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Internals HP/torque vs. stress theory

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Old Jan 2, 2006 | 10:19 AM
  #61  
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IM loving it!!!! And learned alot also!
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Old Jan 2, 2006 | 10:30 AM
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Originally Posted by Enron Exec
Your right, i foo'ked up there. They should be proportional.
Im glad there are actually ppl reading this to make sure no one is just spewing out BS.

Id use lbs or Newtons. To get the force exerted on each piston top, id take the torque at the crank and divide it by 6 ( because we have 6 cylinders ), then divide the result by 2 ( because the crank turns 2 times or 720 degrees to complete the 4 strokes ). The result would be the torque each cylinder delivers to the crank. To convert torque to linear force, id have to find the rod length. That should result in the force exerted on top of each piston during the combustion stroke. I think there are a few other things to consider, like the size of the lobs on the crank but im not sure. Maybe there is an equation floating around where we can plug-n-chug.
Now this is where it starts to get way beyond the scope of an enthusiast forum. Lets talk about the force generated on the piston. The fact is, we have no friggin idea how much that is. What we do know is that the force acts on our piston and crank radius to produce 400lb/ft of torque with our hypothetical VQ in question. Since it is a VQ, and we know the rod length to be 144.15mm, we know the peak torque is achieved with a crank angle of 74.23 degrees on the power stroke. How much force needs to be applied to the piston to achieve this torque given the rod length, piston surface area, compression ratio, and crank radius? Too many other unknown variables to figure. We could use some common assumptions, but we'd still be way off. For example,we have a set compression ratio to press the air/fuel mixture, now we could calculate how much the temperature and pressure would increase, but we would have to know the air temp we strated with among other things, and this baby is boosting so that'd be a rough guess with a lot of other variables. Then, we could guess at the max energy created from the combustion of these gasses, and try and guess how much pressure that would create, and thereby calculate some measure of force applied to the piston crown, but we'd have to guess at the thermal efficiency, combustion efficiency, and mechanical efficiency from friction, among the major items. After all that, we could then say our engine produces x amount of force, I'd prefer Newtons but lbs would be more appropriate, to develop 400lb/ft of torque on our crankshaft. With all the unknowns, we would never be able to really calculate it accurately. Now, at CSU, they have a nifty little gizzmo called a pressure indicator that can be tapped into the head and actually record the max amount of pressure developed during the combustion cycle while the engine is running. What's interesting to note is that if the ma pressure values are plotted along in relation to rpm, they have the exact same plot as the engine's torque curve. Where the maximum amount of pressure from combustion occurs is when the maximum amount of air/fuel is achieved, ergo where the Volumetric Efficiency of the engine of the engine is highest, and that's when the maximum amount of torque is applied to the crank. So whatever the pressure or force acting on the piston crown, what's actually important to note is that it applies a set amount of torque to the crankshaft that rises and falls in direct relation to each other. So, as the torque applied changes, we know then that's when the maximum force on the piston also changes, although we cannot accurately calculate it from what we know of the torque. It's another method to also show that the amount of torque applied at a certain speed is for each individual power stroke, as we can observe that the peak combustion pressure is in direct relation with each individual application of torque to the crankshaft.
Will
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Old Jan 2, 2006 | 10:37 AM
  #63  
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Originally Posted by overZealous1
i would of thought the lever arm would change effective length as the mixture doesn't fire all in one instant, but for a duration of the stroke, and changes the leverage as it travels down. so that 74 degrees of crank angle is where you just get the highest point of power and leverage, with everything past that trailing off?
these are very good write ups and i am learning a few things from them. most all my experience comes from many books and building many motors and hanging out in machine shops though, and not from a classroom invironment, where some of these theories were not covered, but had to figure out on my own, lol. sounds like you have alot of cool tools to play with there though.
real quickly, yes and no, the fact is, when it comes to pressure applied to the piston, with that pressure indicator I spoke of, we can actually record and play back the data by thousndths of a second and see that the presure is applied not for the entire stroke, as it is actually pretty close to atmo inside the cylinder by the time the exhaust valve opens, ( this is a NA engine) but it is applied throughout the first "half" of the stroke down, and the max amount of pressure is applied not at 74 degrees in the case of the VQ, but the max amount of torque applied to the crank is at 74 degrees, so there is a little discrepancy, but the values are in perfect relation to each other, so as one peaks, so does the torque at the same engine speed. The reason for 74 degrees on the VQ, because that's when the conrod is at a 90 degree angle to the crank throw, and even though peak pressures are a little sooner than that, that is when the most effincy of the pressure applied to the crank occurs and when the max torque applied is seen. Make sense? too vague?
Will
EDIT: to be perfectly fair, the force acting on the piston does act all the way through the power stroke, but you have to realize that so friggin much is lost through heat and friction, that not long afte the rod is at 90 to the crank throw, like several more degrees of rotation, the applied torque just drops off so fast its not really contributing anyhting. And on a high revving NA engine like the Yamaha, the valves open pretty damn fast to clear things out, but technically, the force acting on the piston is applied throuh the entire power stroke. For the most part, cause a funny thing happens at BDC due to the accelerative forces and crank/rod angles at BDC, but that's WAY off topic.

Last edited by Resolute; Jan 2, 2006 at 10:47 AM.
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Old Jan 2, 2006 | 11:03 AM
  #64  
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i understand completely what you are saying. and this brings up a good question. so in a V style engine, the cylinder bank angles have to be specifically set to take advantage of this?

how does this crank angle/leverage point apply to inline or "boxer" style engines?
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Old Jan 2, 2006 | 11:59 AM
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Okay... I am on lunch and have had a chance to read over all my little rants through the day so far, and am surprised at some of the mistakes I have made. My apologies, for what it's worth, I am at work doing a job, and I'm just not able to focus enough on this to be COMPLETELY accurate, but for the most part, the theories are right. For those who have read this far, damn, I'm sorry, but you'll have to re-align somethings. Here is what is right and really the important part to answer the question of which engine has the most stress. When the engine produces torque, it is not a function of rpm, but engine speed. the difference lies in the fact that at certain speeds, a certain amount of torque is made, and the fact that the engine is physically turning at x times per minute has nothing else to do with torque production, just the piston speed at that x rpm. What is affected by the number of physical times the crank revolves is the amount of work the engine has done, or the hp. The error I have posted earlier is that the torque placed on the crank is the result of each individual power stroke from a single cylinder in and of itself. This is wrong. It is the amount of torque placed on the crank by all the cylinders that rotation. Even at 4000 rpm, the crank has the same torque applied for one rotation as it does at 2000 rpm if the measured torque is the same. the rpm itself has nothing to do with torque, the piston speeds at 2000 rpm are just better for producing that same amount of torque on one engine and the piston speeds are better at 4000rpm for producing the same amount of torque on the other engine. The physical strain on the engine from the torque is the same. In other words, if an engine making 400lb/ft has one piston, and another making 400lb/ft has ten, then the engine with one piston is taking a much higher load than the one with ten, and again, the rpm at which the peak torque occurs doesn't mean anything for load but when and how much hp will be produced. Since our original question was with two identical engines, each with the same piston area, stroke, etc... then the loads from compression are still the same since the torque is the same. If it were different engines, like which is under more load a V8 or my lawnmower when both make 400 lb/ft, then the stress on the engines would be different, even if the discplacemnt was the same. Ok, even this took about an hour to do inbetween working, so I'll keep checking in, and will do a better job after work when I can better explain things.
Will
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Old Jan 2, 2006 | 12:30 PM
  #66  
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Originally Posted by Resolute
LOL, that's cool. I know the feeling. I'm at work, and would love to just put everything aside and hack this out.
Dorm buddy! I have a wife and a house man.
Now here's the kicker, I'm finishing up my ME, but am planning on going to CSU for my masters asap in Motorsports Engineering. Right now, I get to hang out and help with their prototype racer and facilities on the weekends. Besides being hella fun, I get to schmooze the three profs into liking me enough to enter the program. Now, the facilities they have are pretty awesome. Besides a typical chassis dyno, they have a brake friction dyno, chassis flex dyno, shock dyno, all kinds of geeky metallurgy stuff, and most important for our discussion, an engine brake dyno.
Now, I would love to use some of this stuff on the VQ, and maybe I'll have a chance one day, like hooking up a pressure indicator to the head would be of enormous value, but for now I have to settle for playing with a one liter Yamaha. Now, this is important because of some things you said.
First, why isn't the torque applied over the course of all the revolutions at a certain rpm? In our case, lets imgain the engine with a power peak at 6100rpm makes its peak torque at 4000rpm. Now, if I understood you correctly, you are saying that at 4000rpm, the 400lb/ft of torque is pread over 2000 power strokes. If the max torque occured at say 2000rpm, it would be spread over 1000 power strokes, and therefore more stress is on the engine making torque at the lower rpm. Here is where an engine brake dyno comes in handy, and you pretty much alluded to the same in your last post. The dyno could give a crap about rpm, in fact it doesn't even measure rpm. We only need to moniter rpm to calculate hp. What it does measure is the amount of torque applied on EACH INDIVIDUAL POWER STROKE. Ours actually measures this twofold, by measureing the amount of pressure placed on the mounts and with a brake on the flywheel. Think about it like this, Even with our V6, no two pistons are firing at the same time, and if max torque is applied on every piston when the crank angle is at 74 degrees (it is on the VQ, just trust me on that one cause I couldn't even begin to type out the math) then every time the piston on any cylinder is on its power stroke and the crank angle for that piston is 74.23 degrees, then the max torque is being applied to the crankshaft centerline. Even with 6 cylinders, there are seperate, individual power strokes and seperate individual "surges" of max torque. As you stated, you can feel this at low rpm without that dual-mass flywheel to dampen them out. The dyno records the max amount of torque applied at any one time, regardless of rpm. It just happens that at 4000rpm in our engine, the max torque developed from any one of our six "surges" is 400lb/ft of torque. Now, as far as we are concerned, the rpm is useless, we might as well just say that the engine develops its peak torque, or even better, the individual cylinders each develop their peak torque when the piston speed is 17.7 meters per second. Because that's how fast our piston is moving when the engine is at 4000rpm. The only reason we care about 4000rpm is to calculate the hp. The reality is, if we were measuring the torque over a one minute period, then the max torque developed over the whole minute would be divided out among all the seperate strokes, but we aren't because that's not how torque is measured, that's how horsepower (work) is calculated, the engine at any one instant of time while spinning at 4000rpm has a max torque applied to the crank of 400 lb/ft. If we plot this out with torque as a function of engine speed and time, and kept our engine speed constant at 4000rpm, you would see that the engine has a "push" developing 400lb/ft of torque every .0075 seconds. Every .0075 seconds, another power stroke would occur on the piston and produce 400lb/ft of torque, and this max torque occurs with a piston speed of 17.7 m/s, or when the engine is at 4000rpm. The amount of work the engine does is a function of this torque occuring on each power stroke, and the number of times it occurs in that one minute time period.
I think this is confusing because people see that hp and torque are the same, with a few constants changed around. They are not. They are so different its crazy. As Dave Coleman once said, asking what's the difference between hp and torque is like asking what's the difference between orange and soft, or so he said something to that extent. If we deal with this in terms of Kilowatt output as a function of Newton/meters of torque applied over time, then I think this would be way easier to grasp, especially since the term horsepower is a bit decieving as a term for power.
It's been three hours since I started typing, I keep getting interrupted to actually do some work, and then come back and type a little more while I can. so i hope this is somewhat coherent.
Will
" and therefore more stress is on the engine making torque at the lower rpm."

So i guess we all agree on this now or where you just repeating what i was saying.

"the max torque developed from any one of our six "surges" is 400lb/ft of torque."

Your absolutely right. I dont know how i came to that in the first place.
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Old Jan 2, 2006 | 12:34 PM
  #67  
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Originally Posted by Enron Exec
" and therefore more stress is on the engine making torque at the lower rpm."

So i guess we all agree on this now or where you just repeating what i was saying.

"the max torque developed from any one of our six "surges" is 400lb/ft of torque."

Your absolutely right. I dont know how i came to that in the first place.
Yeah, I was repeating what you were saying, to make sure I understood where you're coming from.
Will
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Old Jan 2, 2006 | 12:48 PM
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ok, here is another point. we have surely drifted from the original topic, but what the hell. ok, the vq35 has a larger bore compared to stroke. 95.5 boreX 81.4 stroke. now larger bore motors are more rpm friendly than a longer stroke version due to piston speed being slower. the loss of rod length and distance of throws on the crank centerline though, result in a loss of torque compared to a square bore/stroke motor. now i have also heard the larger bore, compared to stroke, is more conducive to higher hp #'s. do you feel this reason being the ability to rev higher thus having more work cycles to end up with ultimately higher hp numbers, or is there an advantage to having the larger piston top area for the increase in hp. i an leaning towards the first answer.
now most of my experience is with the small block chevy. last one i did was a 383. instead of the 400 crank in the 350, they now make a specific piston and crank combo that allows using the stock 350 5.7 rod length and taking up the difference in wrist pin placement. so you still gain the c.i. from the piston traveling farther thus more vacuum to draw in the mixture at the sacrifice of higher piston speeds. do you feel this method takes full advantage of the torque increases compared to using the standard pin height and the original 400 6.0 rod length?

ok, doing some searching, i found another force i didn't think about earlier. which is cylinder wall side loading. the piston will generate more piston side loading pushing the rod at more of an angle in relationship to the bore using the shorter rod length as i describer earlier.

Last edited by overZealous1; Jan 2, 2006 at 12:57 PM.
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Old Jan 2, 2006 | 01:02 PM
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Originally Posted by overZealous1
ok, here is another point. we have surely drifted from the original topic, but what the hell. ok, the vq35 has a larger bore compared to stroke. 95.5 boreX 81.4 stroke. now larger bore motors are more rpm friendly than a longer stroke version due to piston speed being slower. the loss of rod length and distance of throws on the crank centerline though, result in a loss of torque compared to a square bore/stroke motor. now i have also heard the larger bore, compared to stroke, is more conducive to higher hp #'s. do you feel this reason being the ability to rev higher thus having more work cycles to end up with ultimately higher hp numbers, or is there an advantage to having the larger piston top area for the increase in hp. i an leaning towards the first answer.
now most of my experience is with the small block chevy. last one i did was a 383. instead of the 400 crank in the 350, they now make a specific piston and crank combo that allows using the stock 350 5.7 rod length and taking up the difference in wrist pin placement. so you still gain the c.i. from the piston traveling farther thus more vacuum to draw in the mixture at the sacrifice of higher piston speeds. do you feel this method takes full advantage of the torque increases compared to using the standard pin height and the original 400 6.0 rod length?
For the first part, you are more or less correct. Longer strokes with a shorter rod make for an engine that doesn't do well at high revs. The longer the rod, and shorter the stroke, the lower the piston speed and better it will do at high revs. This isn't the end all of engine design though. I can show you an SR20 that will outrev some motorcycles and it has a perfectly square bore/stroke. There are other factors in play to determne which engines like high rpm use and hp, and the ones that don't like to rev and make lots of torque.
For the SB, are you saying the 400 crank has a longer stroke and a longer rod than a 350? Is the deck height higher then on the 400? So they have a crank that keeps the shorter 350 rod with the longer stroke of the 400 crank? I'm sorry, I don't think I have all the info to answer that question.
Will
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Old Jan 2, 2006 | 03:25 PM
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ok, heres more info.

383 using 5.7 rods- 4.000 boreX3.80 stroke

383 using 6.0 rod(original 400 crank) 4.030 boreX3.75 stroke

deck height should be identical. this is just one example i am using for a reference. just looking at possible effects of rod length here yet creating the same displacement.

also, the reason i brought up the bore/ stroke relationship and how it can relate to rpm, was based around our own vq's. even with all the forged goodies and the stock main cap girdle and overhead cams, not many people i know about have gotten the thing to be able to rev very high. i was shifting my 383 at 7300rpm and didn't have as good of a crank or rods in it as in my vq. if i am remembering correctly some were floating valves right around that same rpm. now i remember putting in my nismo cams and i was getting pretty close to coil bind with the stock springs (right around 0.012" cold). now there are many ways for the aftermarket to make larger dia. springs or double springs for this motor. i guess just not many people have done it. but waiting for the day i see a street vq35 turning 9000rpm with not much issues.
which brings me to another question, boost effects on valve springs. i have heard from some that it makes no difference, but i have a tough time imagining there is no effect. the higher the boost, the more spring pressure required on the intake side to help keep the intake valve closed at high rpm and boost. correct or false. i believe true.
just trying to keep ya busy here and answering some of my own questions i have, lol.
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Old Jan 2, 2006 | 06:43 PM
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overZealous1, you're killing me here.
For all this who are following this so far, I figure I'll recap everything said so far in the thread on hp,tq, and stress I started in the main Engine/Drivetrain forum. I'll go over, simply, how the cylinder pressures and torque are related but not identical, the vibrations caused byt this phenom, and how the torque we are applying with multiple cylinders is the mean of one cycle, or two revolutions.
For overZealous1, here you go:
Using the shorter rod does several things, one of which is increase the side loading on the cylinder as you have already discovered. Second, it increases the speed the piston must travel because it forces a greater angle to the crank, which in turn increases acceleration and inertial loads on the conrod. Here's the math:
Your first engine with the 5.7in rods at 8500rpm has a max accel of:
167,230 ft/s^2
Your second engine with the 6.0in rods at 8500rpm has a max accel of:
162,451 ft/s^2
I expect both to grenade at this rpm without a LOT of work. By comparison, the VQ at 8500rpm has a max accel of:
97,321 ft/s^2, and can rev much higher without too much worry from the inertial forces at this rpm.
But, as one of our buddies down under is finding out, the VQ needs improvements to the head to breathe and operate this high. Springs, retainers, guides, cams, and valves. Such is the price of high rpm.
As far as boost effect on springs, I assume you mean the pressure acting on the back of the valve would push it open a little? Not gonna happen. Most valve springs have at least 60 lbs of seat pressure, which menas you'll have to boost at least 45lbs of air to budge a valve with a one inch square area on the backside. And if you're running that much boost, i guarantee you'll be running even stronger valves to use that boost at the appropriate rpm.
Will
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Old Jan 2, 2006 | 07:12 PM
  #72  
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my point being not just floating the valves constantly but you will be reducing effective spring pressure by having the force always on the back side of the valve under boost. the vq springs are pretty weak and i was able to disassemble with my hands, lol. now to make it worse, when making even 16psi you are going to be doing it at a higher rpm greatly increasing the chance of floating the valves.
the only way that possibly it wouldn't be something to worry about is if the cylinder fills fast enough to match the intake psi before closing.
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Old Jan 3, 2006 | 04:57 PM
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Originally Posted by overZealous1
my point being not just floating the valves constantly but you will be reducing effective spring pressure by having the force always on the back side of the valve under boost. the vq springs are pretty weak and i was able to disassemble with my hands, lol. now to make it worse, when making even 16psi you are going to be doing it at a higher rpm greatly increasing the chance of floating the valves.
the only way that possibly it wouldn't be something to worry about is if the cylinder fills fast enough to match the intake psi before closing.
The cylinder will not likely match the intake side before the valve closes, but it won't be far off. The increase in rpm and the pressure being applied on the back side of the spring will not be enough to detriment the effective force required to close the valve. Consider that the point at which this is greatest will not be the valve trying to close, beacuse pressure inside the cylinder will already be pushing on it back up, but before it opens. At that time the amount of boost required to budge the valve from its seat prematurely, or aggrivate the timing, is enourmous.
Will
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Old Jan 4, 2006 | 05:44 AM
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Just a minor correction. Stock valve spring seat pressure on the VQ is near 35 lbs of pressure, rather than 65 lbs average you mentioned. JWT upgraded springs have 43lbs of seat pressure. Ferrea valve springs have 85ft/lbs and higher worth of seat pressure, depending on which spring you choose.
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Old Jan 4, 2006 | 06:12 AM
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Originally Posted by Sharif@Forged
Just a minor correction. Stock valve spring seat pressure on the VQ is near 35 lbs of pressure, rather than 65 lbs average you mentioned. JWT upgraded springs have 43lbs of seat pressure. Ferrea valve springs have 85ft/lbs and higher worth of seat pressure, depending on which spring you choose.
Wow, only 35lbs, OverZealous1 was right, pretty weak. Good to know. Sharif, you have a lot of experience with FI VQ's, any problems you've seen with boost on stock VQ springs? I guess with only 35lbs of seat pressure, a built engine could have enough boost to unseat a valve with the stock spring, but again, anyone running that much pressure would certainly upgrade the valvetrain... I would think.
Will
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Old Jan 4, 2006 | 09:08 AM
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So can anyone confirm if the engine in the dyno chart was recieving to much stress for the stock internals or not?
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Old Jan 4, 2006 | 09:44 AM
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Originally Posted by Quamen
So can anyone confirm if the engine in the dyno chart was recieving to much stress for the stock internals or not?
which dyno chart? or are you referring to the figures in your first thread starter? the consensus is that the motor making the peak torque earlier will see more cylinder pressure, but as far as to much stress for stock internals, that is anyones guess. just need to look at others experience and see how far the stock internals can be pushed with a good tune.the guy in puerto rico that did the 10.90 pass on stock internals popped his, but "bigbri" is at 550whp on stock internals and it is still together as far as i know.
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Old Jan 4, 2006 | 10:19 AM
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Originally Posted by Resolute
Wow, only 35lbs, OverZealous1 was right, pretty weak. Good to know. Sharif, you have a lot of experience with FI VQ's, any problems you've seen with boost on stock VQ springs? I guess with only 35lbs of seat pressure, a built engine could have enough boost to unseat a valve with the stock spring, but again, anyone running that much pressure would certainly upgrade the valvetrain... I would think.
Will
Most of the high boost engines we build and tune have upgraded springs. However, I have tuned one stock headed VQ35 to 16psi and stock springs and cams seem to hold up well to 6600rpm. I imagine there might be some issues running it beyond 6600rpm, however.

Can you explain again, how 15psi of boost pressure effects the valve seat, assuming the valve spring is running 35lbs of seat pressure? I was assuming that the air will find the "open" valves, and reduce the pressure on the closed valves. I am wrong?
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Old Jan 4, 2006 | 11:38 AM
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my idea behind it is just thatwhatever boost you are running, it will try opening the intake valve off the seat. now lets say we did a test with valve springs that have 15lbs seat pressure, and through 15psi boost at it , for simplicity, say the motor is not running and head off car, the valve should lift off the seat, correct? now throw in 6000 rpm and the fact the valve spring needs to try and close against the rushing in boost, it seems to me you will have lowered the effectiveness of the normal atmospheric spring pressure and run alot higher chance of floating a valve compared to a n/a motor.

it is a theory i read along time ago, and have heard different ideas on it since, saying it has no effect. i could not even possibly imagine it has no effect though at high boost.
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Old Jan 4, 2006 | 11:42 AM
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the above test is also figuring the inside valve area at 1" sq. area. lol. at 15 psi and a 2" sq head area, you would be able to lift 30lbs with it, taking 30lbs off of the effective spring seat pressure at that boost.
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