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1 CONNECTING RODS From the most refined steel and titanium alloys, Saenz connecting rods are forged and machined with the latest in CNC technology. They are all designed and custom-made for each client, regardless of the quantity required. Each part of the rod has been studied and tested. Many of the new solutions other brands offer today were formerly developed by Saenz. Saenz rods are submitted to exhaustive quality control procedures during the production process. We are proud to say that we have not received any negative feedback in recent years.
2 CONNECTING RODS Since the early '70's Saenz has manufactured connecting rods that have run successfully in the 24 hours of Daytona, WRC, Dakkar Rally, F1 boats and hundreds of continental, national and regional series around the globe. Our designs mark tendencies and Saenz is the exclusive rod supplier in many series. We are proud of the products we manufacture and many of our employees come from the racing industry, and know that excellence is the only option. We do not like to compare our products with low cost ones made for people who only look at the purchasing price. Our target is the medium-high level end of the market, customers who know which the quality of our products is, as well as the costs behind them. We strive to give our customers the best product for their money, which is evidenced by the type of equipment we use to produce the rods as well as the parts themselves.
3 SAENZ WAY Saenz connecting rods are made of SAE 4340 steel, 300M, Titanium and special steel alloys upon request. All materials are made from certifiable stock and every bar is quench tested, 10% are chemically analyzed by Saenz, despite of the chemical certificate our supplier provides. We have 6 forging blank dies that cover most of the racing engine rod dimensions. Our goal is to be close enough to the final dimensions in order to obtain the best fiber orientation from the forging process, but allowing enough stock to remove all the decarburized material that the forging process also generates on the surface. After being forged, they are heat treated to regenerate the molecular structure and to make the machining process easier. Rods are 100% CNC machined and rod weight is controlled during this process using fixed programs so that inspected parts may be compared with previous made parts and can also be used as a reference guide for newer designs. Polishing, shot peening and roto (REM) finishing are used to eliminate any machining marks as well as to compact the surface of the rods. New and definitive heat treatments give our rods their final hardness. This heat treatment process is done in controlled groupings with at least one sacrificial part for testing upon completion of the process. Rods are 100 % hardness tested and magnetic particle inspected after heat treatment. The sacrificial rod is then inspected for core heat treatment results and is checked microscopically for molecular structure. If everything is correct, we mark the sacrificial part and store them for five years, and production resumes. Then the rods are sliced, the guide locations are made and the cutting zone is ground to size. Parts are then fitted with temporary bolts to continue the process. We then grind the width to a dimension within.08" of the final thickness and the diameter of the big end bore within a dimension of.04" of final size; bearing tags are also machined. Most rods have their pin bushing location honed and the bronze bushing is installed at this part of the process. Bushing is then rolled; we have three types of bushing materials, depending on the particular rods final application. At this point, rods are balanced, polished, blasted and shot peened.
4 SAENZ WAY (continues) Then the rods are sliced, the guide locations are made and the cutting zone is ground to size. Parts are then fitted with temporary bolts to continue the process. We then grind the width to a dimension within.08" of the final thickness and the diameter of the big end bore within a dimension of.04" of final size; bearing tags are also machined. Most rods have their pin bushing location honed and the bronze bushing is installed at this part of the process. Bushing is then rolled; we have three types of bushing materials, depending on the particular rods final application. At this point, rods are balanced, polished, blasted and shot peened. Rods are balanced within +/- 1gram in orders up to 80 pieces, within +/- 1% for larger or different orders. Controlling the programming during the machining, gives us better control of the weight during the manufacturing process. After shot peening, the threads are resized and inspected and the temporary bolts are replaced with the shipping bolts. The bolts are then measured for stretch. Final dimensional sizing of the big and the pin end width is then done. Standard tolerances are +/ " but can be done to +/ " for an extra charge when requested. The big end bore is then honed to final size using a two-step process to avoid excessive heat buildup in the parts. Big end size has a standard tolerance of +/ ". We are working with some customers at between +/ maximum by special request. The small end is then bored to 0,0004" smaller than the final size. We have a standard tolerance of +/ in length with respect to the nominal size for different orders of same type. However we guarantee center to center between 0.001" in the same order. Parallelism and perpendicularity tolerances are within 0,001" in 4" of length. Final size of pin end bore is then honed to a standard tolerance of +/ ". After visual inspection, rods are inspected with our Brown & Sharp coordinate measuring machine. Measuring information is available upon request. Rods are given a flash of protective oil and are packed with a card containing dimensional and weight information.
5 SAENZ PART NUMBER Each and every rod order that leaves our facility has a unique part number to help us identify many of the aspects of that order, allowing us to trace the material and forging information, the manufacturing date and the CNC programming that was used to machine the rod. It also allows us to trace the quality control information (dimension and weight) as well as the exact heat treatment information performed. In this way, we can always refer back, and produce the same rod with the same requirements if requested EXTERNAL SURFACE TREATMENTS All of Saenz rods are polished and shot-peened before final dimensional finishing of the overall thickness and bore sizing. Polishing relieves stresses incurred on the material from the machining process and shot-peening creates an external hardened layer that enhances the rods overall performance. These processes also increase the rods useful life and can be used as an indicator of excessive stresses on the rods after being used. Unusual discoloration or marks on the external surfaces are indicators that something is amiss. Excessive temperatures, over tightened bolts, under/over clearance bushings can cause these indications, so a good visual inspection will help correct these problems before they cause disastrous effects. If for any reason the supplied rods are modified in any way Saenz suggests that the rods be polished and shot-peened before being reused BIG END BORE Unless otherwise specified, Saenz uses the manufacturers recommended sizes for the big end bores. The only difference is we use half of the tolerance allowed by the manufacturer for our production inspection. If the factory calls for a.008" total tolerance we manufacture to.004 total tolerance.
6 ASSEMBLING Saenz rods are packed with a protective coating of oil and molybdenum grease in the threaded holes. Before being used, they should be cleaned, especially on the mating surfaces. Relubricate the threads and the seating face of the bolts with high quality molybdenum based grease. Some bolt material can suffer from hydrogen embrittlement, so it is always a good idea to cover the exposed surfaces with an oil coating to protect them from humid air. Saenz recommends the stretch measurement for bolt torques to ensure the rods work properly. Sometimes torque wrenches are not calibrated on a regular basis and can give false readings. It is advisable to calibrate your torque wrench to avoid improper or insufficient clamping forces. The stretch value is determined by the bolt manufacturer and gives exact preload to avoid rod and rod cap separation at engine loads. If the preload is insufficient, it can cause failure of the bolt from fatigue as the bolt stretches and relaxes as a paper clip that is bent back and forth many times. If the preload is excessive, it can exceed the yield strength of the material causing failure. Friction caused by surface finish and by the lubrication used causes a difference in torque values. Newer rods will have slightly higher friction than used rods due to the fact that bolts seat among themselves. The stretch method can eliminate errors occurring from these factors and ensure proper installation. Measure the rod bolts and note the lengths for each bolt and each rod using a vernier caliper or a micrometer of sufficient length, as you will need to measure in the thousandths of an inch. Dip the bolt in engine oil and lubricate the threads with molybdenum grease as stated above and assemble the rods one at a time. Then torque the bolts to half the amount stated on the card included with the rods. Gradually increase the torque wrench setting until the bolts measure the "stretched" value from the original measurement. When the stretched size is reached, no further torque on bolts is necessary. Take note of the end torque reading for your reference. Bear in mind that bolts, when loosened, do not return to their original size and should be discarded. Specifications for bolt torque from the OEM rod manufacturer should not be used for standard rods, as they may not reflect the ARP bolt type supplied by Saenz. Always use the given value on the data sheet supplied with all of our connecting rods.
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