The engine technology for The Bourke Engine Project L.L.C. is supported by two different engine sizes (A 30 cubic inch and a 10 cubic inch) with various configurations for each. There will be various configurations released in the first 5 years. Each engine and each configuration will offer an infinite variety of sizes and horsepower. In the first two years, the company will focus on establishing the perfect mix of engine fuel management and ignition control systems. Once established, the mix will be applied to each engine and configuration. The first two years will focus on the production of the 30 cubic inch engine and a prototype of the second engine (10 cubic inches). The 10 cubic inch engine will be at least 15-25 horsepower and will become the product of high volume (expectations of 250,000 during the first year of mass production).
Five preproduction prototype 30 cubic inch engines will be designed and built by July, 2006. These five preproduction prototypes will then be tested from August, 2006 through December, 2006. Minimally, one of these engines will run continuously under maximum load to determine reliability and time between overhaul (TBO). The engine will be subjected to a minimum of 4,000 hours of testing. The other engines will be utilized to test various configurations that will be made available.
Fifty preproduction engines are scheduled to be available by October, 2007. Production of five hundred 30 cubic inch engines per month is scheduled to begin in December, 2007. The customers will determine the appropriate configuration to meet their needs. The configurations for the 30 cubic inch engine will be targeted for the 100 to 1000 horsepower markets.
To accomplish the above objectives, the project has been classified into three phases:
Phase One:
Bob Zigler will coordinate the design of the preproduction prototype engines with Roger Richard. Solid modeling of the preproduction prototype engines will be finalized using Solid Works®. Finite element analysis (FEA) will be performed on each component and on the assembly as a whole utilizing Cosmos Works™. Air Flow Analysis will be performed on the assembly utilizing Cosmos Flow Works™. Thermal Analysis will be performed on the assembly utilizing Cosmos Professional™. Using Z-Corp Solid Modeling Equipment, plaster models of each component will be made and assembled into a working plaster model for final approval of design concepts. After the final approval of design concepts, casting models will be finalized using Solid Works®. Plaster models will again be made to check for accuracy. Starch patterns will then be made and sent to an investment casting company. From the Solid Works® files, machining drawings with all dimensions, tolerances, finishes and processes will be made. Bob Zigler will co-ordinate the machining of all castings
Roger Richard will assemble and test the engines, obtaining certifiable test results from the five preproduction prototypes. Engineering changes which will finalize the preproduction model will be done and documented from the test results within six months of the receipt of the parts for the five preproduction prototypes.
Phase Two:
After successful testing of the five prototype engines, tooling for wax patterns will be made for the fifty preproduction engines. Solid Works® files will be processed through Feature Cam® in preparation for complete CNC machining of all components.
Phase Three:
Our manufacturing facilities will be producing five hundred 30 cubic inch engines per month by the end of December, 2007.
Note: During all the phases of the 30 cubic inch engine development, work will continue on a prototype for the 10 cubic inch engine. The 10 cubic inch engine with it's various configurations will be targeted to the 10 to 200 horsepower markets. Project plans similar to the 30 cubic inch plan will be developed after successfully testing the prototype.
