weight compact engine that should run 250,000 easily with proper maintenance. Using an updated version of the G10 is genius.

I agree. I have a G10 engined Suzuki Swift and the engine is a little gem, I often take it on my 90 mile commute in preference to my BMW 330D. I also have a G10 engine which will replace the Reliant 850 in my Liege, which is an all ally pushrod engine, good in its day but now sadly outdated.

 

[Ty]

Here's a picture of the Engine...

 

[Neal]

Just saw this on FaceBook. Very encouraging. I'm not very car/mechanically inclined, but it looks really good. I like seeing progress!!!

 

[Jeff Porter]

Am interested in your thoughts Ty... they said this was an aluminum casting of the engine. What does that mean, to those of us that know nothing about building engines?

Does this mean they are close to starting on building the final engine? I read the EM marketers say that the design of the engine is complete. From my point of view in software development, there is analysis, design, build, test. Is there a way to know, from the above casting, that IAV and EM are in the build phase?

 

[Ty]

Am interested in your thoughts Ty... they said this was an aluminum casting of the engine. What does that mean, to those of us that know nothing about building engines?

Does this mean they are close to starting on building the final engine? I read the EM marketers say that the design of the engine is complete. From my point of view in software development, there is analysis, design, build, test. Is there a way to know, from the above casting, that IAV and EM are in the build phase?

Jeff, I can't answer that with much more than a guess. IAV may have cast this one in aluminum to ensure fit while keeping it easy to move around. Pulleys and brackets and such will have to be fit to the block. If aluminum is the final material, which I think it is - Flame spray will harden up the cylinders saving weight over sleeving each cylinder with steel. So, yeah, I'd say this is the engine that will get accessories and eventually put on a dyno to check balance, noise, harshness, vibration, power, fuel consumption, etc.

I've built 7 or 8 engines but have never been involved in casting them. My engineering skills are in making the processes more efficient but not in mechanical design. Anyway, it doesn't take long to machine the engine and assemble it. They'll have to ship it to Flame Spray to get the plasma arc spray done on the cylinders before honing them but that shouldn't take too long. I'd guess in a couple of weeks, they'll have it mostly together and then will be designing brackets to hold the AC, alternator, power steering (if not electric or non existent) stuff. So, early September, I'll be looking for videos of the engine on a test stand being checked. Shortly afterwards, it could be in the car... They haven't said what transmission they are using yet, have they? That'll have to be decided before installing it in the car, too.