Update report - September 15, 2018

Putting the finishing touches to this very special engine rebuild.

Polishing a few engine components ahead of final assembly.

With the new injector bungs welded in place, construction of the intake manifold is now been complete.

	It will be a shame to hide this beautiful workmanship under the hood

The following sequence of photographs show the custom piston design process, as well as some very special Megacycle billet camshafts.

Prototype piston on the lathe
	Piston placed in block ready for plastic mold
Mold shows valve location	Machining valve reliefs on the mill
	Megacycle made the cams to Corey's design
Measuring piston to valve clearance	Machining 3cc dome

I am pleased to report that we have now finished fabricating your custom FI intake manifold.

Custom forged rods provide a weight saving of 4,360 g (9.61 lbs) compared to the original items.

Custom forged rods save 545g per rod compared to the original behemoths	What will the Mercedes purists will think about eight E Type Jaguars spinning inside this M-100 engine?

The following sequence of photographs show Corey's design and fabrication of a completely new intake manifold for this very special M-100 engine.

New CJ designed intake valve	Original intake valve is 35.3g heavier
New CJ designed exhaust valve	Original exhaust valve is 47g heavier
Huge gains on the flow bench, about which more later	Port matching new intake manifold flanges to intake runners
New intake manifold perfectly matches shape of ports	Solid aluminum tube stock will be machined to form tapered intake runners of optimum size and shape
Corey machining the intake runners on the lathe
Note tapered shape starting to form
Jake welding custom intake runners to previously fabricated flanges	About to form/fabricate the main intake plenum
Custom intake manifold repeatedly trial fitted throughout fabrication process
	Welding new runners to plenum body
Manifold now starting to take shape
More trial fitting
	To be continued...
Plate beneath runners adds rigidity

The legendary Mercedes Benz M-100 6.3 engine will need no introduction to most classic car enthusiasts around the world. It came to fame as the power plant of the amazing 300 SEL 6.3 sedan of the late 1960's, a car which held the title as the fastest 4 door sedan in the world for over two decades. Despite the high performance of those amazing "Q" cars of the 60's and early 70's, the massive engine only produced around 250/275 HP. In addition to the sheer weight of the rotating components, another limiting performance factor was the design of the cylinder heads and combustion chambers.

During the course of this exciting build, we are going to re-shape the combustion chambers, re-shape and port the intake and exhaust runners, optimize spark plug positioning at the point of combustion, and we are actually going to reposition the cylinder heads slightly on the the block, allowing us to redesign valve sizing and positioning within the chamber.

We have also designed a custom forged H-beam connecting rod, saving 545g per rod over the originals, which tip the scales at an hefty 1,160 g!

M-100 engine as delivered
	Tear down underway
Cylinder head on tear-down bench
Pressure testing one of the heads	Base line flow testing cylinder head
Measuring cam clearance	Machining out intake seats
Exhaust seats were welded to facilitate removal
Roughing in new shape
Welding chambers prior to re-shaping
Guide boss prior to blend porting
New CJ guides now installed	Custom seats pressed into position
	New chamber shape will promote superior combustion
	Trial fitting heads in 'shifted' position