Mason Delacroix
Building an alcohol-based hot rod engine is a viable option in today's world of rising gas prices. While it may seem like a daunting task, it is possible to convert your existing vehicle's engine to run on alcohol fuel with some careful planning and the right tools. This process can be relatively inexpensive, especially since many modern cars, trucks, and SUVs already use ethanol-compatible parts. The advantages of an alcohol engine include reduced pollution, a cooler running temperature, and independence from foreign fuel suppliers.
Now, let's dive into the specifics of building an alcohol hot rod diesel engine, where the real challenge lies in avoiding costly mistakes.
Characteristics and Values Table for Building an Alcohol Hot Rod Diesel Engine:
| Characteristics | Values |
|---|---|
| Engine Type | Ford small-block with a wet sump and 13.2:1 compression |
| Cylinder Heads | Fully ported cast-iron |
| Horsepower | Capable of producing over 600 hp |
| Fuel Type | Capable of burning gasoline and alcohol |
| Fuel Pump | High-volume fuel pump capable of providing sufficient pressure |
| Fuel Requirements | Alcohol engines need to burn twice as much fuel as gasoline engines |
| Fuel System | Sized appropriately for volume and corrosiveness |
| Oil Changes | More frequent when using alcohol to prevent bearing erosion and acidic compound formation |
| Spark Plugs | Hotter spark plugs may be needed |
| Carburetor | Modified with a carburetor overhaul kit and enlarged fuel-metering jets |
| Float | Heavier float required due to higher density of alcohol |
| Ignition Timing | Advanced timing due to higher burn rate of alcohol |
| Turbo Arrangement | Compound turbo with Aurora 8000 and Aurora 5000 |
| Diesel Rat Rods | Gaining popularity due to reality TV, trade shows, magazines, and social media |
| Creative Freedom | "Anything goes" nature of rat rod builds encourages creativity and originality |
| Budget | Diesel rat rods can be built on shoestring budgets or with more expensive components |
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What You'll Learn
Advantages of an alcohol engine
Alcohol has been used as a fuel for internal combustion engines since their invention. Mixing alcohol with gasoline has several advantages. Firstly, alcohol tends to increase the octane rating, which prevents engine detonation (knock) under load. This, in turn, increases the engine's compression ratio, resulting in greater efficiency and better economy.
Secondly, alcohol burns more cleanly than gasoline, reducing noxious emissions and purging the internal parts of the engine of carbon and gum deposits. This leads to reduced pollution and longer engine life. An alcohol-burning engine tends to run cooler, reducing the chance of overheating.
Thirdly, alcohols burn more completely, increasing combustion efficiency. For example, ethanol is less corrosive and toxic than methanol, requiring less fuel than gasoline while producing more power.
Finally, using alcohol as an engine fuel reduces dependency on outside or foreign fuel suppliers. However, it is important to note that there are also disadvantages to using alcohol as an engine fuel, such as corrosion and increased fuel consumption.
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Fuel conversion
Converting a gasoline engine to run on alcohol is a viable option, and it can be done inexpensively. However, there are some key considerations and potential pitfalls to be aware of.
Firstly, it is important to note that an alcohol engine will require a higher volume of fuel compared to gasoline. This means that the fuel pump and lines, jets, ports, and other components must be appropriately sized to handle the increased flow. For example, engine builder Ken Troutman encountered an issue where the bypass in the pump was not large enough, leading to fuel starvation at high RPM.
Secondly, the corrosiveness of alcohol fuel must be considered. Alcohol can cause corrosion in the fuel system, including the carburetor, if left sitting for extended periods. To mitigate this, it is common to feed gasoline into the engine after disconnecting the alcohol fuel source to flush the system. Additionally, the oil will need to be changed more frequently to prevent bearing erosion and the formation of acidic compounds.
Thirdly, the materials used in the fuel system must be alcohol-resistant. For example, steel needles are often used in the needle and seat assembly to prevent rubber tips from disintegrating.
When converting an engine to run on alcohol, it is crucial to test all components to ensure compatibility. This includes cleaning and soaking parts such as the fuel pump, carburetor, fuel filter, and fuel hose in high-proof alcohol for an extended period. Any parts that show signs of softening or damage must be replaced.
Additionally, modifications are typically required to the carburetor to accommodate the different fuel. A carburetor overhaul kit specific to the model is needed, and the fuel-metering jets must be enlarged, usually by about 40%. The float setting may also need adjustment or replacement, as alcohol is heavier than gasoline, and the ignition timing will need to be advanced due to the different burn rate of alcohol.
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Parts and preparation
The first step in building an alcohol-based hot rod diesel engine is to source the necessary parts and prepare your engine for the conversion. Here are the key components and steps involved in the process:
Engine Selection and Preparation:
Start by choosing an appropriate engine for your hot rod project. In the case of Ken Troutman, the engine in question was a Ford small-block with a wet-sump, 13.2:1 compression, and fully ported cast-iron cylinder heads. This engine was initially powering a Limited Dirt Late Model and was capable of producing over 600 horsepower.
It's important to select an engine that is compatible with ethanol or alcohol-based fuel. Most modern engines are built with ethanol-compatible parts, making it a relatively inexpensive process. However, you should still test your engine components to ensure they can handle alcohol-based fuel.
Carburetor Overhaul Kit:
You will need to acquire a carburetor overhaul kit specifically designed for your carburetor model. This kit will allow you to modify your carburetor for alcohol or ethanol use. The process involves enlarging the fuel-metering jets of the carburetor using a drill press or hand drill. The enlargement increases fuel flow, which is necessary due to the higher volume of fuel required for alcohol engines compared to gasoline.
Fuel System Considerations:
When using alcohol or ethanol, the fuel system must be up to the task in terms of volume and addressing corrosiveness issues. Alcohol engines require a higher volume of fuel, so ensure your fuel pump and lines, jets, ports, and other components are appropriately sized. Additionally, alcohol can be corrosive, so it is common to run gasoline through the engine after using alcohol to prevent corrosion in the carbs. The oil will also need to be changed more frequently to prevent bearing erosion and the formation of acidic compounds.
Ignition System Adjustments:
Alcohol burns at a higher rate and takes more time to ignite and vaporize compared to gasoline. Therefore, you will need to advance the timing of your ignition system. This can be achieved by loosening the distributor by turning it in the opposite direction of the turning rotor inside.
Other Parts:
Other parts you may need include heavier floats for the carburetor, as alcohol is up to 8% heavier than gasoline, and hotter spark plugs. Additionally, you may want to consider using steel needles for the needle and seat assembly to prevent disintegration, as alcohol can affect rubber components.
By carefully sourcing and preparing these parts, you will be well on your way to successfully building an alcohol-fueled hot rod diesel engine.
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Installation
The installation process for an alcohol-based hot rod engine involves several key steps to ensure the engine can effectively run on alcohol fuel.
Firstly, it is imperative to select a suitable fuel pump that can handle the increased fuel demand of an alcohol-based engine. A belt-driven pump, such as the one offered by BLP Products, is recommended due to its superior flow capabilities compared to pushrod-driven alternatives. This type of pump also offers adjustable mounting options, allowing for flexibility in installation.
The next step is to address the issue of alcohol contaminating the oil supply, which can lead to potential bearing failure. To mitigate this, it is advisable to switch to a stand from a low-tension system, as mentioned by Troutman in his experience.
Before assembling the engine, it is crucial to test all parts to ensure compatibility with alcohol-based fuel. Clean and soak the fuel pump, carburetor, fuel filter, and fuel hose in at least 180-proof alcohol for about a month. Replace any components that show signs of damage or softening due to the alcohol.
Once the parts are confirmed compatible, proceed to modify the carburetor. Obtain a carburetor overhaul kit specific to your carburetor model to prepare it for alcohol use. Carefully enlarge the fuel-metering jets of the carburetor by about 40%, using a drill press or hand drill. This enlargement may vary depending on the purity of the alcohol.
The float setting also requires adjustment due to the heavier nature of alcohol compared to gasoline. Bend the float up slightly or opt for a heavier float to maintain the proper fuel level. Finally, reassemble the carburetor and fit it back into the engine, ensuring all connections are secure and no parts are left over.
Additionally, it is important to advance the timing of the ignition system as alcohol burns at a higher rate and takes longer to ignite and vaporize. Loosen the distributor by turning it in the opposite direction of the turning rotor inside.
It is worth noting that during the winter, an engine running solely on alcohol may take longer to warm up. To address this, consider installing a lean-out valve or addressing any vacuum leaks. Furthermore, if the vehicle will be left unused for extended periods, it is advisable to drain the alcohol and add gasoline to the tank to prevent the alcohol from damaging the seals.
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Testing and fine-tuning
Dyno Testing
Dyno testing involves running the engine on a dynamometer, which measures various performance parameters. This testing can be done in stages to compare different configurations. For example, you can first test the engine configured for gasoline and then repeat the test with the alcohol-burning setup. During these tests, monitor key metrics such as horsepower, torque, volumetric efficiency, and exhaust gas temperatures (EGT). Fine-tune the engine by adjusting the timing, fuel pressure, carburetor settings, and jet sizes to optimize performance and avoid issues like running too lean or detonation.
Power Goals and Turbo Sizing
After addressing power goals, focus on engine size, rpm, and fuel consumption. Turbochargers play a significant role in boosting power. To gauge turbo sizing accurately, monitor the drive pressure in relation to the boost. An ideal ratio for efficiency is 1:1, but more boost than back pressure can lead to compressor stall. Consider using different turbine housing sizes to fine-tune the turbo's performance on the engine.
Cooling and Temperature Management
When using alcohol fuel, pay attention to cooling and temperature management. Alcohol has higher Latent Heat Vaporization values, which help remove significant heat from the chamber, reducing the temperature impact of increased timing. However, increased compression ratios can also lead to more heat in the chamber, so ensure adequate cooling measures are in place to prevent overheating.
Drivability vs. Maximum Performance
There is a delicate balance between drivability and maximum performance. While chasing peak horsepower is tempting, it's essential to consider the vehicle's everyday drivability. Fine-tuning the engine may involve making adjustments to strike a balance between power and reliability for street use.
Test Drive and Adjustments
Finally, test drive your hot rod to identify any necessary adjustments. Engines vary, and you may need to fine-tune timing and other parameters to prevent issues like engine cut-out or pinging. Remember that real-world driving conditions can vary, so be prepared to make adjustments based on the specific demands of your vehicle and environment.
By following these testing and fine-tuning steps, you can optimize the performance, reliability, and longevity of your alcohol hot rod diesel engine.
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Frequently asked questions
An alcohol engine runs cooler, produces less pollution, and does not depend on foreign suppliers.
First, ensure your parts can work with alcohol-based fuel. Then, clean your fuel pump, carburetor, fuel filter, and fuel hose, and soak them in at least 180-proof alcohol for about a month. Next, modify your carburetor for alcohol use by enlarging the fuel-metering jets and adjusting the float setting. Finally, advance the timing of the ignition system.
Examples of diesel hot rod builds include a 1950s Ford, a '46 Dodge, and a 7.3L Power Stroke engine in a Ford F-100 chassis. Other examples include diesel rat rods and oil-burning rat rod projects that have rescued vintage trucks, coupes, and sedans from scrapyards.
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