Full engine regeneration:
- technical consulting
- ultrasonic cleaning
- reassembly preparation
We regenerate engine components for:
- classic cars
- performance & sports cars
- passenger cars and commercial vans
- trucks, buses & coaches
- construction machines
- forklift trucks
- farming tractors and machines
- compressors, etc.
Full engine regeneration range:
- removal of broken spark plugs
- removal of seized injectors
- welding of cracked and damaged cylinder heads
- full cylinder head processing
- water jacket leak testing
- superficial facing
- replacement and regeneration of valve guides
- replacement of valve seats
- valve grinding
- valve seat milling
- camshaft seat machining
- thread repairs
- valve manufacturing
- cylinder head reassembly and adjustment
Cylinder blocks and liners
- cylinder bore grinding: boring & honing
- cylinder liner replacement
- cylinder liner manufacturing (dry & wet types)
- superficial facing
- crankshaft bed regeneration (alignment): boring and honing
- boring of camshaft bearing shells
- surfacing of pits & welding of cracks
- grinding & polishing of journals
- resurfacing of worn out journals
- dynamic balancing of:
- row shafts
- V engine shafts
- regeneration of camshaft sprocket and belt pulley necks
- bearing shell manufacturing
- squareness checks
- fork end regeneration
- replacement & boring of little end liner
- balancing of connecting rods
- hot assembly of pistons
- gudgeon pin manufacturing
GRINDING & POLISHING
We grind crankshafts on grinding machines from AMC-Schou, Denmark and Robbi, Italy. We can grind shafts of over 1500 mm long.
All ground crankshaft journals are polished. Journal polishing improves the surface finish quality for better mating of the shaft journals with shells. This results in lower crankshaft turning resistance and extends the crankshaft and shell life.
Ground crankshafts are checked on a dynamic balancer from Sunnen. The balancer can balance crankshafts for inline and vee engines.
The crankshaft balancing process is comprehensive and includes mass equalization of complete pistons and connecting rods, balancing the flywheel and the crankshaft, and finish balancing of the crankshaft and flywheel assembly. Crankshaft balancing reduces vibration of the engine, extends the life of components, increases power output and reduces fuel consumption.
The crankshafts worn out beyond the specification limits can have the damaged journals reconditioned by surfacing. We surface crankshafts with a welding machine from Rege, Germany. Our process restores the correct engineering parameters of surfaced journals.
FORK END REGNERATION
The connecting rods with fork end ovality are processed on a fork end honing machine from Sunnen, USA. The fork end is processed down to the specification dimensions, while the bore to rod shank squareness is retained.
LITTLE END REGENRATION
Excessive play between the gudgeon pin and the rod little end bore liner is removed by replacing and boring the liner. Our connecting rod borer from Sunnen restores the correct clearance between the bore liner and the gudgeon pin with the connecting rod squareness and uniform length of the connecting rod system.
CONNECTING ROD BALANCING
Weight is a critical parameter of any connecting rod. A connecting rod system should meet a single weight selection group. The connecting rod fork end and little end are weighed on a special tool coupled with a precision scales. All differences in weight of individual connecting rods are equalized by deleting the material.
We regenerate engine cylinder heads with the latest welding and machining processes. Our machine stock for cylinder head processing is largely based on the products from Sunnen, USA, which facilitate repairs of all cylinder types and sizes.
Prior to the regeneration process, the cylinder head is disassembled on a special stand, which is designed for safe disassembly and reassembly of regenerated cylinder heads.
Each cylinder head regeneration process begins with cylinder head leak testing with a special tool, which enables processing at the temperatures approximate to the normal hot running engine conditions. Once the leak is located, the cylinder head is prepared for welding, welded and pre-machined.
Another leak test follows, after which new valve seats are installed with new valve guides. We can regenerate valve guides with a special machine. Valve guides are regenerated by upsetting the inner diameter of the worn out guide with a special tool, followed by boring the valve guide with a diamond-tipped borer.
The camshaft installed in the cylinder head has its bearings verified, and if needed, the cylinder is reworked on a specialist machine tool. The valves from the regenerated cylinder head are also verified. Once the valve spindle wear is assessed, the valve heads are ground with a special tool.
The finish processing of the engine cylinder head includes cylinder head facing and machining of the valve seats. The valve seats are processed with a special miller dedicated to the process, using a tool profiled according to the valve seat form. Once each cylinder head valve is adjusted, the valves are tested for leaks on a vacuum machine.
Cylinder blocks and liners
Small and big blocks are usually machined with the machines from AMC-Shou, Denmark and Sunnen, USA.
CYLINDER BORING & FACING
Our cylinder boring and facing processes are done with high-precision borers, which can achieve high working performance.
We hone cylinders with a CNC honing machine, which can produce excellent engineering parameters of cylinder bearing surface. Cylinders are honed with diamond hone heads. We can also process single cylinder liners or non-standard cylinder block designs.
ENGINE BLOCK BED REGENERATION
Engine block beds are reconditioned by restoring the crankshaft bearing bores to specification-compliant nominal sizes, while retaining axial alignment. The crankshaft bearing system is processed on a horizontal borer and a horizontal honing machine.
Seized crankshaft bearings can be restored by surfacing.
CAMSHAFT BEARING SYSTEM REGENERATION
We process the camshaft bearing shells of the engine block with a horizontal borer. The process results in the correct bearing shell bore dimensioning and a perfect alignment of all bores of the system.