420 cc twin cylinder - trying to increase compression ratio

hello,

dark months seem to be over and at least solar panels are producing useful amount of power

so i can do something to increase power output and fuel efficiency of the generator.
by design the engine has pretty low CR 6:1 and i want to reduce the combustion chamber.

this is how 420 cc engine looks like after approximately 500 hours on wood chunks ))

the valves

there is a thick layer of soot in intake channels - clearly reducing power output.
i have to make a fine filter behind hay filter for next winter.

now i have to make a fixture that would allow to fix the head into lathe chuck.

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Hello Andris, have you ever thought that it would be easier to lower the engine cylinder than to grind the head… just thinking…
Praise for the good work on the wood gasification… :+1: :smiley:

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Thanks for the pictures and explanations AndrisL.
What is your operating RPM when on wood gas of your engine?

For your future fine filter look at the work Goran Kinderval @Woodrunner is doing with his bought fine screen stainless steel cloth.
Regards
Steve unruh

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Milling your head is a risky proposition Andris. I would take it to a machine shop. However you first need to check to see if you have enough valve clearance to prevent the valves from contacting the pistons. You can do this simply with just modeling clay as shown in this video. They are doing it to see if changing the profile of the cam causes interference but the same is true for milling the head or decking the block.

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Tone - unfortunately not possible with this engine because at TDC the piston is only 1.3mm below cylinder flange - only way is to modify the head.

Steve - typically the generator produced around 2kw at 1900 RPM,
engine limited to 2400 by my DIY electronic ignition (some bug in program or micro controller limitation ,i think).
the engine was missing original magneto when i got it, so i had to DIY something.

the stainless steel mesh filter should be placed on hot side, where soot is still dry, i assume.
it would require major alterations in construction to fit the filter between gasifier and heat exchanger or between heat exchanger and cooler.

Tom - that is very common engine in post soviet countries and there is lot of information about head milling online.
most suitable option for me would be using lathe rather than milling machine
like in this video

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Do keep us updated on this project Andris. I’ve never seen anyone mount something like that in a lathe and get it centered like that. Very interesting. Again. Way outside my skill level.

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I don’t know where on earth you are, I assume somewhere far north by the angle of those panels. The other way to do it is to put them on an axle so they rotate east to west daily for more morning and evening hours. Most people just change the tilt of them a few degrees around spring and fall, which you are probably doing. hopefully, they can start producing useful amounts! :slight_smile:

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I wonder if those might be tracking mounts. It looks like a lot of hardware behind those panels. It could also be a high angle to shed snow. As I stumble through the world of solar energy, I noticed our used panels are rated for 20 pounds per square foot load. Our county design load for snow on roofs is 80 psf. So how do you handle the difference?

I found a website that explained the civil engineering design rules, and basically, the snow load varies from 0 to 100% as the tilt from horizontal varies from, I think, 20 degrees to 70 degrees. At 70 degrees, the projected downward load is small, and snow slides of the panels, so you’re in good shape. I hope it’s true :slightly_smiling_face:

edit: Let’s try: . . . the snow load varies from 0 to 100% as the tilt from horizontal varies from 70 degrees to 15 degrees.

The information came from this site:

It’s a great read if you like being overwhelmed.

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Tom - of course i will keep the community updated - even if i screw that head up. ))

Sean - i do live a few hundreds kilometers south from Sweden - so it is further north than mainland US.
the panels are mounted on trackers and are facing west, the photo was taken in late afternoon - around 17:00

here is snippet from tracker control program - a lookup table for altitude angle of the sun at noon of every day of the year, according to that table, altitude angle varies between 9 degrees 55 moa at winter solstice to 56 degrees and 21 minute of angle at summer solstice.

unsigned int max_altitude (unsigned int numof_day) {
–numof_day;
const static unsigned int alt[] PROGMEM = {955,1000,1002,1005,1011,1017,1024,1031,1038,1046,1054,1103,1112,1122,1132,1142,1153,1204,1216,1228,1240,1253,1306,1320,1333,1348,1402,1417,
1433,1448,1504,1521,1537,1554,1612,1629,1647,1705,1723,1742,1801,1820,1840,1900,1920,1940,2000,2021,2042,2103,2124,2145,2207,2229,2251,2313,2335,2358,2420,2443,2506,2529,2552,2615,
2638,2702,2725,2749,2812,2836,2900,2924,2947,3011,3035,3059,3123,3147,3211,3235,3259,3323,3346,3410,3434,3444,3458,3522,3545,3609,3633,3656,3720,3743,3806,3829,3852,3915,3938,4001,
4024,4046,4108,4130,4152,4214,4236,4258,4319,4340,4401,4422,4443,4503,4523,4543,4603,4623,4642,4701,4720,4739,4757,4816,4833,4851,4908,4926,4942,4959,5015,5031,5047,5102,5117,5132,
5146,5200,5214,5228,5241,5253,5306,5318,5330,5341,5352,5403,5413,5423,5432,5441,5450,5458,5506,5514,5521,5528,5534,5540,5546,5551,5556,5600,5604,5608,5611,5613,5616,5618,5619,5620,
5621,5621,5621,5620,5619,5618,5616,5614,5611,5608,5604,5600,5556,5551,5546,5541,5535,5529,5522,5515,5508,5500,5452,5443,5434,5425,5416,5406,5355,5345,5334,5322,5311,5259,5246,5234,
5221,5207,5154,5140,5126,5111,5057,5042,5026,5011,4955,4939,4922,4906,4849,4832,4814,4756,4739,4721,4702,4644,4625,4606,4547,4527,4508,4448,4428,4408,4348,4327,4306,4246,4225,4203,
4142,4121,4059,4038,4016,3954,3932,3910,3847,3825,3803,3740,3717,3655,3632,3609,3546,3523,3500,3437,3414,3350,3327,3304,3241,3217,3154,3131,3107,3044,3021,2958,2934,2911,2848,2825,
2802,2739,2716,2653,2630,2608,2545,2523,2500,2438,2416,2354,2332,2310,2248,2227,2205,2144,2123,2102,2042,2021,2001,1941,1921,1902,1842,1823,1804,1745,1727,1709,1651,1633,1616,1559,
1542,1525,1509,1453,1438,1422,1408,1353.1339,1325,1311,1258,1245,1233,1221,1209,1158,1147,1136,1126,1117,1107,1058,1050,1042,1034,1027,1020,1014,1008,1003,958,953,949,946,942,940,
937,936,934,933,933,933,933,934,936,938,940,943,946,950};
unsigned int flashread = pgm_read_word_near(alt + numof_day);
return (flashread / 100 * 60) + (flashread % 100);
}

Kent - what annoys me most about the solar panels in winter is that raised aluminum frame rim around panel surface - bottom part of it it prevents snow from slipping off the panels even at steep angle.

edit: it is 9d 33m at winter solstice, forgot that start of calendar year does not match solstice. ))

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what i did today…

i have 30mm thick a steel pancake roughly cut with plasma cutter

some surfaces rounded and flattened, some guidelines cut

drilling and tapping four holes

for 4 M8 bolts

head in chuck

centering

one cylinder done

both cylinders done

everything went surprisingly well, a lucky day. ))

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Excellent work, Andris. For someone like me, who does nothing but freehanding and just hope things end up true enough, it’s amazing what can be done with a lathe.

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thank you, Jan, lathe is a great tool to have, but my favorite tool is angle grinder. ))

some progress on the engine in pictures below:

head fixed by valve cover bolts in order to cut non contact surface.

although valve seats were not bad, i decided that some grinding would not hurt.

grinding done, by the way see how skewed the casting is - as everything made in commie country ))

the engine turns over fine, i hope to test run it tomorrow (the gasifier is not assembled yet also).

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2 thumbs up and a lot of likes for the achievement.

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Typically it’s heads that are milled down. If valves will hit the pistons at TDC you have to machine relief pockets into the pistons so that doesn’t happen. The relief pockets are a bit of a step backwards in terms of compression ratio but required. The solution is to shave the head a little more than simple math suggests to offset the volume gained from the pockets.

Some modders will add filler to the head instead of shaving it (welding rod, braze, etc). Both methods reduce head volume and increase compression. Adding fill to the head can change the gas flow dynamics, generally to poorer results. Head shaving is much more common.

You can play around with gasket thickness to adjust the compression ratio a bit but cut the valve relief pockets with the thinnest option!

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Anthony - nothing sticks out of combustion chamber on this engine - neither valves nor spark plug. ))
i milled it by 4.5mm, it is not recommended to go beyond that - there is a thin spot at the spark plug.

at first run i was baffled because power was way lower than expected.
i think i found the problem.
seems that it is some blockage either in muffler or exhaust gas cooler.

on video muffler disconnected and power output is close to 3kw instead of 2kw like it was before milling.

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Andris, if you get 3 kW at 1500 rpm with a 420 cc engine, this is the ideal power that such a large wood gas engine can handle. If you have the option, it is a good idea to make the exhaust pipe from two separate pipes for each cylinder, which are joined in the shape of the letter Y, and then install the muffler.

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Amazing results here Andris. I am really impressed.

My target engine (Predator 670) has very little clearance between open valve and top of the piston at TBC so relief pockets are part of my plan. That’s great that you didn’t need to go that route. 4.5mm is an impressive shave!

Relief pockets don’t need engineering tolerances so it can be done in a shed with care and basic tools. That said, if you shave heads yourself… the pockets would be easy!

The comment about a thin spot by the spark plug is a little surprising. Spark plugs are normally central to the head - between the valves, while the head material removed is around edge mating surfaces? You know your engine better than I ever will so I’ll take your word for it that the thin spot is a factor.

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Hey AnthonyB. if you go back up to AndrisL.'s first starting post in his pictures set it shows the spark plug angled in from the side.
Machining down the cylinder protrusion step in the cylinder head puts him right down onto the spark plug intrusion.

And his picture set showing both piston up TDC at the same time tells me the crankshaft type on his vertical twin cylinder engine. Its balance and its degrees firing sequence possibilities.

Regards
Steve unruh

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yes it is just like Steve explained.

Tone - the engine must spin up more than 1500RPM in order to produce 3kw, but usually the MPPT solar charger that i use, chokes down the engine and does not let it operate at optimal RPM.

using solar charger is temporary solution, i must make something that would step down 150…200v DC to around 54v DC.
a simple DC-DC converter without that MPPT part.

as for exhaust - clogged intercooler radiator was the culprit, the muffler is unobstructed.

for your entertainment here are some thermal images:

the gasifier
55

the engine and alternator
56

hot and cold side of the cooler
58

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Andris, I’m also thinking about a 50V generator, fortunately, used 48V 200A alternators are already available, from hybrid cars, these alternators reach a power of 10kW

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