{"version":"1.0.0","episode":{"title":"150: The Self-Taught Way: Building Wild Engines from Scratch","url":"http://getcarcurious.com/episodes/150-the-self-taught-way-building-wild-engines-from-scratch","audioUrl":"https://www.buzzsprout.com/1755412/episodes/18140041-150-the-self-taught-way-building-wild-engines-from-scratch.mp3","description":"Imagine being a self-taught engineer who mastered the intricacies of engine design and is now building bespoke engines from the ground up. That’s exactly what Josh Valman from Motorsport_Engineering has done.We welcome Josh back for his second appearance on the podcast. This time, we catch up on his wild Alpha V8 Hayabusa project and dive into his latest creation — a turbocharged hot-vee V6 bespoke engine.👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipIn this episode of Tuned In, Josh shares his journey from self-taught engineer to bespoke engine designer and builder. We check in on his progress with the Alpha project before unpacking the details of his new V6 design.We explore the technical side of engine performance — including pre-ignition chambers, variable valve timing, and the unique benefits of a V6 engine configuration. Josh also discusses the finer points of engine design and the importance of balancing stroke and bore ratios while selecting the right compression ratios for boosted engines.With deep expertise in machining and manufacturing, Josh offers valuable insights into precision machining, materials selection, heat treatment, and maintaining tight tolerances in high-performance engine parts.If you’re fascinated by engine design, engine building, machining, or CAD, this episode is packed with knowledge. Josh’s passion for sharing his experience makes it a must-listen for anyone interested in the art and science of building engines.👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvipFollow Josh here:Instagram: Motorsport_engineeringYoutube: Motorsport_engineeringTimestamps:0:00 The Self-Taught Way: Building Wild Engines from Scratch3:34 Welcome back, Who are you? Where are you from and what do you do?8:45 How did you learn your CAD skills?2:11 What’s the complexities with manufacturing in China?18:31 What’s happening with the Alpha project?21:31 What is the process for making the tooling for carbon fibre body panels?23:20 When do you see this competing in the British Hillclimb Championship?23:46 What engine changes would you make to run the car at Pikes Peak?27:05 What is a pre-ignition chamber and what’s the advantage?34:40 What is pre-ignition and what causes it?38:04 What’s the advantage of variable valve timing?40:26 How did you go from a manufacturi45:49 How do you choose the V angle for an engine?51:17 How do you design parts & get them right without years of experience? 55:25 Why would a V6 require balance shafts?58:27 Is it easier to design an engine from scratch than modify an existing one?1:04:12 What are the factors that affect deciding on a stroke length? 1:06:36 How critical is the rod to stroke ratio?1:07:55 How do you choose a compression ratio?1:11:05 How do you confirm the strength of your engine parts?1:13:53 Why do we need to heat treat our parts?  1:17:11 How do you keep accurate tolerances while machining these parts?1:21:09 Why are you using a liner over a coated bore?1:22:31 How hard is it machining coolant passages into the block & Head?1:25:45 How are you confirming you have sufficient cooling when designing these engines?1:30:40 How are you sealing the head on this engine?1:34:12 How did the V8 engine go when you got it on the dyno?1:35:53 Why did you go gear drive between the crank and cams?1:40:09 How long between over"},"annotations":[{"startTime":0.0,"endTime":5.0,"type":"term","title":"V8","url":"/glossary/v8","quote":"I appreciate the V8s or the V10s sounded incredible, but sounding good doesn't necessarily win you anything.","canonicalId":"term:v8","priority":0.9,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"A V8 engine has eight cylinders arranged in a V‑shaped 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car","canonicalId":"concept:tube-frame-hill-climb-car","priority":0.9,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"A lightweight racing car built on a tubular steel chassis, designed for uphill time‑trial competitions.","simplifiedExplanation":"A tube frame hill climb car is a small, fast vehicle made with steel tubes for the frame, used in races up steep hills."}},{"startTime":85.0,"endTime":100.0,"type":"concept","title":"3D modeling and CAD software","url":"/glossary/3d-modeling-and-cad-software","quote":"leveraging his engineering skills and engineering knowledge, which is interestingly almost exclusively self‑taught, but also his insane ability when it comes to 3D modeling and CAD software","canonicalId":"concept:3d-modeling-and-cad-software","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Computer programs used to design and visualize parts or entire vehicles in three dimensions before building them.","simplifiedExplanation":"3D modeling and CAD let engineers draw a virtual car on the computer so they can see how it looks and works before making it."}},{"startTime":111.0,"endTime":115.0,"type":"term","title":"EFI","url":"/glossary/efi","quote":"we specialize in teaching people how to build performance engines, how to tune EFI","canonicalId":"term:efi","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Electronic Fuel Injection controls fuel delivery to the engine using sensors and computer algorithms for optimal performance.","simplifiedExplanation":"EFI is a system that tells the engine how much fuel to use, making it run smoother and more efficiently."}},{"startTime":115.0,"endTime":120.0,"type":"term","title":"wiring harnesses","url":"/glossary/wiring-harnesses","quote":"how to tune EFI, how to construct wiring harnesses","canonicalId":"term:wiring-harnesses","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"A bundle of electrical cables that connect various components in a vehicle, ensuring proper power and signal distribution.","simplifiedExplanation":"Wiring harnesses are groups of wires that link all the car’s electronic parts together."}},{"startTime":120.0,"endTime":125.0,"type":"concept","title":"fabrication","url":"/glossary/fabrication","quote":"we also cover topics on fabrication","canonicalId":"concept:fabrication","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"The process of building or shaping metal and other materials into parts for vehicles, often using tools like lathes, mills, and CNC machines.","simplifiedExplanation":"Fabrication means making the physical parts of a car, like cutting and shaping metal to fit together."}},{"startTime":1290.0,"endTime":1295.0,"type":"part","title":"bodywork","url":"/glossary/bodywork","quote":"Before we move on just in terms of that bodywork with it design what was the process you'll go through...","canonicalId":"part:bodywork","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Bodywork refers to the exterior panels and structural components of a vehicle that protect occupants and give the car its shape.","simplifiedExplanation":"Bodywork is the outside shell of a car, like its doors and hood. It keeps you safe and gives the car its look."}},{"startTime":1290.0,"endTime":1295.0,"type":"part","title":"panels","url":"/glossary/panels","quote":"Before we move on just in terms of that bodywork with it design what was the process you'll go through...","canonicalId":"part:panels","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Panels are flat sections of a vehicle’s body, such as doors, fenders, or hoods.","simplifiedExplanation":"Panels are the flat pieces that make up a car’s exterior, like the side panels or the hood."}},{"startTime":1290.0,"endTime":1295.0,"type":"concept","title":"tooling","url":"/glossary/tooling","quote":"Before we move on just in terms of that bodywork with it design what was the process you'll go through in terms of to to make the tooling to produce these come farther panels.","canonicalId":"concept:tooling","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Tooling is the set of tools, molds, and dies used to manufacture parts in large quantities.","simplifiedExplanation":"Tooling means the special tools and molds you need to make many parts of a car, like stamping metal panels."}},{"startTime":1461.0,"endTime":1469.0,"type":"term","title":"variable valve timing","url":"/glossary/variable-valve-timing","quote":"So it probably will run variable valve timing which you don't have on the high boost but it allows you to account for the fact that the air gets thinner as you go up.","canonicalId":"term:variable-valve-timing","priority":0.9,"confidence":0.97,"source":"openai/gpt-oss-20b","data":{"explanation":"Variable valve timing (VVT) is a technology that adjusts the timing of engine valves opening and closing to improve performance, fuel efficiency, and emissions across different RPM ranges.","simplifiedExplanation":"Variable valve timing lets the engine change when its valves open and close, helping it run better at low or high speeds."}},{"startTime":1513.0,"endTime":1516.0,"type":"term","title":"chassis","url":"/glossary/chassis","quote":"We could talk to you another five years and you'll be back in the same situation but with a completely different chassis and engine combination is the problem.","canonicalId":"term:chassis","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"The chassis is the vehicle's frame and structural base that supports all other components, including the engine, suspension, and body. It determines rigidity, weight distribution, and overall vehicle dynamics.","simplifiedExplanation":"Think of the chassis as the skeleton of a car. It holds everything together and helps keep the car stable and safe."}},{"startTime":1533.0,"endTime":1540.0,"type":"term","title":"engine tuning","url":"/glossary/engine-tuning","quote":"If you're a fan of the podcast and you're interested in topics like engine tuning, automotive wiring, performance engine building...","canonicalId":"term:engine-tuning","priority":0.9,"confidence":0.97,"source":"openai/gpt-oss-20b","data":{"explanation":"Engine tuning involves adjusting an engine’s parameters—such as fuel injection, ignition timing, and air-fuel mixture—to optimize performance, efficiency, or emissions.","simplifiedExplanation":"It’s like fine‑tuning a car’s engine settings so it runs better or faster, similar to adjusting a recipe for the best taste."}},{"startTime":1540.0,"endTime":1550.0,"type":"term","title":"performance engine building","url":"/glossary/performance-engine-building","quote":"If you're a fan of the podcast and you're interested in topics like engine tuning, automotive wiring, performance engine building...","canonicalId":"term:performance-engine-building","priority":0.9,"confidence":0.96,"source":"openai/gpt-oss-20b","data":{"explanation":"Performance engine building is the process of assembling or modifying an engine to achieve higher power output, better reliability, or specific performance characteristics.","simplifiedExplanation":"It means building or upgrading a car’s engine so it can go faster or handle better, like putting in stronger parts."}},{"startTime":1772.0,"endTime":1780.0,"type":"term","title":"lean","url":"/glossary/lean","quote":"Does this kind of tune things on its heed in terms of being able to run a lean if your ratio, but still make great power?","canonicalId":"term:lean","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"A lean mixture has more air than fuel, allowing the engine to run efficiently and produce less exhaust gas. It can improve power output when managed correctly.","simplifiedExplanation":"Lean means the engine is using more air and less fuel. This can make it run better if done right."}},{"startTime":2200.0,"endTime":2205.0,"type":"term","title":"dynamic compression ratio","url":"/glossary/dynamic-compression-ratio","quote":"Yeah, and giving you a lower dynamic compression ratio by closing the valve early...","canonicalId":"term:dynamic-compression-ratio","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"The dynamic compression ratio is the effective compression ratio of an engine during operation, which can change due to valve timing and other factors. It influences power output and fuel efficiency.","simplifiedExplanation":"Think of it as how much the engine squeezes air and fuel together before ignition. A higher ratio can mean more power, but it also needs careful control to avoid engine damage."}},{"startTime":2238.0,"endTime":2245.0,"type":"term","title":"direct injected engines","url":"/glossary/direct-injected-engines","quote":"With production, direct injected engines, one of the problems that is pretty well known.","canonicalId":"term:direct-injected-engines","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Direct injection is a fuel delivery system where gasoline is sprayed directly into the combustion chamber of each cylinder, rather than mixing with air in a separate intake manifold. This allows for more precise fuel metering and higher compression ratios, improving efficiency and power.","simplifiedExplanation":"Direct injection means the engine sprays fuel straight into each cylinder instead of mixing it with air first. It helps engines run better and use less fuel."}},{"startTime":2901.0,"endTime":2904.0,"type":"part","title":"exhaust manifolds","url":"/glossary/exhaust-manifolds","quote":"and exhaust manifolds between the two cylinder heads","canonicalId":"part:exhaust-manifolds","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Exhaust manifolds collect exhaust gases from multiple cylinders and channel them into the turbocharger or exhaust system.","simplifiedExplanation":"Exhaust manifolds are metal tubes that gather the hot gases from each cylinder and send them together to go out of the car."}},{"startTime":2961.0,"endTime":2963.0,"type":"part","title":"intake manifolds","url":"/glossary/intake-manifold","quote":"even with the intake manifolds","canonicalId":"part:intake-manifold","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Intake manifolds are components that distribute air (and sometimes fuel) from the intake system to each cylinder of an internal combustion engine. They help ensure balanced airflow for efficient combustion.","simplifiedExplanation":"An intake manifold is a part of the engine that takes air from the air filter and sends it to each cylinder so the engine can run properly."}},{"startTime":3389.0,"endTime":3392.0,"type":"term","title":"damping","url":"/glossary/damping","quote":"you can do without it, embracing, because the vibration isn't the end of the world, but you still need an element of damping on the crankshaft and certainly on the camshaft.","canonicalId":"term:damping","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Damping refers to the use of materials or devices that absorb vibrations and reduce oscillations in engine components, improving smoothness and longevity.","simplifiedExplanation":"It’s like putting a cushion around parts of the engine so they don’t shake too much, keeping everything running quieter and more reliably."}},{"startTime":3391.0,"endTime":3393.0,"type":"part","title":"crankshaft","url":"/glossary/crank-shaft","quote":"but you still need an element of damping on the crankshaft and certainly on the camshaft.","canonicalId":"part:crank-shaft","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"The crankshaft is a rotating shaft in an internal combustion engine that converts the linear motion of pistons into rotational motion to drive the vehicle’s wheels.","simplifiedExplanation":"Think of it as a big metal rod that spins inside the engine, turning the up-and-down motion of the pistons into the spinning power that moves your car."}},{"startTime":3604.0,"endTime":3609.0,"type":"part","title":"high boost head redesign","url":"/glossary/high-boost-head-redesign","quote":"[3604.0s] I was effectively trying to see, well, how they done it, how would I do it, but in Billet","canonicalId":"part:high-boost-head-redesign","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"A high‑boost head is the cylinder head of an engine designed to handle very high intake pressures, often used in racing or performance applications. Redesigning it involves improving airflow, cooling, and structural integrity to support increased boost levels.","simplifiedExplanation":"A high‑boost head is a part of an engine that lets it run with more air and fuel, making it faster. Engineers change its shape or materials to keep it strong when the pressure inside is very high."}},{"startTime":3806.0,"endTime":3812.0,"type":"concept","title":"OE engine world","url":"/glossary/oe-engine-world","quote":"[3806.0s] and in the OE engine world, [3809.0s] a good example of that","canonicalId":"concept:oe-engine-world","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"The \"OE engine world\" refers to engines that are sold as original equipment by manufacturers, meaning they come factory‑installed and meet the manufacturer’s specifications for performance, durability, and emissions.","simplifiedExplanation":"This means the engine is built by the car company itself, not a third‑party maker. It follows the exact rules and parts the factory uses."}},{"startTime":4007.0,"endTime":4015.0,"type":"term","title":"rod to strike ratio","url":"/glossary/rod-to-strike-ratio","quote":"[4007.0s] Is the rod moves through its cycle? [4009.0s] It's effectively, look at it as a triangle, right? ... [4015.0s] And you want to try and minimize that angle,","canonicalId":"term:rod-to-strike-ratio","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"The rod-to-stroke ratio is the proportion between an engine’s connecting rod length and its piston stroke. A higher ratio reduces the angle of the rod during operation, improving efficiency and reducing wear.","simplifiedExplanation":"In a car engine, the connecting rod pushes the piston up and down. The rod-to-stroke ratio tells how long that rod is compared to the distance the piston travels. A higher ratio means the rod stays more straight, which can make the engine run smoother."}},{"startTime":4180.0,"endTime":4183.0,"type":"term","title":"turbo","url":"/glossary/turbo","quote":"But to get to that much boost on the turbo, you have to go through a whole range of low levels of boost","canonicalId":"term:turbo","priority":0.9,"confidence":0.97,"source":"openai/gpt-oss-20b","data":{"explanation":"A turbocharger (turbo) uses exhaust gases to spin a turbine, which compresses incoming air and increases engine power.","simplifiedExplanation":"A turbo is a device that takes exhaust gas and uses it to push more air into the engine, making it stronger."}},{"startTime":4237.0,"endTime":4241.0,"type":"term","title":"pressure sensors","url":"/glossary/pressure-sensors","quote":"send it to pressure sensors and temp sensors","canonicalId":"term:pressure-sensors","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Pressure sensors measure the force exerted by fluids or gases inside a vehicle’s systems, such as engine oil pressure or brake fluid pressure. The data helps diagnose issues and ensure components operate within safe limits.","simplifiedExplanation":"Pressure sensors check how hard fluids or gases are pushing inside parts of a car, like the oil in the engine. They help make sure everything is working correctly."}},{"startTime":4237.0,"endTime":4241.0,"type":"term","title":"temp sensors","url":"/glossary/temp-sensors","quote":"send it to pressure sensors and temp sensors","canonicalId":"term:temp-sensors","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Temperature sensors monitor the heat levels of various components, such as engine coolant or air intake. This information is used to adjust performance and prevent overheating.","simplifiedExplanation":"Temp sensors keep track of how hot parts of the car are, like the engine coolant. They help the car stay cool and run smoothly."}},{"startTime":4457.0,"endTime":4463.0,"type":"term","title":"aluminium 6061","url":"/glossary/aluminium-6061","quote":"So it's already been so with aluminium 606-1, which is sort of your run of the mill machining aluminium, that normally comes in it in a T6 format,","canonicalId":"term:aluminium-6061","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Aluminium 6061 is a widely used alloy in automotive manufacturing, known for its good strength-to-weight ratio and excellent machinability.","simplifiedExplanation":"Aluminium 6061 is a type of metal that car makers use because it’s strong, light, and easy to shape into parts."}},{"startTime":4551.0,"endTime":4555.0,"type":"term","title":"3D printed part","url":"/glossary/3d-printed-part","quote":"[4551.0s] If you think about a 3D printed part that's got layers, [4555.0s] it's very easy to break it across the layers,","canonicalId":"term:3d-printed-part","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"A component manufactured using additive manufacturing, where material is deposited layer by layer to build the final shape.","simplifiedExplanation":"It’s a part made by printing it in layers, like using a 3D printer instead of cutting or molding it."}},{"startTime":4635.0,"endTime":4646.0,"type":"term","title":"billet aluminium","url":"/glossary/billet-aluminium","quote":"but when you're machining a piece of billet aluminium like this, I can only assume it's putting a lot of heat into the aluminium","canonicalId":"term:billet-aluminium","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Billet aluminium refers to a solid block of aluminum that has been cast and then machined or formed into parts. It is commonly used for high-performance components because it offers a good balance of strength, lightness, and workability.","simplifiedExplanation":"Billet aluminum is a solid piece of metal that you can cut or shape into parts. It’s lighter and stronger than many other materials, so it’s popular for making things that need to be both strong and not too heavy."}},{"startTime":4746.0,"endTime":4754.0,"type":"term","title":"heat treating","url":"/glossary/heat-treating","quote":"I might have missed it, but do you do a final heat treat after the final machining, or is that it?","canonicalId":"term:heat-treating","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Heat treating is a metallurgical process that heats and cools metal parts to alter their physical properties, such as hardness and strength.","simplifiedExplanation":"Heat treating is when a metal part is heated and then cooled in a controlled way to make it stronger or harder."}},{"startTime":4804.0,"endTime":4815.0,"type":"term","title":"line honing","url":"/glossary/line-honing","quote":"...such as the line honing, the main bearing tunnel and the block...","canonicalId":"term:line-honing","priority":0.5,"confidence":0.95,"source":"openai/gpt-oss-20b","data":{"explanation":"Line honing is a precision machining process that smooths the cylinder walls inside an engine block, improving surface finish and reducing friction.","simplifiedExplanation":"Line honing is a special polishing step that makes the inside of engine cylinders smoother, which helps the engine run better and last longer."}},{"startTime":5219.0,"endTime":5221.0,"type":"concept","title":"Formula One","url":"/glossary/formula-one","quote":"[5219.0s] but I mean, you'll see every weekend on Formula One [5221.0s] as well where they go.","canonicalId":"concept:formula-one","priority":0.9,"confidence":0.98,"source":"openai/gpt-oss-20b","data":{"explanation":"Formula One is the highest class of single-seat, open-wheel racing sanctioned by the FIA. It features cutting-edge technology and highly specialized cars designed for maximum performance.","simplifiedExplanation":"Formula One is the top level of car racing, with very fast and advanced cars that are built for speed and performance."}},{"startTime":5466.0,"endTime":5470.0,"type":"part","title":"cylinder head","url":"/glossary/cylinder-head","quote":"How difficult, how complex is it to keep the cylinder head sealed to that block?","canonicalId":"part:cylinder-head","priority":0.9,"confidence":0.97,"source":"openai/gpt-oss-20b","data":{"explanation":"The cylinder head sits atop the engine block and contains valves, spark plugs, and combustion chambers. It must be tightly sealed to prevent leaks under high pressure.","simplifiedExplanation":"This is the top part of an engine that holds the valves and spark plugs. It needs to stay sealed so the engine runs properly."}},{"startTime":5468.0,"endTime":5470.0,"type":"part","title":"block","url":"/glossary/blocks","quote":"to that block?","canonicalId":"part:blocks","priority":0.9,"confidence":0.96,"source":"openai/gpt-oss-20b","data":{"explanation":"The engine block is the main structure that houses pistons, crankshaft, and valves. It must be robust enough to withstand combustion pressures.","simplifiedExplanation":"This is the big metal part of an engine that holds everything together. It needs to be strong so it doesn’t break under pressure."}}],"speakers":[{"id":"s1","name":"High Performance Academy","role":"host"}],"transcripts":[{"url":"http://getcarcurious.com/episodes/150-the-self-taught-way-building-wild-engines-from-scratch/transcript.vtt","type":"text/vtt"}]}