Cylinder head and crankcase manufacturing and assembly techniques

1. A method of manufacturing a cylinder head for a small engine comprising the steps of

casting a cylinder head having an as-cast cylinder chamber defined by a cylinder wall, an as-cast spark plug blind opening, cooling fins, an exhaust port extending from the cylinder chamber to a first face on an exhaust port flange, an intake port extending from said cylinder chamber to a second face on an intake port flange, fastener openings in said first and second faces, a foot flange having an as-cast mounting surface at an end of said cylinder chamber, and having as-cast fastening openings in said foot flange, wherein said as-cast spark-plug blind opening is formed without the use of a through core pin and the blind opening is entirely closed at one end by a thin web;

machining said cylinder wall to a predetermined tolerance;

removing said thin web of the blind opening to form a spark plug through aperture communicating with another end of the cylinder chamber; and

tapping said spark plug through aperture.

2. A method of manufacturing a cylinder head according to claim 1 , wherein the flatness of the as-cast mounting surface of said foot flange is 0.006 inch over its entire surface.

3. A method of manufacturing a cylinder head according to claim 1 , wherein said as-cast fastening openings in said foot flange are cast to a perpendicularity of 0.002 inch with respect to the foot flange mounting surface.

4. A method of manufacturing a cylinder head according to claim 1 , wherein said as-cast fastening openings in said foot flange are cast to within 0.006 inch of a true positional location on said foot flange.

5. A method of manufacturing a cylinder head according to claim 1 , wherein apertures are cast in said fins, each of said fin apertures are axially aligned with a corresponding one of the fastening openings in said foot flange.

6. A method of manufacturing a cylinder head according to claim 1 , wherein apertures are machined in said fins, each of said fin apertures are axially aligned with a corresponding one of the fastening openings in said foot flange.

7. A method of manufacturing a cylinder head for a small engine comprising the steps of

casting a cylinder head having an as-cast cylinder chamber defined by a cylinder wall, an as-cast spark plug aperture communicating with one end of said cylinder chamber, cooling fins, an as-cast blind exhaust port an as-cast blind intake port, fastener openings in a first face on an exhaust port flange, additional fastener openings in a second face on an intake port flange, a foot flange having an as-cast mounting surface at another end of said cylinder chamber, and having as-cast fastening openings in said foot flange, wherein the as-cast blind exhaust port is formed without the use of a through core pin and the as-cast blind exhaust port is entirely closed at one end by a first thin web comprising a portion of the cylinder wall, the as-cast blind intake port is formed without the use of a through core pin and the as-cast blind intake Port is entirely closed at one end by a second thin web comprising another portion of the cylinder wall;

machining said cylinder wall to a predetermined tolerance, wherein the first web of the blind exhaust port and the second web of the blind intake port are removed by the step of machining the cylinder wall to form a through exhaust port extending from the cylinder chamber to the first face on the exhaust port flange and a through intake port extending from the cylinder chamber to the second face on the intake port flange; and

tapping said spark plug aperture.

8. A method of manufacturing a cylinder head for a small engine comprising the steps of

casting a cylinder head having an as-cast cylinder chamber defined by a cylinder wall, an as-cast spark plug blind opening, cooling fins, an exhaust port extending from the cylinder chamber to a first face on an exhaust port flange, an intake port extending from said cylinder chamber to a second face on an intake port flange, fastener openings in said first and second faces, a foot flange having an as-cast mounting surface at an end of said cylinder chamber, and having as-cast fastening openings in said foot flange, said as-cast fastening openings in said foot flange being cast within 0.006 inch of a true positional location on said foot flange and being cast to a perpendicularity of 0.002 inch with respect to the foot flange mounting surface, said as-cast mounting surface of said foot flange being 0.006 inch over its entire surface, wherein said as-cast spark-plug blind opening is formed without the use of a through core pin and the blind opening is entirely closed at one end by a thin web;

boring said cylinder wall to a predetermined tolerance;

removing said thin web of the blind opening to form a spark plug through aperture communicating with another end of the cylinder chamber; and

tapping said spark plug through aperture.

9. A method of manufacturing a cylinder head for a small engine comprising the steps of

casting a cylinder head having an as-cast cylinder chamber defined by a cylinder wall, an as-cast spark plug aperture communicating with one end of said cylinder chamber, cooling fins, an as-cast blind exhaust port an as-cast blind intake port, fastener openings in a first face on an exhaust port flange, additional fastener openings in a second face on an intake port flange, a foot flange having an as-cast mounting surface at another end of said cylinder chamber, and having as-cast fastening openings in said foot flange, said as-cast fastening openings in said foot flange being cast within 0.006 inch of a true positional location on said foot flange and being cast to a perpendicularity of 0.002 inch with respect to the foot flange mounting surface, said as-cast mounting surface of said foot flange being 0.006 inch over its entire surface; wherein the as-cast blind exhaust port is formed without the use of a through core pin and the as-cast blind exhaust port is entirely closed at one end by a first thin web comprising a portion of the cylinder wall, the as-cast blind intake port is formed without the use of a through core pin and the as-cast blind intake port is entirely closed at one end by a second thin web comprising another portion of the cylinder wall;

boring said cylinder wall to a predetermined tolerance, wherein the first web of the blind exhaust port and the second web of the blind intake port are removed by the step of boring the cylinder wall to form a through exhaust port extending from the cylinder chamber to the first face on the exhaust port flange and a through intake port extending from the cylinder chamber to the second face on the intake port flange; and

tapping said spark plug aperture.

10. A method of manufacturing an assembly for a small engine comprising the steps of

casting a cylinder head having an as-cast cylinder chamber defined by a cylinder wall, an as-cast spark plug blind opening, cooling fins, an exhaust port extending from the cylinder chamber to a first face on an exhaust port flange, an intake port extending from said cylinder chamber to a second face on an intake port flange, fastener openings in said first and second faces, a foot flange having an as-cast mounting surface at another end of said cylinder chamber, and having as-cast fastening openings in said foot flange, wherein said as-cast spark-plug blind opening is formed without the use of a through core pin and the blind opening is entirely closed at one end by a thin web;

machining said cylinder wall to a predetermined tolerance; removing said thin web of the blind opening to form a spark plug through aperture communicating with one end of the cylinder chamber;

tapping said spark plug through aperture;

casting a crankcase having a crank chamber, a crankcase connecting flange defining an opening to said crank chamber, said crankcase connecting flange having an as-cast flange mounting surface, and having first and second fastener openings cast into said crankcase flange mounting surface;

positioning the as-cast mounting surface of said cylinder head foot flange in face-to-face contact with the as-cast flange mounting surface of said crankcase so that the as-cast fastening openings in the cylinder head foot flange are in axial alignment with the first and second fastener openings of said crankcase flange mounting surface; and

fastening said cylinder head to said crankcase by threading said openings and apertures with self-threading fasteners.

11. A method of manufacturing an assembly according to claim 10 , wherein the flatness of the as-cast mounting surface of said foot flange is 0.006 inch over its entire surface.

12. A method of manufacturing an assembly according to claim 10 , wherein said as-cast fastening openings in said foot flange are cast to a perpendicularity of 0.002 inch with respect to the foot flange mounting surface.

13. A method of manufacturing an assembly according to claim 10 , wherein said as-cast fastening openings in said foot flange are cast to within 0.006 inch of a true positional location on said foot flange.

14. A method of manufacturing an assembly according to claim 10 , wherein apertures are cast in said fins, each of said fin apertures are axially aligned with a corresponding one of the fastening openings in said foot flange.

15. A method of manufacturing an assembly according to claim 10 , wherein apertures are machined in said fins, each of said fin apertures are axially aligned with a corresponding one of the fastening openings in said foot flange.

16. A method of manufacturing an assembly according to claim 10 , wherein the flatness of the crankcase flange mounting surface is 0.006 inch over its entire surface.

17. A method of manufacturing an assembly according to claim 10 , wherein said first and second fastener openings are cast into said crankcase flange mounting surface to a perpendicularity of 0.002 inch with respect to said crankcase flange mounting surface.

18. A method of manufacturing an assembly according to claim 10 , wherein said first and second fastener openings are cast to within 0.006 inch of a true positional location on said crankcase flange mounting surface.

19. A method of manufacturing an assembly according to claim 10 , wherein an O-ring groove is cast into said crankcase flange mounting surface to surround said opening defined by said crankcase connecting flange, and wherein an O-ring is inserted into said groove.

20. A method of manufacturing an assembly for a small engine comprising the steps of

casting a cylinder head having an as-cast cylinder chamber defined by a cylinder wall, an as-cast spark plug aperture communicating with one end of said cylinder chamber, cooling fins, an as-cast blind exhaust port, an as-cast blind intake port, fastener opening in a first face on an exhaust port flange, additional fastener openings in a second face on an intake tort flange, a foot flange having an as-cast mounting surface at another end of said cylinder chamber, and having as-cast fastening openings in said foot flange, wherein the as-cast blind exhaust port is formed without the use of a through core pin and the as-cast blind exhaust port is entirely closed at one end by a first thin web comprising a portion of the cylinder wall, the as-cast blind intake port is formed without the use of a through core pin and the as-cast blind intake Port is entirely closed at one end by a second thin web comprising another portion of the cylinder wall;

machining said cylinder wall to a predetermined tolerance, wherein the first web of the blind exhaust port and the second web of the blind intake port are removed by the step of machining the cylinder wall to form a through exhaust port extending from the cylinder chamber to the first face on the exhaust port flange and a through intake port extending from the cylinder chamber to the second face on the intake port flange;

tapping said spark plug aperture;

casting a crankcase having a crank chamber, a crankcase connecting flange defining an opening to said crank chamber, said crankcase connecting flange having an as-cast flange mounting surface, and having first and second fastener openings cast into said crankcase flange mounting surface;

positioning the as-cast mounting surface of said cylinder head foot flange in face-to-face contact with the as-cast flange mounting surface of said crankcase so that the as-cast fastening openings in the cylinder head foot flange are in axial alignment with the first and second fastener openings of said crankcase flange mounting surface; and

fastening said cylinder head to said crankcase by threading said openings and apertures with self-threading fasteners.