Abstract: A core box assembly for casting a crankshaft. The core box assembly comprises axially aligned cores that define different axial portions of a cavity that receives molten metal to cast the crankshaft. Oil gallery cores are placed in the core box assembly to form as-cast oil galleries in the crankshaft. Heavy metal inserts are held by sand cores disposed in the portions of the cavity that form the counterweights of the crankshaft.

Abstract: A crankshaft casting pattern insert 10 which includes selectively adjustable portions 14, 16, which respectively correspond the front and rear main bearing journal portions of the crankshaft. Each adjustable portion 14, 16 includes a removable insert or member 18, a key member 20, several “vertical” spacers 22, several “lateral” spacers 24, and a fastener 26. Adjustable portions 14, 16 allow the pattern 10 to be selectively modified in shape, effective to compensate for pattern wear and to allow multiple crankshafts to be produced which have a substantially similar balance capability. Pattern 10 may also include several validation pads or points 50 which allow the produced crankshafts to be measured with improved accuracy.

Abstract: An integrated fluid recovery reservoir and thermostat assembly 12 for use within an engine cooling system 10. The integrated fluid recovery reservoir and thermostat assembly 12 includes a coolant reservoir housing 26 which is mounted directly to the engine 14 and which includes inlet ports 28, 30 for receiving coolant 38 from engine 14 and an outlet flow portion or module 46 which is fluidly coupled to the radiator 18. The assembly 10 further includes a flow control module and thermostat assembly 42 which is attached to the reservoir housing 26 and which selectively and fluidly communicates with the reservoir housing 26, with the coolant pump 20 and with the radiator 18. A thermostat valve 72 is attached to and/or within assembly 42 and cooperates with assembly 42 to selectively control the flow of the coolant 38 through the engine cooling system 10.

Abstract: A water jacket 10 which includes an outer core 12 and a plurality of pre-formed bridge cores 14. The water jacket 10 allows for the selective creation of cylinder bores 16 which have a substantially uniform and circular cross sectional area.