Cylinder Head Reconditioning

22/12/2025

Milky gearbox

22/12/2025

Leaking water engine bay

03/12/2025

30/11/2025

To determine whether a jetski has a cylinder head issue or worn piston rings, I use a smoke tester to locate where pressure is escaping inside the engine. First, I remove the spark plug of the cylinder being tested and rotate the engine so that the piston sits at top dead centre (TDC) on the compression stroke. This ensures both valves are closed and the cylinder is sealed as much as possible.

I then connect the smoke tester hose into the spark-plug hole using the correct adapter. Once the tester is turned on, smoke is gently pushed into the combustion chamber. With the cylinder pressurised, I carefully watch and listen around the engine to see exactly where the smoke leaks out.

If smoke starts coming out of the intake manifold or throttle body, it indicates a leaking intake valve or damaged valve seat. If smoke appears from the exhaust outlet, the exhaust valve is leaking. Smoke coming from the breather/PCV hose or crankcase points to worn piston rings, a scored bore, or excessive blow-by. And if smoke escapes from the outside of the cylinder head—around the head gasket area—then the problem is the head gasket or a warped/cracked cylinder head.

This method quickly shows whether the issue is in the cylinder head, valves, or the piston/rings without needing to completely tear the engine apart.

29/11/2025

I’ve fully converted a standard Bridgeport milling machine into a CNC-operated system to increase precision, repeatability, and overall machining capability. The machine is now driven by high-torque stepper motors on all axes, providing smooth and accurate movement without the inconsistencies of manual operation.

Control is handled through a DDCS Expert standalone CNC controller, giving me full G-code programming and ex*****on directly from the screen. I can load, write, and modify G-code, create custom toolpaths, adjust feed rates in real time, and control zero points and spindle functions just like a modern CNC machining center.

One of the key applications of this setup is cylinder head surfacing. With the CNC auto-feed table, I can perform precise, consistent cylinder head shaving with controlled step-over and feed direction, achieving better flatness and finish compared to manual milling. The rigid Bridgeport frame combined with CNC control lets me resurface a wide range of automotive cylinder heads accurately and repeatably.

This conversion essentially transforms a classic Bridgeport into a powerful CNC mill capable of producing custom parts, prototype work, precise resurfacing jobs, and any detailed machining task that benefits from automated motion and programmable toolpaths.

29/11/2025

I designed and built a fully custom CNC honing machine entirely from scratch — everything from the steel frame fabrication to the electronics, programming, and final calibration. The machine started as raw steel, which I cut, welded, and machined to create a rigid, vibration-free structure capable of precise cylinder honing.

I converted the machine to CNC control using stepper motors, ball screws, and linear guides to achieve accurate vertical feed and consistent cross-hatch patterns. The control system runs through a DDCS Expert CNC controller, allowing me to write and run G-codes for automatic honing cycles, stroke length, dwell time, and feed rate.

All programming, wiring, and motion tuning were done by me. The machine features:
• Heavy-duty steel frame for stability and no flex
• CNC-controlled vertical stroke for perfect consistency
• Adjustable honing pressure and feed
• Custom spindle assembly built for smooth operation
• Automatic cross-hatch control through programmable patterns
• Stepper motor drive system for accurate repeatability
• Fully integrated DDCS Expert screen for live monitoring and control

This custom CNC honing machine allows me to achieve extremely consistent cylinder finishes, perfect for engine rebuilds, cylinder head work, and precision machining where surface finish and accuracy are critical.

29/11/2025

I’ve designed and machined a custom fly-cutter tool specifically for resurfacing and machining cylinder heads. Unlike my previous steel version, this new cutter is made from high-grade aluminium, which significantly reduces weight and eliminates the vibration and ringing noise that steel cutters usually produce.

The body is precision-balanced to run smoothly at higher RPM, and because aluminium absorbs resonance better, the machining process is noticeably quieter and cleaner. I’ve also integrated a dual-insert system: the cutter accepts two interchangeable carbide inserts, allowing quick adjustment for different cylinder head sizes. This means I can switch between smaller heads and large, wide faces—such as Range Rover heads or Ford Ranger/BT-50 3.2L heads—without needing a separate tool.

The result is a lightweight, rigid, and extremely stable cutting tool that produces a consistent surface finish with minimal chatter and excellent control.

22/09/2024

Cylinder Head Reconditioning
for 1, 2, 3, 4, v6, v8 Cylinder heads.

- Cylinder Head Resurfacing
- Vacuum Testing EXT/INT
- Valve Resurfacing
- Shim Adjusting

Feel free to message me for more

Zero four one three zero two nine five nine nine any questions give me a call

Located Roxburgh Park 3064

22/09/2024