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Old 02-14-2011, 11:16 AM   #1
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Exclamation Camaro ZL1 Gets Deck Plate Honing, Treatment for High-End Engines

Just found this neat bit of info on GM's media site, good read and video.

Z06 and the ZR1 as the only other production engines to receive deck plate honing!

PRESS RELEASE
http://media.gm.com/content/media/us...eb/0214_camaro

VIDEO
http://media.gm.com/media/us/en/vide...00f0b60d&rf=bm

Quote:
DETROIT – Deck plate honing a cylinder block, a precision-machining process typically reserved for high-performance engines, will be used on the Camaro ZL1 6.2L supercharged V8, helping maximize engine life, reduce friction between engine parts and increase horsepower.

Deck plate honing refers to a machining process in which aluminum plates, sometimes called torque plates, are clamped to the block, simulating the cylinder heads, before the final bore and hone of the cylinders takes place. The clamp load of 10 bolts per head creates normal, minute distortions in the block and thus makes the bore slightly out-of-perfect shape or cylindricity.

While the simulated cylinder heads, or deck plates, are attached to the block, a boring machine does its work boring, and then honing each cylinder. Later, when the actual cylinder heads are assembled to the block under identical torque loads, the cylinder bores are near perfect for the engine’s lifetime of piston travel up and down in the bore up to 6,200 times a minute.

“It amazes me what GM does with some of their production engines,” said Andy Randolph, engine technical director at Earnhardt-Childress Racing. “Deck plating is a time-consuming process that fine tunes the bore to get every ounce of power, torque and durability possible. It’s standard practice when building high-end race engines. It tells me the Camaro ZL1 will have some serious performance.”

The deck plating process is used in applications where cylinder head pressures are greater than average, to ensure cylinder sealing and prevent scuffing of the piston against the bore wall. In the Camaro LSA engine, this means improved bore life and ring sealing. True bores and better sealing are keys to optimizing power. This is a common process also used with the Corvette ZR1 and Z06 blocks.

The deck plate bore-and-hone process uses billet aluminum plates with steel bolt sleeves for compression limitation. The plate’s bolt attachment points have the same height and clamp loads as the actual cylinder heads. The LSA cylinder block is made of 319T7 aluminum and has cast-in-place cast iron cylinder bore liners. The final honing process brings the final 103.25 mm (4.06 inches) bores to within a tolerance of eight microns or .00031 of an inch. The deck plates remain installed for the final honing of the crankshaft bores.

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Old 02-14-2011, 11:18 AM   #2
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Don't CTS-Vs use that, too, like ZR1s (and their LS9s)?
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Old 02-14-2011, 11:22 AM   #3
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I am not sure but it could be possible although the press release only mentions the Z06 and the ZR1 as the only other production engines to receive this treatment.
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Old 02-14-2011, 11:32 AM   #4
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Quote:
Originally Posted by RLHMARINES View Post
I am not sure but it could be possible although the press release only mentions the Z06 and the ZR1 as the only other production engines to receive this treatment.
You're absolutely correct... I noticed that, too, after I posted. Hmm... Regardless - thanks for posting this information!!! It's definately a plus for ZL1 guys
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Old 02-14-2011, 08:48 PM   #5
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Camaro ZL1 Gets Deck Plate Honing, Treatment for High-End Engine

From: http://media.gm.com/content/media/us...eb/0214_camaro

This is pretty cool!

Quote:
DETROIT – Deck plate honing a cylinder block, a precision-machining process typically reserved for high-performance engines, will be used on the Camaro ZL1 6.2L supercharged V8, helping maximize engine life, reduce friction between engine parts and increase horsepower.

Deck plate honing refers to a machining process in which aluminum plates, sometimes called torque plates, are clamped to the block, simulating the cylinder heads, before the final bore and hone of the cylinders takes place. The clamp load of 10 bolts per head creates normal, minute distortions in the block and thus makes the bore slightly out-of-perfect shape or cylindricity.

While the simulated cylinder heads, or deck plates, are attached to the block, a boring machine does its work boring, and then honing each cylinder. Later, when the actual cylinder heads are assembled to the block under identical torque loads, the cylinder bores are near perfect for the engine’s lifetime of piston travel up and down in the bore up to 6,200 times a minute.

“It amazes me what GM does with some of their production engines,” said Andy Randolph, engine technical director at Earnhardt-Childress Racing. “Deck plating is a time-consuming process that fine tunes the bore to get every ounce of power, torque and durability possible. It’s standard practice when building high-end race engines. It tells me the Camaro ZL1 will have some serious performance.”

The deck plating process is used in applications where cylinder head pressures are greater than average, to ensure cylinder sealing and prevent scuffing of the piston against the bore wall. In the Camaro LSA engine, this means improved bore life and ring sealing. True bores and better sealing are keys to optimizing power. This is a common process also used with the Corvette ZR1 and Z06 blocks.

The deck plate bore-and-hone process uses billet aluminum plates with steel bolt sleeves for compression limitation. The plate’s bolt attachment points have the same height and clamp loads as the actual cylinder heads. The LSA cylinder block is made of 319T7 aluminum and has cast-in-place cast iron cylinder bore liners. The final honing process brings the final 103.25 mm (4.06 inches) bores to within a tolerance of eight microns or .00031 of an inch. The deck plates remain installed for the final honing of the crankshaft bores.
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Old 02-14-2011, 08:49 PM   #6
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Camaro ZL1 Uses Deck Plate Honing on High-End Engine

From: http://media.gm.com/content/media/us...eb/0214_camaro

This is pretty cool!

Quote:
Precision Machining Process Makes for Perfect Bores

[DETROIT – Deck plate honing a cylinder block, a precision-machining process typically reserved for high-performance engines, will be used on the Camaro ZL1 6.2L supercharged V8, helping maximize engine life, reduce friction between engine parts and increase horsepower.

Deck plate honing refers to a machining process in which aluminum plates, sometimes called torque plates, are clamped to the block, simulating the cylinder heads, before the final bore and hone of the cylinders takes place. The clamp load of 10 bolts per head creates normal, minute distortions in the block and thus makes the bore slightly out-of-perfect shape or cylindricity.

While the simulated cylinder heads, or deck plates, are attached to the block, a boring machine does its work boring, and then honing each cylinder. Later, when the actual cylinder heads are assembled to the block under identical torque loads, the cylinder bores are near perfect for the engine’s lifetime of piston travel up and down in the bore up to 6,200 times a minute.

“It amazes me what GM does with some of their production engines,” said Andy Randolph, engine technical director at Earnhardt-Childress Racing. “Deck plating is a time-consuming process that fine tunes the bore to get every ounce of power, torque and durability possible. It’s standard practice when building high-end race engines. It tells me the Camaro ZL1 will have some serious performance.”

The deck plating process is used in applications where cylinder head pressures are greater than average, to ensure cylinder sealing and prevent scuffing of the piston against the bore wall. In the Camaro LSA engine, this means improved bore life and ring sealing. True bores and better sealing are keys to optimizing power. This is a common process also used with the Corvette ZR1 and Z06 blocks.

The deck plate bore-and-hone process uses billet aluminum plates with steel bolt sleeves for compression limitation. The plate’s bolt attachment points have the same height and clamp loads as the actual cylinder heads. The LSA cylinder block is made of 319T7 aluminum and has cast-in-place cast iron cylinder bore liners. The final honing process brings the final 103.25 mm (4.06 inches) bores to within a tolerance of eight microns or .00031 of an inch. The deck plates remain installed for the final honing of the crankshaft bores.
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Old 02-14-2011, 08:52 PM   #7
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We use them as well as line hone every single engine not just the most expensive ones....LOL
GM doesnt. They do/did to the LS7 as well.
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Old 02-14-2011, 08:54 PM   #8
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Not sure how this would translate to the real world, I assume it makes it more reliable for owners to increase the boost?
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Old 02-14-2011, 09:02 PM   #9
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It translates into more hp and a very reliable engine. Two very important real world issues.
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Old 02-14-2011, 09:03 PM   #10
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Nice! Dammit, I'm trying SO hard not to want this car!
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Old 02-14-2011, 09:04 PM   #11
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Yes and it keeps the cylinder bores round after you bolt the head down, ensuring good ring seal which is critical for power.
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Old 02-14-2011, 09:15 PM   #12
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I had read that was one of the processes that took place on ZR1, but didn't know Z06 and ZL1 use the same.

Nice find!
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Old 02-14-2011, 09:28 PM   #13
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So does the CTS-V's LSA go through this same process? If it doesn't, this could be a good indicator that the ZL1 will surpass the current CTS-V power rating.
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Old 02-15-2011, 12:18 AM   #14
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Already posted but still good.
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Old 02-15-2011, 09:53 AM   #15
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Nice info...........
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Old 02-15-2011, 10:05 AM   #16
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Do they do this on the CTS-V LSA too?
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Old 02-15-2011, 10:38 AM   #17
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Do they do this on the CTS-V LSA too?
Yes. Common process with ZR1, Z06 and CTSV and Camaro ZL1 blocks.
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Old 02-15-2011, 02:21 PM   #18
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Yes and it keeps the cylinder bores round after you bolt the head down, ensuring good ring seal which is critical for power.

Is there an echo in here?
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Old 02-15-2011, 02:22 PM   #19
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Cool and all but probably not necessary for 99.99% of us who use our cars as daily drivers.
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Old 02-15-2011, 02:27 PM   #20
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Basically in short, this is them breaking in the engine correct? This process helps seat the rings?
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Old 02-15-2011, 02:28 PM   #21
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Basically in short, this is them breaking in the engine correct? This process helps seat the rings?
LMAO
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Old 02-15-2011, 02:34 PM   #22
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Cool and all but probably not necessary for 99.99% of us who use our cars as daily drivers.
For a reliable engine over extended years? it would relate to all of us..

However, what I don't get is it says a near perfect design based on this honing...so if that near perfect..what in the world is in our cars? Just decent? Not trying to sound whiny, just have no knowledge of this process.
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Old 02-15-2011, 02:43 PM   #23
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Interesting, dont really know what this means but interesting lol
so will it have more hp? lol
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Old 02-15-2011, 02:50 PM   #24
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Deck plate honing nearly duplicates the head bolt loads that cause distortion in the block when they are screwed in. By using the same gaskets, bolts, and torquing procedure, the cylinders deform like they would after the engine is assembled. After the plate is on, honing the cylinders makes them perfectly round again thereby eliminating blow-by and keeping the cylinder shape constant, improving efficiency and getting a longer life. When the engine runs, the block actually twists and deforms, and gets pulled every which way when all the components are screwed and bolted to it. By duplicating the loads that influence the distortion, you eliminate little inconsistancies, get a happier engine that will live a longer life. This is more important when pushing a design to it's limits. The higher the performance, the less room there is for error. This process is one that racers have been using for ions, and while these little inconsistancies don't effect the engine too much, when you're looking for every little bit of power, or looking for hitting a specific safety factor when you're pushing the envelop, this is one of the tools one can use to nearly assure the best running and longest lasting engine possible. If you've ever heard of engine blue-printing - this is an element of that process.
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Old 02-15-2011, 03:03 PM   #25
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When I had the LT-1 engine built for my '73 Corvette in 1975 the engine builder used a torque plate, and a few years later the engine was checked by a local guy who ran Top Fuel dragsters and he told me my engine had better leak-down than his mega-buck Top Fuel engines. I definitely think it's worth it.
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