Brozz 250 Head Porting

[JerryHawk250]

Originally Posted by China Rider 27

1/8 inch flat aluminum sheet. I think you can buy it a Home Depot or Lowes maybe. Use paper to trace the outline on the head. Transfer to aluminum, draw, cut with jig saw, drill bolt holes, and shape with grinder. Home Depot has MM bolts to fit. I didn't use a gasket on mine seems to seal. Later I am going to put some high temp RV gasket maker on it. Somebody had bought one to fit off ebay somewhere.

^^^ This is what I did. ^^^ I reused gasket and bolts.

[alex_in_az]

Originally Posted by TxTaoRider

I ordered a complete brozz head from Peace to work on later, and it has some type of egr port on the head (my tbr7 doesn't have it). What did you use to cap it off with?

I drilled and tapped the port 7/16-20 and ran a bolt in. I then blended the end of the bolt to match the inside of the exhaust port

[grumpyunk]

Was there any difference in performance after closing off the EGR port?
tom

[franque]

Vs left open? If you leave it open it'll be ear splittingly loud, and it won't run that great.

[tknj99]

Got in touch with Joe after emailing a few questions. I was happy to hear that the gains from the full head p/p work come to 4hp.. a sweet 26% gain in performance which is pretty amazing. Now just need to find out how long the process will take from when i ship it out to when i have it back in my hands.

[TxTaoRider]

Originally Posted by tknj99

Got in touch with Joe after emailing a few questions. I was happy to hear that the gains from the full head p/p work come to 4hp.. a sweet 26% gain in performance which is pretty amazing. Now just need to find out how long the process will take from when i ship it out to when i have it back in my hands.

4hp on these motors is super impressive. How much is he charging?

[grumpyunk]

I realize there would be more noise without the EGR being connected and the passage/port uncovered.
To simplify. Was there significant difference in power output with the EGR passage covered with a plate, and the EGR function disabled? My quick view is that it uses a controlled amount of exhaust gas that is fed to the intake via the air cleaner. I did not dig in deeply to figure the actual inlet used. I guess I could do that, and plug the 'feed' to see if there was a difference, but being a bit lazy, and being chilled outside, asking is quicker, easier, and adequate.
tom

[franque]

EGR is just used for emissions, just plug it. It is a way to reburn exhaust gases. If it's actually SAI, aka secondary air injection (which is what I think it actually is), that just takes some air from the atmosphere and adds it to the exhaust, which warms the cat up quicker, but really doesn't make it run any cleaner, except that it dilutes exhaust gases/forces a more complete burn of fuel outside of the combustion chamber. It just looks better to emissions sniffers.

There won't be a noticeable difference to how you do it, just make sure it isn't venting directly to the atmosphere from the cylinder head, because you might burn up a valve. If send the one that doesn't have the casting for the valve, myself, and get it ported, running the one with the blocked off EGR/SAI now.

[tknj99]

Originally Posted by TxTaoRider

4hp on these motors is super impressive. How much is he charging?

$125 XMas special.. I just removed the head.. was easier than i expected. Did not have to remove the tank. I unscrewed the intake manifold as well as having to remove the 2 metal panels that connect to the head.
I set her to top dead center before doing anything else. I was very careful and used a magnetic telescope wand to make sure that the washers didnt fall anywhere in addition to stuffing paper towels into the holes next to the bolts to be removed.

I spoke with Joe this morning and he also told me that he sells a 4 degree flywheel advance key for $22 and im going to buy that as well. He said that while the port and polish adds horsepower, the ignition advance increases torque very a very large amount, so it sounds like a winning proposition to me. Ill just have to buy a flywheel puller and look into that procedure.

On a sidenote, on the exhaust manifold there was a ratty piece of metal that i pulled out, i assume it was the leftover of the crush washer, if anyone knows the part # for this it would be appreciated as ill need it for sure.

[cycleway4]

Properly functioning EGR has no effect on performance..as Franque says, its for exhaust system emissions...it takes no power to run it.
That being said, many remove it to clean things up,...looks neater.

[China Rider 27]

Hard to get good pix of the ports. I used a headlamp to shine around the camera. Exhaust gasket link

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

[tknj99]

Just mailed the head out to JH. Turn around should be 4 days plus transit time. Very excited for the anticipated results.

[tknj99]

Originally Posted by China Rider 27

Hard to get good pix of the ports. I used a headlamp to shine around the camera. Exhaust gasket link

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Thanks! I assume this is the same part for the Brozz as well

[tknj99]

I also am purchasing his 4 degree timing key. Does anyone have experience with this on a Brozz? Was it an easy install? Do i just need a flywheel puller?

[tknj99]

Originally Posted by RedCrowRides

Joe Henner is absolute fire on head porting and has long experience with the CG clone engines, and his pricing his very reasonable. You can locate at him at joe henner motorsports on facebook or through the RXB owners group page on facebook. i am all for learning new skills but if you might consider paying to have it done by a pro then joe is as good as they come and his pricing is decidely amazing given the quality of his work.dont tell him i said so tho, or he might go up on rates lol !

The party may be ending as rates go up after the new year to $200, thats why i jumped on it right away.. that and the Xmas discount, cant go wrong