WEBINAR: Cylinder Finish & Piston Ring Relationship Explained with Total Seal

Ed Kiebler of Rottler Manufacturing and Keith Jones of Total Seal team up Wednesday, October 21, 2020 at 10:00 AM CDT to discuss the science behind what makes a great finish. Ed will explain and demonstrate how proper honing techniques produce the right surface finish for optimal piston ring performance. Keith will package it all together from the ring’s point of view. This webinar will be done at location at Robert Yates Racing in Charlotte, NC .

After registering, you will receive a confirmation email containing information about joining the webinar. If you register for this webinar you will automatically receive a link to the recording whether you watch the webinar live or not.

You can access all 62 past recordings 24/7 at www.pera.org/webinars


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VIRTUAL EVENT: Engine Professional Expo

Mark Your Calendar & Register Today

Start 2021 with a one-of-kind, interactive, online event – The Engine Performance Expo. January 7th, 8th & 9th, 2021. No travel required, and registration is FREE.

This 3-day event showcases industry-leading engine builders, suppliers, machinists, and equipment manufacturers. The top people, parts, and processes in the high-performance engine industry will be featured each day.

From live panel discussions to detailed instructional demonstrations, the Engine Performance Expo delivers the “know-how” to go faster in 2021 and beyond. Connect with industry experts and see the latest products and processes.

Featuring engine builders from NASCAR to Diesel Drag Racing and beyond, the top names in the performance engine industry come together with leading suppliers to fill the “knowledge gap” left by the cancellation of PRI.

More details to come in the next few weeks as the schedule of speakers and demonstrations are confirmed. In the meantime, make sure to visit www.EnginePerformanceExpo.com to register and mark your calendar. These 3 days can change the season.

Tentative Schedule:

Day 1:
8 AM Opening & Featured Engine Builder Interview
8:30 AM Seminar with Q&A – Block Selection & Machining Considerations
9:30 AM Demonstration with Q&A – Block Machining
10:30 AM Seminar with Q&A – Surface Finishes & Sealing
11:30 AM Demonstration with Q&A – Surface Machining
12:30 to 1 PM – Break
1:00 PM Seminar with Q&A – Cylinder Honing & Surface Finish Considerations
2:00 PM Demonstration with Q&A – Honing & Profilometer
3:00 PM Seminar with Q&A – Rotating Assembly Balancing & Considerations
4:00 PM Demonstration with Q&A – Balancing Machine
5:00 PM Seminar with Q&A – Pistons, Pins, Clearances & Coatings
6:00 PM Demonstration with Q&A – Cleaning Equipment
7:00 PM Closing

Day 2:
8 AM Opening & Featured Engine Builder Interview
8:30 AM Seminar with Q&A – Engine Lubrication System – Pumps, Pans, Clearances, Filters & More
9:30 AM Demonstration with Q&A – Custom Parts Manufacturing
10:30 AM Seminar with Q&A – Cylinder Head & Manifold Porting
11:30 AM Demonstration with Q&A – 5 Axis Machining
12:30 to 1 PM – Break
1:00 PM Seminar with Q&A – Valves, Valve Seats & Guides
2:00 PM Demonstration with Q&A – Seat & Guide Machining
3:00 PM Seminar with Q&A – Valvetrain – Cams, Push rods, Rockers, Lifters & Valve Springs
4:00 PM Demonstration with Q&A – Spintron
5:00 PM Seminar with Q&A – EFI
6:00 PM Demonstration with Q&A – EFI Software
7:00 PM Closing

Day 3:
8 AM Opening & Featured Engine Builder Interview
8:30 AM Seminar with Q&A – Turbos
9:30 AM Demonstration with Q&A – Sleeving
10:30 AM Seminar with Q&A – Nitrous
11:30 AM Demonstration with Q&A – Bushing Installation
12:30 to 1 PM – Break
1:00 PM Seminar with Q&A – Diesel
2:00 PM Demonstration with Q&A – Diesel Specific Machining
3:00 PM Seminar with Q&A – Assembly Tips & Tricks
4:00 PM Demonstration with Q&A – Power Ring Filers, Bolt Stretch Gauge & Torque Angle
5:00 PM Seminar with Q&A – Dyno Testing & Health Checks
6:00 PM Demonstration with Q&A – Dyno Room Tools
7:00 to 8 PM Closing Roundtable

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Next Generation CNC Machining Centers

Rottler’s innovative EM Series CNC Machining Centers have been specifically designed to be the most technically advanced industry specific systems available. More than just a single machine, these new “Engine Machining” CNC Vertical Machining Centers are designed to give customers even more flexibility for engine parts machining, digitizing and porting, and custom parts manufacturing.

Rottler’s newest EM Series equipment is designed for maximum ease of use and efficiency thanks to our advanced 4C Machining Software. This advanced software lets users know they are machining with the most state-of-the-science equipment available.

Seamlessly integrating Computer Numeric Control (CNC), Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) in the industry’s most advanced Computer Measuring Machine (CMM), the 4C technology allows users to digitize, edit designs and begin cutting in less time but also requires less machining/programming expertise compared to many other systems. This brand new, revolutionary CNC machine CAD/CAM software allows 3D CAD Solid Models to be imported or created at the machine – the built-in CAM functions can be used to semi-automatically and interactively create complex 3D tool paths direct from the CAD geometry.

The advanced software design allows professional engine builders and head developers to maximize production and minimize preparation time. The next generation CNC control gives even greater capability beyond porting by letting users probe parts for duplication and modification all within the machine control – no external or third-party software or equipment required.

One of the main features is the EM series’ massive 32˝ touch screen – by maximizing screen size, Rottler’s CAM software allows unprecedented amounts of information to be displayed for the operator’s use. The user can choose the information to be displayed for incremental and interactive functionality. Rottler’s next generation CNC control found in the EM Series machines continues to give users unmatched speed of learning and ease of use when probing/digitizing without the need of additional cumbersome and expensive software.

Rottler EM69 Machine

Can’t find the parts you need for that one-off project? Make them yourself! More and more customers, after researching the real-world adequacy and challenges found in top-of-the-line industrial CNC machines, recognize the value and benefits of the parts machining capabilities built into Rottler’s equipment. Many of the EM Series machines can easily be programmed to custom create the parts you need when you need them.

Customers say it is the most user-friendly software they have ever operated because it allows even novices to be productive right away. Thanks to the speed and efficiency of 4C software, some machinists report being able to produce parts and port cylinder heads four-to-five-times faster than with other systems.

The software is only part of the secret to the EM Series’ attractiveness. These machines are designed to be up to the task of creating whatever our customers can dream up.

A lot of research and development has been put into sourcing and engineering the new high output spindle motors in the EM machines. CNC machine spindle motor power and torque is commonly given in two different ways – continuous and peak.

Continuous power and torque rating refers to the maximum cutting load that a spindle can sustain running non-stop, 24 hours per day without overheating. Advanced technology spindle motors are able for a limited time period to deliver substantially more power and torque before overheating.

Peak power and torque rating can be significantly higher compared to continuous rating but the limiting factor is heat. It is common when CNC machining that spindle motors are not running continuously (for example when changing tools). The depth of cut and feed rates will also determine to amount of heat that the spindle motor has to overcome. The integral spindle motors on the EM 5 axis models are liquid-cooled and the liquid’s temperature is accurately controlled by a special AC chiller unit allowing peak operation for longer periods of time.

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Building the Best, Using the Best

DFC Diesel, Alberta, British Columbia, Canada

When DFC Diesel first started rebuilding engines in 2010, president Matt Adams says the team quickly realized it wanted to build the best, using the best. “Thanks to brand new cutting-edge Rottler equipment we were able to bring an unrivaled level of precision machining to the Canadian diesel industry.”

Today, DFC uses a variety of Rottler equipment, including Rottler’s SG10XY for all of its 5.9L Cummins cylinder heads – “It can work on all 24 guides or seats while one of our machinists is able to operate other equipment during its cycle time,” says Adams.

“The rigidity of the spindle head and live pilot design gives mirror like seat finishes that are repeatedly cut to the same depth. This allows us to maintain strict quality control and have identical results on every cylinder head we remanufacture. Its automatic functions allow more production to be done and being CNC controlled gives repeatable results each time it is used.”

DFC received the fi rst automated hone from Rottler in existence and Adams says his workers are proud to showcase its abilities with every engine they remanufacture. “With a CNC controlled operating system it allows every engine to have the exact same crosshatch angle in every cylinder and with a load sensing honing head gets every bore within 0.0002˝ (two tenths of a thousandth inch) for taper and out of round with ease. Finishing off with a preprogrammed plateau mode gives our engines the same level of quality found when built in the OE manufacturing plants. These fi nishes are QC checked using a profi lometer ensuring the proper RA surface fi nish for proper ring seating and longevity.

“A welcome addition to our lineup of precision Rottler equipment, our EM69 was the fi rst one sold in Canada. This machine allows fast and precise digitizing and cutting of head ports and allows reverse engineering of existing port designs through the use of a Reninshaw probe. The ability to design intakes and produce custom parts as well as cut O-rings in cylinder heads raises the bar for precision engine machining equipment and further demonstrates our desire of bringing the most advanced machining equipment to the business.

“Finishing off our lineup of the most advanced automotive machining equipment in Canada is the SG9MTS seat and guide machine. The SG9MTS has all the same design features of the SG10X but in a manual version. The live UNIPILOT design keeps concentricity of seat cutting to above industry standard and the production fi xture combined with programmable cutter heights and speeds allows for precision machining with production speeds. Perfect sealing of valves is possible each time, every time.”

– Matt Adams, Owner, Alberta, British
Columbia, Canada

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VIDEO: EM69HP LS Cylinder Head Performance Porting

The Rottler EM69HP is Rottler’s flagship 5-axis machining center. Building on the strong foundation from previous generation porting and block work machines, the all-new EM69HP now incorporates Rottler’s next-generation 4C control as well as a newly designed 20,000RPM spindle. This allows the Rottler EM69HP to create race-winning ports faster and with a better finish than the competition.

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Customer Spotlight: Choate Engineering Performance

When a family puts their name on a product they produce you know there’s a lot of pride that went into that work; ensuring they have a customer who can trust what they are putting in their vehicle. Choate Engineering Performance is one of those companies that have put the years of experience, investment in equipment, and industry know-how behind creating a top rate product that will handle anything the customer wants to throw at it.

Born out of a frustration in being able to find a machine shop with dedication and pride in their work, Choate Engineering Performance made the investment themselves with a mission to keep all of their work on an engine build in house. This way they control the quality from start to finish. The capabilities of the shop speak for themselves; with 4 and 5 axis CNC machinery as well as flow bench and testing equipment the customers who come to Choate know what they’re going to get; excellence and performance.

A major component of the capabilities and the investment Choate has made in creating an elite machine shop is their lineup of machinery. The Rottler P69AHD Porting machine, F69ATC machining center, SG9MTS Seat and Guide alongside the added benefit a solid hone in the H85AY have given Choate Engineering Performance the confidence to put their name on their product and know their customers will be satisfied and returning again for their next project.

A project that Choate was able to participate in and sponsor was The Punisher Truck Build. Choate donated all of the machining, camshaft, cylinder heads, pistons and more – about 98% of that build and did all of the machining from start to finish. The Punisher is a 1964 F100 with a 6.0/6.4 hybrid. This thing hauls!! Check out full build details on Truck Trend by clicking here.

A changed approach

While operating as an engine rebuilder, Choate has continued to provide their services through the COVID-19 pandemic. While some business has slowed, they know that parts production and repairs statistically do well in this type of economic climate. They have focused their efforts on that work and know they have the foundation to keep going and come out of these challenging times as strong as ever.

Choate offers programming, or “Reverse Engineering”  for Rottler machines as well as cam technology. We at Rottler are proud to call Choate Engineering Performance a customer and trusted partner in the engine rebuilding world. Being family-owned and operated ourselves for over 97 years we know what it means to put our name on our product. It takes pride, dedication, and trust. We look forward to continuing to support companies like Choate in the future and are honored to have them as a strong Rottler customer.

Follow Choate Engineering Performance on Facebook and Instagram.

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VIDEO: Custom Part Manufacturing With Fusion 360

Here at Rottler Manufacturing we recognize that our customers come from backgrounds just as diverse as the types of products they produce. Therefore we are always looking to provide the most versatile platform possible. In this video, we demonstrate how the popular Autodesk Fusion 360 software can be used directly with our Rottler 4C Machine Control to produce and run edit-free G-Code programs.

The Rottler EM69HP is an all-in-one 5-axis engine machining center designed for producing race-ready cylinder heads and blocks. It also provides a great platform for creating custom parts such as mounts, spacers, brackets.

JOIN US LIVE!

Rottler will go LIVE for the first time Wednesday, May 20, 2020 at 5pm PST, 7pm CT and 8pm EST to demonstrate custom parts manufacturing with Fusion 360! Watch live by tuning in to the Rottler YouTube Live channel. You’ll be able to watch along and send in questions as we demo!

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VIDEO: Automated Cylinder Head Machining – High Production

See how one machinist can produce a finished cylinder head approximately every 3 minutes in our new video showcasing Rottler’s SG10XY cutting valve seats coupled with the S86A surfacer. A dream team for serious production.

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Large Diesel Engines – Using the Mainline as the Reference Point

At left, CAT 3616 block in Rottler F109. At right, CAT C175-20 in Rottler F105A

Large High Horsepower engine blocks have their own inherent and unique wear factors.   Machining the deck and cylinder bores while using the mainline as the reference point is critical to proper alignments and efficient operation – consider this…

C175-20 block in Rottler F105A using the mailline as a reference

The exact same engine block could be used in many different and demanding applications such as mining, marine, stationary power, oil and gas.   Take a mine truck for example… the engine is under tremendous load and stress with variable and extreme cycles.   The block undergoes torsional fatigue, liner seating issues, fretting on the deck, etc. etc.    As machinists, we always need to consider the best repair strategy that will yield better overall reliability and uptime for the operator.

Unlike most traditional bore mills which use the pan rail as reference, Rottler’s EM100s series machines use the main line as the reference point for machining.   There are a number of key benefits which include:

  • The decks are machined parallel to the main line to within .001”.  This allows for consistent piston protrusions for engine assemblers.   Torsional fatigue / gasket sealing finishes are properly addressed yielding better engine life with fewer problems.
  • The upper and lower receiving bores are machined perpendicular to the deck while achieving better concentricity.   This equates to less fatigue on the liner flange due to better alignment.
F105 line boring CAT 3508 block with CAT 3408 setup for deck / bore work

This simple difference is one of many examples of how Rottler Manufacturing teams up with machine shops and engine builders in critical industries to improve overall engine performance and reliability.

Stay tuned for the next technical bulletin in this series… or go to www.rottlermfg.com for more information.

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Rottler Customer Spotlight: Dave’s Complete Auto

Dave’s Complete Auto Center is a family-owned full-service automotive shop in Centerville, Utah. Since opening their doors in 1990, they have grown from an unheated storage shed to now operating in a 25 bay, state-of-the-art facility with full auto and machine shop capabilities. They hold the reputation of being Utah’s most well-equipped shop for almost 15 years. A major part of that being their Rottler machinery consisting of the Multi-purpose CNC machining center, the F79A, alongside their SG80MTS head machine, S86A surfacer and H85AX Hone. Miles Bell says, “We stand out in our state because of the equipment we have that is far beyond other competitors and the quality work we strive to do.” Because of the exceptionally skilled technicians they employ, coupled with this top-of-the-line equipment, they are able to go above and beyond to provide a wide range of different services. These services include crankshaft grinding, align bore and align hone, valve jobs, porting and polishing, rotating assembly balancing, CNC boring, CNC honing, and much more.

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