This is really cool!

[Jstas]

It's a video of a CNC machine taking a billet of aluminum and carving out a 427 FE engine block.

Kirkham Motorsports usually needs about 30 hours of computer-controlled machining to turn a 383-lb. aluminum billet into a 64-lb. engine block for its self-designed 427. Luckily for manufacturing geeks, they've shortened the process to seven minutes for this video.

While it looks like a button-pressing gig once in the machine, the programming for the CNC took 50 hours, on top of an additional 30 hours designing the block itself.

Pretty neat stuff.

BTW, for those that don't know, a 427 FE is also know as the Ford FE Engine. It powered Mustangs in a 390ci size, especially the Bullitt Mustang from the movie. It's also powered the Ford GT-40, the Shelby Cobras, the first funny cars, several record breaking racing boats and the original Batmobile. On top of that, the manufacturing process for the FE was ground breaking at the time because it used a thin cast process.

The FE block was cast using a thinwall casting technique. Instead of relying on large quantities of metal being poured into molds in unnecessary thicknesses, Ford engineers determined the proper amount of metal actually needed and reengineered the casting process to allow for consistent dimensional results pour after pour. This resulted in less metal being used, lower cost of materials for Ford and lighter engines. A Ford FE from the factory weighed 650 lb (295 kg) with all iron components. With an aluminum intake and aluminum water pump this weight could be reduced to under 600 lb (272 kg). At the time, engines of similar displacements such as the 7 liter offerings from GM and Chrysler weighed over 700 lb (318 kg). This weight savings was significant to boaters and to racers.

The process was used to make most of the engines that many of us can rattle off the tongue now. Ford 302/351, Chevy 350, Dodge 318 and so on all benefited from that process by making the waste minimal and the casting method consistent. That dropped costs and made production fast and easy. The FE isn't just a famous hot Ford engine, it's a pioneer in manufacturing techniques. It was so successful that it had 11 variants and powered all but the smallest Ford's as well as multiple race cars and even industrial applications.

[NotaSuv]

very cool thanks for sharing Jstas

[maximillian]

Isn't aluminum a bad choice for an engine block? I know it's weighs much less compared to steel, but it's also far less durable. I guess for people into racing this is great, but for average consumers I would prefer not having to replace engine block parts at 100K.

[Jstas]

Isn't aluminum a bad choice for an engine block? I know it's weighs much less compared to steel, but it's also far less durable. I guess for people into racing this is great, but for average consumers I would prefer not having to replace engine block parts at 100K.

No, it has superior cooling capabilities and is a fraction of the weight of iron. Besides, it's not raw aluminum, it's an alloy and it has similar strength properties to a high nickel content steel block. It's not quite on par with steel but it's close enough.

Besides, the block is likely sleeved with iron liners in the bores. That way the steel or aluminum pistons will be riding in an iron liner which can likely be milled in-block without having to be removed. It also give the engine the long term wear properties of iron without the weight and cooling disadvantages.

The only problem with aluminum is the steel casting process doesn't translate to aluminum. So it gets cast by either compressing and then baking powdered or pelleted aluminum or it gets cut out of billets. There is another casting process that Ford uses but it's proprietary and I don't know anything about it.

Most engines in modern vehicles are aluminum blocks now anyway. Only trucks are still standard steel because of weight. The truck's weight causes the engine's torque to have more resistance to fight against. So aluminum is not a structurally strong and resistant to shearing as steel so high torque applications still need steel to resist twisting. Aluminum alloys still have pretty good pressure and compression properties though which makes it great for racing vehicles!

[Joe08867]

Most engines in modern vehicles are aluminum blocks now anyway. Only trucks are still standard steel because of weight. The truck's weight causes the engine's torque to have more resistance to fight against. So aluminum is not a structurally strong and resistant to shearing as steel so high torque applications still need steel to resist twisting. Aluminum alloys still have pretty good pressure and compression properties though which makes it great for racing vehicles!

Well Said, That was eloquent and concise.

Thanks for posting the video. I love this kind of stuff.

[nguyendot]

The main downside on the aluminum blocks is working on them - stripping the holes is a big problem. Otherwise they're great.

[Jstas]

The main downside on the aluminum blocks is working on them - stripping the holes is a big problem. Otherwise they're great.

Well, it's not so bad. Just gotta be careful. Everything needs to be torqued down properly and you need to use an anti-galling lube.

[virtualdean]

No, it has superior cooling capabilities and is a fraction of the weight of iron. Besides, it's not raw aluminum, it's an alloy and it has similar strength properties to a high nickel content steel block. It's not quite on par with steel but it's close enough.

Besides, the block is likely sleeved with iron liners in the bores. That way the steel or aluminum pistons will be riding in an iron liner which can likely be milled in-block without having to be removed. It also give the engine the long term wear properties of iron without the weight and cooling disadvantages.

The only problem with aluminum is the steel casting process doesn't translate to aluminum. So it gets cast by either compressing and then baking powdered or pelleted aluminum or it gets cut out of billets. There is another casting process that Ford uses but it's proprietary and I don't know anything about it.

Most engines in modern vehicles are aluminum blocks now anyway. Only trucks are still standard steel because of weight. The truck's weight causes the engine's torque to have more resistance to fight against. So aluminum is not a structurally strong and resistant to shearing as steel so high torque applications still need steel to resist twisting. Aluminum alloys still have pretty good pressure and compression properties though which makes it great for racing vehicles!

I've always been fascinated by metal mills...I could get into casting and rolling steel...The Power!...