Manufacture of a structural 'ladderframe' dry sump

[murpia]

Hi,
I'm looking at the feasibility of designing a new, structural, ladder-frame type dry sump to fit to an existing in-line 4 cylinder engine. By structural I mean the transfer of loads from gearbox to monocoque, similar to a Formula 3 concept. Currently I'm considering machining the sump from solid.
I'm worried about the machining processes required to match the new sump to the existing block, particularly main bearings and cap bolts.
Any help / advice or pointers to good references will be appreciated.
Regards, Ian

 

[EngJW]

You will want a solid metal to metal contact between the sump and crankcase- no gaskets. A compressible gasketed joint would not hold up if you are transferring loads through it (besides you need a metal to metal joint for the main bearings). You will need dowels or some other arrangement to maintain alignment. The mains will have to be bored with the sump torqued up to the crankcase. Machining for the crankshaft oil seals will have to be considered, for example whether they are in the crankcase or in another housing attached to it.