Lost foam pattern assembly for V-block engine

Disclosed herein is a lost foam pattern assembly comprising a crankcase section including first and second planar surfaces intersecting at an angle defined therebetween, a port cylinder section fixed to the first surface of the crankcase section, and a starboard cylinder section fixed to the second surface of the crankcase section, which port and starboard cylinder sections are fixed to each other along a glue face located in a plane bisecting the angle.

BACKGROUND OF THE INVENTION 
The invention relates generally to lost foam patterns for use in the lost 
foam casting process. 
More particularly, the invention relates to multi-piece lost foam pattern 
assemblies for casting multi-cylinder, V-block, two stroke internal 
combustion engines. 
Attention is directed to the following U.S. Pat. Nos.: 
______________________________________ 
3,374,827 Schebler March 26, 1968 
3,727,671 Kawai April 17, 1973 
3,744,468 Braun July 10, 1973 
4,197,899 Ernest April 15, 1980 
4,273,182 Winterhalter, et al. 
June 16, 1981 
4,598,757 Bailey July 8, 1986 
4,609,030 Heater, et al. September 2, 1986 
4,632,169 Osborn, et al. December 30,1986 
4,640,333 Martin, et al. February 3, 1987 
4,640,728 Martin, et al. February 3, 1987 
4,657,063 Morris April 14, 1987 
______________________________________ 
SUMMARY OF THE INVENTION 
The invention provides a lost foam pattern assembly comprising a crankcase 
section including first and second planar surfaces intersecting at an 
angle defined therebetween, a port cylinder section fixed to the first 
surface of the crankcase section, and a starboard cylinder section fixed 
to the second surface of the crankcase section, which port and starboard 
cylinder sections are fixed to each other along a glue face located in a 
plane bisecting said angle. 
The invention also provides a lost foam pattern assembly comprising a port 
crankcase section including first and second surfaces extending at a right 
angle to each other, and a third surface extending in inclined relation to 
the first and second surfaces, a starboard crankcase section including 
first and second surfaces extending at a right angle to each other, and a 
third surface extending in inclined relation to the first and second 
surfaces of the starboard crankcase section and fixed to each other along 
a first glue face, which first surfaces of the port and starboard 
crankcase sections are co-planar, which second surfaces of the port and 
starboard crankcase sections are fixed to each other along a first glue 
face, a port cylinder section fixed to the third surface of the port 
crankcase section, and a starboard cylinder section fixed to the third 
surface of the starboard crankcase section, which port and starboard 
cylinder sections are fixed to each other along a second glue face 
co-planar with the first glue face. 
The invention also provides a lost foam pattern assembly comprising a first 
piece including first and second surfaces extending at a right angle to 
each other, and a third surface extending in inclined relation to the 
first and second surfaces, a second piece including first and second 
surfaces extending at a right angle to each other and a third surface 
extending in inclined relation to the first and second surfaces of the 
second piece, the second surfaces of the first and second pieces being 
fixed to each other along a first glue line and the first surfaces of the 
first and second pieces being co-planar, a third piece having a first 
surface fixed to the third surface of the first piece along a second glue 
line, and a fourth piece having a first surface fixed to the third surface 
of the second piece along a third glue line, which second and third glue 
lines extend at a substantial angle at each other, and which first, second 
and third glue lines are free of intersection with one another. 
The invention also provides a lost foam pattern assembly for a V-block 
multi-cylinder two stroke internal combustion engine, which pattern 
comprises a first piece having a first surface, an other surface in 
inclined relation to the first surface of the first piece, a cylindrical 
bore extending from the first surface of the first piece, and wall means 
defining a cavity extending in the first surface in the first piece and 
communicating with the bore in the first piece and extending to the other 
surface of the first piece and partially defining a first exhaust passage, 
a second piece having a first surface, an other surface in inclined 
relation to the first surface of the second piece and in co-planar 
relation to the second surface of the first piece, a cylindrical bore 
extending from the first surface of the second piece, and wall means 
defining a cavity extending in the first surface of the second piece and 
communicating with the bore in the second piece and extending to the other 
surface of the second piece and partially defining a second exhaust 
passage, a third piece including a first surface fixed to the first 
surface of the first piece, an other surface extending in inclined 
relation to the first surface of the third piece and in co-planar relation 
to the other surfaces of the first and second pieces, a cylindrical bore 
extending from the first surface of the third piece and in alignment with 
the cylindrical bore in the first piece, and wall means defining a cavity 
extending in the first surface of the third piece and communicating with 
the bore in the third piece and extending to the other surface of the 
third piece and partially defining the first exhaust passage, a fourth 
piece including a first surface fixed to the first surface of the second 
piece, an other surface in inclined relation to the first surface of the 
fourth piece and in co-planar relation to the other surfaces of the first, 
second, and third pieces, a cylindrical bore extending from the first 
surface of the fourth piece and in alignment with the cylindrical bore in 
the second piece, and wall means defining a cavity extending in the first 
surface of the fourth piece and communicating with the bore in the fourth 
piece and extending to the other surface of the fourth piece and partially 
defining the second exhaust passage, an exhaust manifold piece having a 
first surface fixed to the other surfaces of the first, second, third, and 
fourth pieces, and wall means defining a cavity extending in the first 
surface of the exhaust manifold piece and partially defining the first and 
second exhaust passages, and a water jacket cover piece having a first 
surface fixed to the third and fourth pieces, and a cover surface 
extending from the first surface of the water jacket piece and in spaced 
and covering relation to the exhaust manifold piece. 
The invention also provides a lost foam pattern assembly for a V-block 
multi-cylinder two stroke internal combustion engine, which pattern 
comprises a first piece including first and second surfaces extending at a 
right angle to each other, and a third surface extending in inclined 
relation to the first and second surfaces, a second piece including first 
and second surfaces extending at a right angle to each other and a third 
surface extending in inclined relation to the first and second surfaces of 
the second piece, the second surfaces of the first and second pieces being 
fixed to each other and the first surfaces of the first and second pieces 
being co-planar, a third piece fixed to the first piece and having a first 
surface in parallel relation to the third surface of the first piece, an 
other surface in inclined relation to the first surface of the third 
piece, a cylindrical bore extending from the first surface of the third 
piece, and wall means defining a cavity extending in the first surface in 
the third piece, communicating with the bore in the third piece, extending 
to the other surface of the third piece, and partially defining a first 
exhaust passage, a fourth piece fixed to the second piece and having a 
first surface in parallel relation to the third surface of the second 
piece, an other surface in inclined relation to the first surface of the 
second piece and co-planar with the other surface of the third piece, a 
cylindrical bore extending from the first surface of the fourth piece, and 
wall means defining a cavity extending in the first surface of the fourth 
piece, communicating with the bore in the fourth piece, extending to the 
other surface of the fourth piece, and partially defining a second exhaust 
passage, a fifth piece including a first surface fixed to the first 
surface of the third piece, an other surface in inclined relation to the 
first surface of the first piece and in co-planar relation to the other 
surfaces of the third and fourth pieces, a cylindrical bore extending from 
the first surface of the fifth piece and in alignment with the cylindrical 
bore in the third piece, and wall means defining a cavity extending in the 
first surface of the fifth piece, communicating with the bore in the fifth 
piece, extending to the other surface of the fifth piece, and partially 
defining the first exhaust passage, a sixth piece including a first 
surface fixed to the first surface of the fourth piece, an other surface 
in inclined relation to the first surface of the second piece and in 
co-planar relation to the other surfaces of the third, fourth, and fifth 
pieces, a cylindrical bore extending from the first surface of the sixth 
piece and in alignment with the cylindrical bore in the fourth piece, and 
wall means defining a cavity extending in the first surface of the sixth 
piece, communicating with the bore in the sixth piece, extending to the 
other surface of the sixth piece, and partially defining the second 
exhaust passage, an exhaust manifold piece having a first surface fixed to 
the other surfaces of the third, fourth, fifth, and sixth pieces, and wall 
means defining a cavity extending in the first surface of the exhaust 
manifold piece and partially defining the first and second exhaust 
passages, and a water jacket cover piece having a first surface fixed to 
the fifth and sixth pieces, and a cover surface extending from the first 
surface of the water jacket piece and in spaced and covering relation to 
the exhaust manifold piece. 
The invention also provides a lost foam pattern assembly for a V-block 
multi-cylinder two stroke internal combustion engine, which pattern 
comprises a port crankcase section including first and second surfaces 
extending at a right angle to each other, and a third surface extending in 
inclined relation to the first and second surfaces, a starboard crankcase 
section including first and second surfaces extending at a right angle to 
each other and a third surface extending in inclined relation to the first 
and second surfaces of the starboard crankcase section, the second 
surfaces of the port and starboard crankcase sections being fixed to each 
other and the first surfaces of the port and starboard crankcase sections 
being co-planar, a port lower cylinder section having a first surface 
fixed to the third surface of the port crankcase section, a second surface 
in spaced and parallel relation to the first surface of the port lower 
cylinder section, and a cylindrical bore extending between the first and 
second surfaces of the port lower cylinder section, a starboard lower 
cylinder section having a first surface fixed to the third surface of the 
starboard crankcase section, a second surface in spaced parallel relation 
to the first surface of the starboard lower cylinder section, and a 
cylindrical bore extending between the first and second surfaces of the 
starboard lower cylinder section, a port middle cylinder section having a 
first surface fixed to the second surface of the port lower cylinder 
section, a second surface in spaced parallel relation to the first surface 
of the port middle cylinder section, a third surface in inclined relation 
to the second surface of the port middle cylinder section, a cylindrical 
bore extending between the first and second surfaces of the port middle 
cylinder section and in alignment with the cylindrical bore in the port 
lower cylinder section, and wall means defining a cavity extending in the 
second surface in the port middle cylinder section and communicating with 
the bore in the port middle cylinder section and extending to the third 
surface of the port middle cylinder section and partially defining a first 
exhaust passage, a starboard middle cylinder section having a first 
surface fixed to the second surface of the starboard lower cylinder 
section, a second surface in spaced parallel relation to the first surface 
of the starboard middle cylinder section, a third surface in inclined 
relation to the second surface of the starboard middle cylinder section 
and co-planar with the third surface of the port middle cylinder section, 
a cylindrical bore extending between the first and second surfaces of the 
starboard middle cylinder section and in alignment with the bore in the 
starboard lower cylinder section, and wall means defining a cavity 
extending in the second surface of the starboard middle cylinder section 
and communicating with the bore in the starboard middle cylinder section 
and extending to the third surface of the starboard middle cylinder 
section and partially defining a second exhaust passage, a port upper 
cylinder section including a first surface fixed to the second surface of 
the port middle cylinder section, a second surface in spaced parallel 
relation to the first surface of the port upper cylinder section, a third 
surface in inclined relation to the second surface of the port upper 
cylinder section and in co-planar relation to the third surfaces of the 
port and starboard middle cylinder sections, a cylindrical bore extending 
between the first and second surfaces of the port upper cylinder section 
and in alignment with the cylindrical bore in the port middle cylinder 
section, and wall means defining a cavity extending in the first surface 
of the Port upper cylinder section and communicating with the bore in the 
port upper cylinder section and extending to the third surface of the port 
upper cylinder section and partially defining the first exhaust passage, a 
starboard upper cylinder section including a first surface fixed to the 
second surface of the starboard middle cylinder section, a second surface 
in spaced parallel relation to the first surface of the starboard upper 
cylinder section, a third surface in inclined relation to the second 
surface of the starboard upper cylinder section and in co-planar relation 
to the third surfaces of the port and starboard middle cylinder sections 
and the port upper cylinder section, a cylindrical bore extending between 
the first and second surfaces of the starboard upper cylinder section and 
in alignment with the cylindrical bore in the starboard middle cylinder 
section, and wall means defining a cavity extending in the first surface 
of the starboard upper cylinder section and communicating with the bore in 
the starboard upper cylinder section and extending to the third surface of 
the starboard upper cylinder section and partially defining the second 
exhaust passage, an exhaust manifold section having a first surface fixed 
to the third surfaces of the port and starboard middle and upper cylinder 
sections, and wall means defining a cavity extending in the first surface 
of the exhaust manifold section and partially defining the first and 
second exhaust passages, and a water jacket cover section having a first 
surface fixed to the port and starboard upper cylinder sections, and a 
cover surface extending from the first surface of the water jacket section 
and in spaced and covering relation to the exhaust manifold section. 
The invention also provides a lost foam pattern assembly comprising a first 
piece including a planar surface, a cylindrical bore extending from the 
planar surface, and a first cavity communicating with the cylindrical bore 
and with the first planar surface, and a second piece including a planar 
surface fixed to the planar surface of the first piece, a cylindrical bore 
extending from the planar surface of the second piece and in registry with 
the cylindrical bore of the first piece, a cavity communicating with the 
cylindrical bore of the second piece and with the planar surface of the 
second piece and in registry with the cavity of the first piece, and 
another cavity having an end in spaced relation to the planar surface of 
the second piece, communicating with the cylindrical bore of said second 
piece, and extending from the end in the direction away from the first 
piece. 
Various of the features and advantages of the invention will become 
apparent to those skilled in the art upon review of the following detailed 
description, claims, and drawings

GENERAL DESCRIPTION 
Shown in the drawings is an end view of a lost foam pattern assembly 11 for 
casting, in the lost foam process, a multiple cylinder V-block two stroke 
engine (not shown). While other V-block arrangements could be employed, in 
the disclosed construction, the angle of the V is 90.degree. and the 
number of cylinders in each bank is two, thereby providing a total of four 
cylinders. 
As shown in the drawings, the lost foam pattern assembly 11 includes (see 
FIG. 1) a front crankcase face 13 to which, in the resulting cast engine 
block , a crankcase cover (not shown) is attached. The lost foam pattern 
assembly 11 also includes a bottom end 17 including an exhaust outlet or 
port 19, and a pair of coolant inlet ports 21 and 23 which are L-shaped 
and extend to the side and rear of the exhaust outlet 19. In addition, the 
bottom end 17 includes a pair of coolant drain ports 25 and 27. Centrally 
thereof, the bottom end 17 also includes a central opening 29. 
The lost foam pattern assembly 11 also includes (see FIG. 2) a top end 31 
having a central, generally rectangular access opening or port 33. In 
addition, the lost foam pattern assembly 11 includes (see FIG. 3) a rear 
face 35, a pair of cylinder head faces 37 and 39 to which, in the 
resulting cast engine block, a pair of cylinder heads (not shown) are 
attached, and (see FIG. 1) a pair of exterior side faces 41 and 43 having 
portions extending between the cylinder head faces 37 and 39 and the rear 
face 31 and portion extending between the cylinder head faces 37 and 39 
and the front face 13. The cylinder head faces 37 and 39 respectively 
include coolant drain ports 38 and 40. 
The lost foam pattern assembly 11 also includes a pair of cylinders 51 and 
53 (see FIG. 3) which are located in a first or port bank 55 and extend 
from the cylinder head face 37 and which are provided with exhaust ports 
communicating with a first exhaust passage 57 extending to the exhaust 
outlet 19. The lost foam pattern assembly 11 also includes cylinders 61 
and 63 (see FIG. 11) which are located in a second or starboard bank 65 
and extend from the cylinder head face 39 and which are provided with 
exhaust ports which communicate with a second exhaust passage 67 extending 
to the exhaust outlet 19. Interiorly, the lost foam pattern assembly 11 is 
provided with a cavity or water jacket space 71 which, in general, 
surrounds the cylinders 51, 53, 61 and 63 and exhaust passages 57 and 67 
and communicates with the coolant inlet ports 21 and 23 and with the 
coolant drain ports 25 and 27. 
The lost form pattern assembly 11 comprises ten major pieces and eight 
additional inserts or pieces which are glued together to form the pattern 
assembly 11. All of the pieces are formed of plastic foam material and all 
are designed to facilitate die casting thereof by conventional means. 
The first piece 101 comprises a port crankcase section or piece and 
includes, as shown in FIGS. 1, 2 and 4, a first planar surface 103 which 
forms part of the front crankcase face 13, together with a second planar 
surface 105 which extends at a right angle to the first planar surface 
103. The first and second planar surfaces 103 and 105 are connected by a 
series of curved surfaces 107 which form a cavity 109 providing a partial 
crankcase chamber. 
The other side of the first piece or port crankcase section 101 includes a 
third planar surface 111 which extends at an incline to the first and 
second surfaces 103 and 105. While other angles could be employed, in the 
disclosed construction, the third surface 111 extends at an angle of 
45.degree. to each of the first and second surfaces 103 and 105. 
Extending between the third surface 111 and the curved crankcase surface 
107 are (see FIGS. 4 and 5) first and elongated slots 113 and 115 which, 
in the resulting casting, provide first and second openings for the 
passage of associated connecting rods (not shown). 
The first piece or port crankcase section 101 also includes (see FIG. 4) 
opposite or bottom and top end surfaces 117 and 119. 
The lost foam pattern assembly 11 further includes a second or starboard 
quarter crankcase section or piece 151 which is similar to the first piece 
101 and includes, as shown in FIGS. 1 and 2, a first planar surface 153 
which forms part of the front or crankcase face 13, together with a second 
planar face 155 which extends at a right angle to the first planar surface 
153. The first and second planar surfaces 153 and 155 are connected by a 
series of curved surfaces 157 which form a cavity 159 partially forming 
the internal wall of the resulting crankcase chamber. The second surfaces 
105 and 155 are glued or otherwise suitably attached to each other. 
The other side of the second piece or starboard crankcase section 151 
includes (see FIGS. 1 and 2) a third planar surface 161 which extends at 
an incline to the first and second surfaces 153 and 155. While other 
angles could be employed, in the disclosed construction, the third surface 
161 extends at an angle of 45.degree. to each of the first and second 
surfaces 153 and 155. 
Extending between the third surface 161 and the curved crankcase surface 
157 are (see FIGS. 4 and 6) first and elongated slots 163 and 165 which, 
in the resulting casting, provide first and second openings for the 
passage of associated connecting rods (not shown). The elongated slots 163 
and 165 in the second piece 151 are offset axially of the the length of 
the crankcase with respect to the elongated slots 113 and 115 in the first 
piece 101. 
The second piece or starboard crankcase section 151 also includes opposite 
or bottom and top end surfaces 167 and 169. 
The lost foam pattern assembly 11 also includes (see FIGS. 1, 2 and 5) a 
third piece or port lower cylinder section 201 which includes a first 
planar surface 203 which is glued or otherwise suitable attached to the 
third planar surface 111 of the first piece 101. In addition, the third 
piece or port lower cylinder section 201 includes a second planar surface 
205 which is spaced from and parallel to the first planar surface 201. 
Extending between the first and second planar surfaces 203 and 205 of the 
third piece or port lower cylinder section 201 are wall means defining 
first and second cylindrical bores 207 and 209 which are respectively 
aligned with the first and second elongated slots 113 and 115 in the first 
piece 101, and which form portions of the cylinders 51 and 53. 
The third piece or port lower cylinder section 201 also includes a bottom 
end wall 211 which extends between the first and second surfaces 203 and 
205 and from a side wall 213 which extends in the direction of the length 
of the crankcase from the wall means defining the cylindrical bores 207 
and 209, and to the bottom end wall 211. 
The third piece or port lower cylinder section 201 also includes a top end 
wall 215 which extends between the first and second surfaces and which is 
provided (see FIG. 2) with a surface 219 extending in coplanar relation to 
the second surface 105 of the first piece 101. 
The bottom end wall 211, the side wall 213, and the top end wall 215 
cooperate with the wall means defining the cylindrical bores 207 and 209, 
together with wall portions of the first piece 101, to define portions of 
the water jacket space 71. 
In addition, the third piece or port lower cylinder section 201 also 
includes, for each of the cylindrical bores 207 and 209 (see FIG. 5) a 
series of cavities 221, 223, and 225 which respectively form a crankcase 
end portion of a pair of transfer passages 231 and 233 and a crankcase end 
portion of a boost transfer passage 235. The transfer passages 231 and 233 
are angularly spaced from each other at an angle which is known in loop 
scavenged two-stroke, internal combustion engine design. It is noted that 
the cavities 221, 223 and 225 increase in size in the direction toward the 
second planar surface 205 to enable separation of the third piece 201 and 
a forming die (not shown). 
The lost foam pattern assembly 11 also includes (see FIGS. 1, 2 and 6) a 
fourth piece or starboard lower cylinder section 251 which includes a 
first planar surface 253 which is glued or otherwise fixed to the third 
planar surface 161 of the second piece 151. In addition, the fourth piece 
or starboard lower cylinder section 251 includes a second planar surface 
255 which is spaced from and parallel to the first planar surface 253. The 
fourth piece or starboard lower cylinder section 251 also includes wall 
means defining first and second cylindrical bores 257 and 259 which are 
generally aligned with the first and second elongated slots 163 and 165 in 
the second piece 151, and which form portions of the cylinders 61 and 63. 
The fourth piece or starboard lower cylinder section 251 also includes a 
bottom wall 261 which extends between the first and second surfaces 253 
and 255 and from the wall means defining the cylindrical bores 257 and 
259. 
The fourth piece or starboard lower cylinder section also includes a top 
end wall 265 which extends between the surfaces 253 and 255 and which is 
provided (see FIG. 2) with a surface 269 which extends in coplanar 
relation to the second surface 155 of the second piece 151 and which is 
glued or otherwise fixed to the surface 219 of the third piece 201. 
The bottom end wall 261 and the top end wall 265 cooperate with the wall 
means defining the cylindrical bore 257 and 259, together with wall 
portions of the second piece 151, to define portions of the water jacket 
space 71. 
In addition, each of the cylindrical bores 257 and 259 of the fourth piece 
or starboard lower cylinder section 251 includes a series of cavities 271, 
273 and 275 defining a crankcase end portion of first and second transfer 
passages 281 and 283 and a crankcase end portion of a boost transfer 
passage 285 as generally described with respect to the third piece 201. It 
is noted that the cavities 271, 273, and 275 increase in size toward the 
second planar surface 255 to enable separation of the fourth piece 251 and 
a forming die (not shown). 
The lost foam pattern assembly 11 also includes (see FIGS. 1, 2, 9 and 10) 
a fifth piece or port middle cylinder section 301 which includes (see FIG. 
10) a first planar surface 303 which is glued or otherwise affixed to the 
second planar surface 205 of the third piece 201. In addition, the fifth 
piece or port middle cylinder section 301 also includes (see FIG. 9) a 
second planar surface 305 which extends in parallel and spaced relation to 
the first planar surface 303. Still further, the fifth piece or port 
middle cylinder section 301 is provided with wall means forming first and 
second cylindrical bores 307 and 309 which are aligned with the first and 
second cylindrical bores 207 and 209 in the third piece 201 and which form 
portions of the cylinders 51 and 53. 
The fifth piece or port middle cylinder section 301 also includes (see 
FIGS. 9 and 10) a bottom end wall 311 which extends between the first and 
second surfaces 303 and 305 and in general alignment with the bottom end 
wall 211 of the third piece 201 and from a side wall 313 which extends 
between the bottom end wall 311 and the wall means defining the 
cylindrical bores 307 and 309 and which is aligned or in register with the 
side wall 213 of the third piece 201. 
The fifth piece or port middle cylinder section 301 also includes (see 
FIGS. 9 and 10) a top end wall 315 which extends from the wall means 
defining the cylindrical bores 307 and 309 and between the first and 
second surfaces 303 and 305 and in general alignment with the top end wall 
215 of the third piece 201. 
The cylindrical walls of the first and second bores 307 and 309 are 
provided with recesses or cavities 321, 323 and 325 which provide the head 
end portions of the first and second transfer passages 231 and 233 and the 
first boost transfer passage, 235 respectively. The cavities or recesses 
321, 323 and 325 which complete the transfer passages 231, 233 and 235 
extend from a location in slightly spaced relation from the second surface 
305 and toward the first surface 303 and increase in size toward the first 
surface 303 to facilitate separation of the fifth piece 301 from a forming 
die (not shown). In other words, the last portion of the first and second 
cylinder bores 307 and 309, adjacent the second surface 305 is 
uninterrupted by the transfer passages 231, 233 and 235. 
The fifth piece or port middle cylinder section 301 also includes (see 
FIGS. 9 and 15) a third planar surface 341 which intersects the second 
planar surface 305 and extends in inclined relation thereto and in 
generally parallel relation to the first surfaces 103 and 153 of the first 
and second pieces 101 and 151. 
The fifth piece or port middle cylinder section 305 also includes (see FIG. 
1) a fourth or additional planar surface 340 which extends perpendicularly 
from the third planar surface 341 in coplanar relation to the second 
surface 155 of the second piece 151. 
The fifth piece or port middle cylinder section 301 also includes (see FIG. 
9) wall means defining a cavity 343 formed in the second planar surface 
305 and extending between the first and second cylindrical bores 307 and 
309, and the third planar surface 341 to provide an exhaust passage wall 
344 partially defining the exhaust passage 57. The cavity 343 includes a 
first branch 345 extending from the first cylindrical bore 307 and a 
second branch 347 extending from the second cylindrical bore 309. The 
first and second branches 345 and 347 communicate respectively with the 
first and second cylindrical bores 307 and 309 through respective exhaust 
ports 346 and 348 which are each divided into sub-ports by respective 
separators or partitions 349. 
The cross sections of the exhaust ports 346 and 348 and of the cavity 343 
in the fifth piece 301 increase in size toward the second surface 305 to 
facilitate separation of the fifth piece 301 and a forming die (not 
shown). 
At their other ends, the branches 345 and 347 merge into a common branch 
342 which extends to the third surface 341 and which is also defined by a 
wall portion 346 extending to the bottom end wall 311. 
If desired, the exhaust passage wall 344 can also be formed to provide an 
opening 338 between the cavity branches 345 and 347 forming another 
portion of the water jacket space 71. 
The lost foam pattern assembly 11 also includes (see FIGS. 1, 2, 13 and 14) 
a sixth piece or starboard middle cylinder section 351 which is similar to 
the fifth piece or port middle cylinder section 301 and which includes a 
first planar surface 353 which is glued or otherwise affixed to the second 
planar surface 253 of the fourth piece or starboard middle cylinder 
section 251. The sixth piece or starboard middle cylinder section 351 also 
includes a second planar surface 355 which is spaced from and parallel to 
the first planar surface 353. In addition, the sixth piece or starboard 
middle cylinder section 351 includes wall means defining first and second 
cylindrical bores 357 and 359 which are respectively aligned with the 
cylindrical bores 257 and 259 in the fourth piece 251 and which form 
portions of the cylinders 61 and 63 (see FIG. 11). 
The sixth piece or starboard middle cylinder section 351 also includes a 
bottom end wall 361 which extends between the first and second surfaces 
353 and 355 and from the wall means defining the cylindrical bores 357 and 
359 and in general alignment with the bottom end wall 261 of the fourth 
piece 351. 
The sixth piece or starboard middle cylinder section 351 also includes (see 
FIGS. 13 and 14) a top end wall 365 which extends from the wall means 
defining the cylindrical bores 357 and 359 and between the first and 
second surfaces 353 and 355 and in general alignment with the top end wall 
265 of the fourth piece 251. 
The cylindrical walls of the first and second bores 357 and 359 are 
provided with recesses or cavities 371, 373 and 375 which provide the head 
end portions of the first and second transfer passages 281 and 283 and the 
first boost transfer passage, 285 respectively. The cavities or recesses 
371, 373 and 375 which complete the transfer passages 281, 283 and 285 
extend from a location in slightly spaced relation from the second surface 
355 and toward the first surface 353 and increase in size toward the first 
surface 353 to facilitate separation of the sixth piece 351 from a forming 
die (not shown). In other words, the last portion of the first and second 
cylinder bores 357 and 359, adjacent the second surface 355 is 
uninterrupted by the transfer passages 281, 283 and 285. 
The sixth piece or starboard middle cylinder section 351 also includes (see 
FIGS. 13 and 15) a third planar surface 391 which intersects the second 
planar surface 355 and extends in inclined relation thereto and in 
generally coplanar relation to the third surface 341 of the fifth piece 
301 and in generally parallel relation to the first surfaces 103 and 153 
of the first and second pieces 101 and 151. 
The sixth piece or starboard middle cylinder section 351 also includes (see 
FIG. 1) a fourth or additional planar surface 390 which extends 
perpendicularly from the third planar surface 391 incoplanar relation to 
the second surface 155 the second piece or starboard crankcase section 151 
and which is glued to the fourth or additional wall 340 of the fifth piece 
or port middle cylinder section 301. 
The sixth piece or starboard middle cylinder section 351 also includes wall 
means forming a cavity 393 in the second planar surface 355, and extending 
between the third surface 391 and the cylindrical bores 357 and 359, to 
provide an exhaust passage wall 394 partially defining the exhaust passage 
67. The cavity 393 including a pair of branches 395 and 397 which 
communicate respectively with the first and second bores 357 and 359 
through exhaust ports 396 and 398 and which are sub-divided by respective 
separators or partitions 399. 
The cross sections of the exhaust ports 396 and 398 and of the cavity 393 
in the sixth piece or starboard middle cylinder section 351 increase in 
size toward the second surface 355 to facilitate separation of the sixth 
piece 351 and a forming die (not shown). 
At their other ends, the branches 395 and 397 merge into a common branch 
392 which extends to the third surface 391 and which is also defined by a 
wall portion 390 extending to the bottom end wall 361. 
If desired, the exhaust passage wall 394 can be formed to provide an 
aperture 388 between the cavity branches to 395 and 397 to provide still 
another portion of the water jacket space 71. 
The lost foam pattern assembly 11 also includes (see FIGS. 1, 2, 7 and 8) a 
seventh piece or port upper cylinder section 401 including a first planar 
surface 403 which is glued for otherwise suitably fixed to the second 
surface 305 of the fifth piece or port middle cylinder section 301. In 
addition, the seventh piece or port upper cylinder section 401 includes a 
second generally planar surface 405 which is spaced from and parallel to 
the first surface 403, and which provides the cylinder head face 37. 
Extending between the first and second surfaces 403 and 405 are wall means 
defining first and second cylindrical bores 407 and 409 which are 
respectively aligned with the first and second cylindrical bores 307 and 
309 in the fifth piece 301, and which form portions of the cylinders 51 
and 53. 
The seventh piece or port upper cylinder section 401 also includes (see 
FIGS. 7 and 8) a bottom end wall 411 which extends from the first surface 
403 in general alignment with the bottom end wall 311 of the fifth piece 
or port middle cylinder section 301 and from a side wall 413 which extends 
between the bottom end wall and the wall means defining the cylinder bores 
407 and 409 and which is aligned or in registry with the side wall 313 of 
the fifth piece or port middle cylinder section 301. 
The seventh piece or port upper cylinder section 401 also includes (see 
FIGS. 7 and 8) a top end wall 415 which extends from the wall means 
defining the cylindrical bores 407 and 409 and from the first surface 403 
in general alignment with the top end wall 315 of the fifth piece 301. 
The seventh piece or port upper cylinder section 401 also includes a third 
surface 421 which, in the completed assembly, extends in parallel relation 
to the surfaces 103 and 153 of the first and second pieces 101 and 151 and 
in co-planar relation to the third surface 341 of the fifth piece 301. 
Still further in addition, the seventh piece or port upper cylinder section 
401 includes (see FIGS. 1 and 15) a fourth or additional surface 425 
located on the exterior of the seventh piece 401 and between the third 
surface 421 and the second surface 405 and extending in parallel relation 
to the third surface 421. 
The seventh piece or port upper cylinder section 401 also includes (see 
FIG. 8) a cavity 431 which extends inwardly from the first surface 403 and 
between the wall means defining the cylinder bores 407 and 409 and the 
third surface 421 and in registry with the cavity 343 provided in the 
fifth piece 301 and which provides an exhaust passage wall 434 which 
defines the remaining portion of the exhaust passage 57. 
The cavity 431 includes two branches 435 and 437 respectively communicating 
at one end with the first and second cylindrical bores 407 and 409 through 
respective exhaust ports 439 and 441 divided into two sub-ports by 
respective spliter walls or partitions 443. 
At their other ends, the branches 435 and 437 merge into a common branch 
445 which extends to the third surface 421 and which is also defined by a 
wall portion 446 extending to the bottom end wall 411. 
The cross sections of the the exhaust ports 439 and 441 and of the cavity 
431 in the seventh piece 401 increase in size toward the first surface 403 
to facilitate separation of the seventh piece or port upper cylinder 
section 401 and a forming die (not shown). 
The top end wall 415 and the outer side of the exhaust passage wall 434 
form a portion of the water jacket space 71 which can be referred to as an 
exhaust manifold water jacket portion and which extends to and opens into 
the bottom end wall 411. 
The wall means defining the cylinder bores 407 and 409 also defines a pair 
of circular cavities 448 and 449 which respectively surround the 
cylindrical bores 407 and 409, which form portions of the water jacket 
space 71, and which communicate, through ports 449a extending parallel to 
the axis of the cylindrical bores 407 and 409, with portions of the water 
jacket space 71 formed by the fifth piece 301. The circular cavities 448 
and 449 increase in size toward the second surface 405 to facilitate 
separation of the seventh piece 401 and a forming die (not shown). 
The lost foam pattern assembly 11 also includes an eighth piece or 
starboard upper cylinder section 451 which is similar to the seventh piece 
or port upper cylinder section 401 and which includes (see FIGS. 1, 2, 11 
and 12) a first planar surface 453 which is glued or otherwise suitably 
fixed to the second surface 355 of the sixth piece or starboard middle 
cylinder section 351. In addition, the eighth piece or starboard upper 
cylinder section 451 includes a second planar surface 455 which is spaced 
from and in parallel relation to the first surface 453 and which forms the 
cylinder head face 39. 
The eighth piece or starboard upper cylinder section 451 also includes wall 
means defining first and second cylindrical bores 457 and 459 which extend 
between the first and second surfaces 453 and 455 in alignment with the 
first and second bores 357 and 359 in the sixth piece or starboard middle 
cylinder section 351 which form portions of the cylinders 61 and 63. 
The eighth piece or starboard upper cylinder section 451 also includes a 
bottom end wall 461 which extends from the first surface 453 and from the 
wall means defining the cylindrical bores 457 and 459 and in general 
alignment with the bottom end wall 361 of the sixth piece 351. 
The eighth piece or starboard upper cylinder section 451 also includes (see 
FIGS. 11 and 12) a top end wall 465 which extends from the wall means 
defining the cylindrical bores 467 and 459 and from the first surface 453 
in general alignment with the top end wall 365 of the sixth piece or 
starboard middle cylinder section 351. 
Still further in addition, the eighth piece or starboard upper cylinder 
section 451 includes (see FIG. 1) a third surface 471 which, in the 
assembly, is parallel to the first surfaces 103 and 153 of the first and 
second pieces 101 and 151 and co-planar to the third surfaces 341, 391, 
and 421 of the fifth, sixth and seventh pieces 301, 351 and 401 
respectively. 
Still further in addition, the eighth piece or starboard upper cylinder 
section 451 includes (see FIGS. 1 and 15) a fourth surface 475 which 
extends parallel to the first surfaces 103 and 153 of the first and second 
pieces 101 and 151, which is located in spaced, parallel, outwardly offset 
relation to the third surface 471, and in spaced relation to the second 
surface 455, and in coplanar relation to the fourth surface 425 of the 
seventh piece or port upper cylinder section 401. 
Still further in addition, the eighth piece or starboard upper cylinder 
section 451 includes (see FIG. 12) a cavity or recess 481 which extends in 
the first surface 453 and from the cylindrical bores 457 and 459 to the 
third surface 471, and in registry with the cavity 393 in the sixth piece 
or starboard middle cylinder section 351 and which provides an exhaust 
passage wall 484 defining the remaining portion of the exhaust passage 67. 
The cavity 481 includes branches 485 and 487 which respectively communicate 
with the cylindrical bores 457 and 459 through respective exhaust ports 
489 and 491 which are sub-divided by a divider wall or partition 493. The 
cross sections of the exhaust ports 489 and 491 and of the cavity 481 in 
the eight piece or starboard upper cylinder section 451 increase in size 
toward the first surface 453 to facilitate separation of the eight piece 
or starboard upper cylinder section 451 and a forming die (not shown). 
At their other ends, the branches 485 and 487 merge to form a common branch 
495 which extends to the third surface 471 and which is also defined (see 
FIG. 15) by a wall portion 496 extending to the bottom end wall 461. 
The wall means defining the cylinder cylindrical bores 457 and 459 also 
defines two circular cavities 498 and 499 which respectively surround the 
cylindrical bores 457 and 459. The cavities 498 and 499 form a portion of 
the water jacket space 71 and communicate, through bores 499aextending 
parallel to the axis of the cylindrical bores 457 and 459, with portions 
of the water jacket space 71 formed by the sixth piece 351. The circular 
cavities 498 and 499 increase in size toward the second surface 455 to 
facilitate separation of the eight piece 451 and a forming die (not 
shown). 
The lost foam pattern assembly 11 also includes (see FIGS. 1 and 16 through 
18) a ninth piece or exhaust manifold or bridge section 501 which includes 
a first planar surface 511 which registers with and is glued to the third 
surfaces 341, 391, 421 and 471 of the fifth, sixth, seventh, and eighth 
pieces 301, 351, 401, and 451, respectively, and a second planar or bottom 
end wall surface 513 which registers with and is co-planar with the bottom 
end walls 411 and 461 of the seventh and eighth pieces 401 and 451, 
respectively. In addition, the ninth piece 501 includes wall means 
defining a pair of cavities 521 and 523 which complete the exhaust 
passages 57 and 67 and which are separated from each other by a partition 
531 extending from the first surface 511. The partition 531 terminates in 
an end surface 533 spaced inwardly from the second surface or bottom end 
wall surface 513 so as to provide thereafter a single main exhaust passage 
which terminates in the generally rectangular exhaust outlet 19 in the 
bottom end 17, which outlet 19 is adapted for discharging exhaust gases 
into an adaptor or drive shaft housing (not shown) located below the 
resulting engine block. 
The lost foam pattern assembly 11 also includes a tenth piece or exhaust 
manifold water jacket section 551 which includes (see FIGS. 1, 2 and 18) a 
first planar surface 561 which is glued or otherwise suitably fixed to the 
fourth surfaces 425 and 475 of the seventh and eighth pieces 401 and 451, 
together with a bottom end wall surface 563 which registers with and is 
co-planar with the bottom end wall surfaces 411 and 461 of the seventh and 
eighth pieces 401 and 451, and a top end wall 565 which registers with 
flat surfaces 571 and 572 on the end walls 415 and 465 of the seventh and 
eight pieces 401 and 451 and which is coplanar with surfaces 573, 574, 575 
and 576 of the third, fourth, fifth, and sixth top end wall surfaces 211, 
261, 311, 361, to complete the access port 33 which is located in the top 
end 31 of the pattern assembly 11 and in communication with the water 
jacket space 71. 
The exhaust manifold water jacket piece or section 551 also includes wall 
means extending from the first planar surface 561 and between the bottom 
and top end walls 563 and 565 and defining a cavity 581 providing a cover 
wall 583 which, in general, is located in spaced relation to the ninth 
piece 501 and in covering relation to the otherwise open interior water 
jacket space 71. Preferably, the ninth and tenth pieces 501 and 551 
respectively include, adjacent the bottom end walls 513 and 563, abutting 
bosses 591 and 593 which are glued or otherwise suitable affixed to each 
other, thereby strengthening the tenth piece 551 in relation to the 
remainder of the pattern assembly 11. 
The fifth, sixth, seventh and eighth pieces 301, 351, 401, and 451 are 
provided with water jacket drain passages 701 and 751 which extend from 
the coolant drain ports 25 and 27 in the bottom end walls 311 and 361 of 
the fifth and sixth pieces 301 and 351 and which terminate in the ports 38 
and 40 (see FIGS. 9 and 11) provided in the second surfaces 405 and 455 of 
the seventh and eighth pieces 401 and 451, which second surfaces 405 and 
455, as already noted, form the cylinder head faces 37 and 39. The ports 
38 and 40 are adapted to receive coolant water discharged from the 
cylinder heads (not shown). 
The passages 701 and 751 extend interiorly in the fifth, sixth, seventh and 
eighth pieces 301, 351, 401, and 451 and include mating ports 703 and 705 
(see FIGS. 8 and 9) in the fifth and seventh pieces 301 and 401 and mating 
ports 753 and 755 in the sixth and eighth pieces 351 and 451. 
Each of the eight transfer passages 231, 233, 281 and 283 formed in the 
cylinders 51, 53, 61 and 63 is provided (see FIGS. 10 and 14) with a 
curved radially inwardly located wall 591 by respective inserts or pieces 
593 which are received into the cavities 321, 323, 371 and 373 and located 
against movement by reason of such entry into spaced recesses formed in 
the transfer passage cavities as more fully explained in my co-pending 
U.S. application Ser. No. 202212 filed June 3, 1988 and entitled "Lost 
Foam Engine Block Pattern" which application is incorporated herein by 
reference. Preferably, the eight inserts or pieces 593 are glued in the 
associated eight transfer passage cavities 321, 323, 371 and 373. 
The opening 29, provided in the bottom end 17, affords drainage of the 
water jacket space 71 in the cast engine block and, in the lost foam 
pattern, serves to advantageously avoid intersection of glue lines. Such 
glue line intersection is tolerated at the opening or port 33 in the upper 
or top end 31 of the pattern assembly 11. 
In an alternative embodiment shown in FIG. 19, the first and third pieces 
101 and 201 are fabricated by die casting in a single piece 801 and the 
second and fourth pieces 151 and 251 ar fabricated by die casting in a 
single piece 851. With such pieces 801 and 851, and referring to the 
pattern assembly top end 31, shown in FIG. 2, the pattern assembly 11 can 
be glued together without intersection, as in the FIG. 2 embodiment, of 
the glue plane defined by the surfaces 219 and 269 either with the glue 
plane defined by the surfaces 111 and 203 or with the glue plane defined 
by the surfaces 161 and 253. 
Various of the features of the invention are set forth in the following 
claims.