Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

Discussion of 4-Cam Type 547 engines (and all the Fuhrmann racing variants) and cars that powered them.
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Ibrahim Kuzu
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Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#1 Post by Ibrahim Kuzu » Mon Feb 22, 2021 2:26 pm

After four years with many designs and changes, we had success on 3 piece Carrera 4 cam cylinder head casting and machining.

Now we have a 4 Cam Carrera cylinder head that racers and drivers can enjoy, not to worry getting their original one piece head damaging or having big expensive welding repairs .

On 3 piece cylinder head ,each piece can be exchanged incase one section gets damaged.

We pour castings out of A356-T6 which is an aerospace quality primary aluminum alloy. The cylinder head utilizes a cast aluminum chill to produce a superior grain structure for heat resistance. The castings are poured at 1500 degrees Fahrenheit. The castings are then heat treated at 1000 degrees Fahrenheit and quenched in water to provide excellent material properties.

Please enjoy the crazy work went in to the casting ,specially the so thin and close to each other cooling fins......
IK
4 Cam Cooling
Attachments
Carrera 1600 cc 3 piece Cylinder head 1.jpg
Carrera 1600 cc 3 piece Cylinder head 1.jpg (629.97 KiB) Viewed 3132 times
Carrera 1600 cc 3 piece Cylinder head 2.jpg
Carrera 1600 cc 3 piece Cylinder head 2.jpg (609.93 KiB) Viewed 3132 times
Carrera 1600 cc 3 piece Cylinder head.jpg
Carrera 1600 cc 3 piece Cylinder head.jpg (610.64 KiB) Viewed 3132 times
Carrera 1600 cc 3 piece Cylinder head 3.jpg
Carrera 1600 cc 3 piece Cylinder head 3.jpg (664.65 KiB) Viewed 3132 times
Carrera 1600 cc 3 piece Cylinder head 4.jpg
Carrera 1600 cc 3 piece Cylinder head 4.jpg (631.84 KiB) Viewed 3132 times
Carrera 1600 cc 3 piece Cylinder head 5.jpg
Carrera 1600 cc 3 piece Cylinder head 5.jpg (648 KiB) Viewed 3132 times
Carrera 1600 cc 3 piece Cylinder head 6.jpg
Carrera 1600 cc 3 piece Cylinder head 6.jpg (543.56 KiB) Viewed 3132 times
Carrera 1600 cc 3 piece Cylinder head 7.jpg
Carrera 1600 cc 3 piece Cylinder head 7.jpg (551.99 KiB) Viewed 3132 times

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Jacques Lefriant
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#2 Post by Jacques Lefriant » Mon Feb 22, 2021 2:38 pm

BZ!
j
 

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Ibrahim Kuzu
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#3 Post by Ibrahim Kuzu » Mon Feb 22, 2021 2:46 pm

Appreciate it very much Jacques.
IK

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Jacques Lefriant
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#4 Post by Jacques Lefriant » Mon Feb 22, 2021 2:54 pm

HI
do we need to use longer head studs?
 

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Martin Benade
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#5 Post by Martin Benade » Mon Feb 22, 2021 3:12 pm

That’s an outstanding project, looking good! I wish I needed some.
Cleveland Ohio
62 Cabriolet
56 VW
02 IS 300
04 Sienna

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Ibrahim Kuzu
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#6 Post by Ibrahim Kuzu » Mon Feb 22, 2021 3:18 pm

No Jacques. Original head studs stays on the Engine case.
There will be two options to bold the Cam box to the cylinder heads.
Great question.
Thank you,
IK

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Ibrahim Kuzu
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#7 Post by Ibrahim Kuzu » Mon Feb 22, 2021 3:20 pm

Thank you Martin.
IK

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Joris Koning
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#8 Post by Joris Koning » Mon Feb 22, 2021 4:05 pm

Very cool!
'56 Coupe
'57 Coupe
'59 Cab 
'60 Coupe

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Ibrahim Kuzu
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#9 Post by Ibrahim Kuzu » Mon Feb 22, 2021 4:49 pm

Thank you Joris...
IK

Bill Richardson
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#10 Post by Bill Richardson » Mon Feb 22, 2021 5:41 pm

Ibrahim,
Fantastic parts and machining, as well as casting!
Very nice and a great idea

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Ibrahim Kuzu
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#11 Post by Ibrahim Kuzu » Mon Feb 22, 2021 7:10 pm

Thank you Bill.
Apricated your help on some original machining dimensions need it for confirmation.
IK

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Martin Benade
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#12 Post by Martin Benade » Mon Feb 22, 2021 7:16 pm

Is that a permanent mold type or lost foam/wax or something else?
You are not casting them yourself are you? If so you are having waaaay too much fun. ( actually you are anyway)
Cleveland Ohio
62 Cabriolet
56 VW
02 IS 300
04 Sienna

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Wil Mittelbach
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#13 Post by Wil Mittelbach » Tue Feb 23, 2021 12:59 am

Ibrahim -
An admirable and suberb accomplishment. Kudos!

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Harlan Halsey
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#14 Post by Harlan Halsey » Tue Feb 23, 2021 5:13 am

Hello Ibrahim,
Bob told me about the 3 piece head project years ago. I assumed that it had been abandoned. I was not aware that you were now working together. At the time I believe that he was going to cast smaller intake and exhaust passages to optimize the power band lower. As you know the Carrera is a 9,000 RPM head on a 6,000 RPM bottom end. There have always been two problems with the reproduction of 356 heads: the high aspect ratio of the fins on both the pushrod and the Carrera heads, and the oil passage "tree" in the Carrera heads. Obviously you have solved the aspect ratio issue, and I suspect that the tree has been eliminated, replaced by drillings o-ringed at the junctions of the three parts.
Now, if you figure out how to put a plain bearing crank into the 547 case, we could have an improved 7.500 RPM Carrera engine!

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Joris Koning
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Re: Bob Garretson's idea 3 piece Carrera Cylinder Head work completed.

#15 Post by Joris Koning » Tue Feb 23, 2021 8:51 am

Harlan Halsey wrote:
Tue Feb 23, 2021 5:13 am
Now, if you figure out how to put a plain bearing crank into the 547 case, we could have an improved 7.500 RPM Carrera engine!
Harlan, this has been done and is currently being done. Perhaps Jeff will chime in and share.
'56 Coupe
'57 Coupe
'59 Cab 
'60 Coupe

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