Koenig Expander® Sealing Solutions Drive Innovation in Motorsports

By Bernard Martin

Motorsports and high-performance engineering is on the verge of a transformative innovation. Boneham Metal Products Inc., a leader in precision-engineered solutions, is excited to bring the Koenig Expander® plug to North American customers. This advanced sealing solution has already revolutionized the design and maintenance of fluid systems in motorsports and automotive industries worldwide, and it’s now available to support engineers and manufacturers in North America.

The Koenig Expander® plug offers an unparalleled solution for sealing and restricting the flow of drilled holes in fluid systems. Unlike traditional methods such as counterboring and tapping, which require additional steps and increase the risk of failure points, the Koenig Expander simplifies operations while delivering superior reliability and durability.

For motorsports applications, this cutting-edge technology offers distinct advantages:

• Improved Reliability: The Koenig Expander is ideal for critical fluid systems, such as engines and braking systems, where failure is not an option.
• Exceptional Durability: Designed to withstand the high-pressure and high-temperature environments of motorsports.
• Enhanced Efficiency: Reduces machining complexity, eliminating the need for extra operations and lowering costs without compromising performance.

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Pull-Type Expanders: High-Performance Sealing for Critical Applications

Pull-Type Expanders are engineered to excel in high-pressure environments where sealing integrity and strength are paramount. These expanders rely on a pull-style installation mechanism, which uses a controlled force to expand the sealing element uniformly, ensuring a secure and robust fit. This method eliminates potential leak paths and guarantees long-term reliability, even under extreme operating conditions.

Pull-Type Expanders are used in a variety of applications including:

• Engine Blocks - These expanders are perfect for sealing coolant and oil passageways in high-performance engine blocks. They prevent fluid leakage under extreme temperatures and pressures, maintaining engine efficiency and reliability during high-speed operations.
• Hydraulic Systems - Hydraulic systems  rely on precise pressure management, making pull-type expanders a critical component in preventing fluid loss.  Ideal for motorsports vehicles, where hydraulic systems often control braking, steering, and suspension systems
• High-Stress Motorsports Components - Pull-type expanders are frequently used in turbochargers, transmission cases, and differential housings. Their ability to withstand vibration, thermal cycling, and high-pressure pulsations makes them indispensable in race-ready vehicles.
  

Advantages of Pull-Type Expanders
Pull-Type Expanders provide numerous benefits that make them the preferred choice for engineers working on high-performance systems:

• Exceptional Sealing Strength - The pull-style installation ensures a uniform expansion, creating a tight seal that can withstand pressures exceeding 6,000 psi (or higher in custom applications). This robust seal eliminates the risk of micro-leaks that could compromise system integrity over time.
• Reliability in Extreme Conditions - Designed to perform in harsh environments, including exposure to high temperatures, aggressive fluids, and constant vibration. Their proven reliability reduces the need for maintenance or replacement, critical in motorsports where downtime is costly.
• Reduced Machining Requirements - Unlike traditional threaded plugs that require counterboring or tapping, pull-type expanders can be installed directly into precision-drilled holes.  This simplifies the machining process, saving time and reducing the risk of manufacturing errors.
• Consistent Performance - The pull-style mechanism ensures consistent sealing performance across a wide range of applications, making it a versatile solution for engineers.
• Compact Design - Pull-type expanders are lightweight and compact, an important factor in motorsports where weight reduction is a critical performance consideration.

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Push-Type Expanders: A Versatile and Cost-Effective Sealing Solution

Push-Type Expanders provide an efficient and reliable method for sealing drilled holes in fluid systems. Designed for moderate pressure and temperature environments, these expanders offer a quick and cost-effective alternative to traditional sealing methods such as threaded plugs or welded seals. Their straightforward installation process makes them a popular choice for various automotive and motorsports applications, where precision and durability are required without the complexity of more involved sealing techniques.

Push-type expanders are ideal for a wide range of fluid control and sealing applications in motorsports and automotive engineering, particularly in systems where pressure and fluid integrity must be maintained consistently

• Braking Systems - Used to seal hydraulic brake lines and components, ensuring no loss of pressure within the braking circuit. Helps maintain consistent braking performance by preventing leaks in drilled passages and hydraulic blocks. Commonly found in master cylinders, calipers, and ABS control units where fluid integrity is critical.
• Fuel Delivery Systems - Effectively seals ports and passages in fuel rails, injection systems, and high-performance fuel delivery components. Prevents leaks and ensures efficient fuel management, optimizing combustion and engine performance. Resistant to fuel corrosion and pressure fluctuations, making them a durable choice in both gasoline and ethanol-based fuel systems.
• Cooling Systems - Used in engine coolant passageways, radiators, and heat exchangers to seal excess or unused drilling points. Helps maintain coolant pressure and prevents leaks that could lead to overheating or inefficient thermal management. Compatible with both liquid- and oil-based cooling systems, ensuring long-term durability even under high operating temperatures.
• Transmission System - Seals fluid passages in automatic and manual transmissions, preventing leakage and maintaining hydraulic pressure for smooth gear shifts.  Ensures consistent lubrication flow, reducing wear on gears, clutches, and bearings.  Resists temperature fluctuations and mechanical stress, making it ideal for high-performance racing transmissions where reliability is paramount.
• Fluid Reservoirs - Used in oil, fuel, and coolant reservoirs to seal manufacturing access points and control flow dynamics.  Prevents contaminants from entering critical fluid storage systems, ensuring the purity and longevity of essential lubricants and coolants. Provides long-lasting durability, reducing maintenance needs and minimizing the risk of system failures due to leaks.
• Oil Circuits - Seals drilled holes within high-pressure oil galleries in engines, turbochargers, and hydraulic components. Prevents oil starvation in performance applications by maintaining precise pressure and flow rates. Ensures consistent lubrication in high-revving engines, reducing the likelihood of component failure due to friction or overheating.
  

Advantages of Push-Type Expanders
Push-type expanders offer several benefits that make them a preferred sealing solution for engineers and manufacturers looking for efficiency, cost-effectiveness, and reliability.

• Easy Installation - Push-type expanders do not require complex tools or specialized machinery for installation. They are simply inserted into the hole and pushed into place, making the process quick, repeatable, and highly efficient.
  
• Cost-Effective Solution - Compared to threaded or welded seals, push-type expanders reduce machining costs by eliminating the need for threading or additional finishing operations. Their straightforward design reduces production time, making them ideal for high-volume manufacturing environments.
• Reliable Sealing Performance -  Engineered to provide a tight and leak-proof seal under moderate pressure conditions. Resistant to common automotive fluids such as brake fluid, fuel, coolant, and lubricants, ensuring long-term durability.
• Lightweight and Space-Saving Design -  Their compact size and low-profile design make them ideal for applications where space is limited, such as compact brake calipers or fuel injection systems. Minimizes weight, which is especially important in high-performance and motorsports applications where every gram counts.
• Adaptability for Various Applications - Push-type expanders are available in different sizes and material options, allowing for customization based on specific application needs. They can be used in aluminum, steel, and composite materials, making them suitable for a wide range of engineering projects.
  

Why Choose Boneham Metal Products for the Koenig Expander®?
With over a century of experience in precision engineering, Boneham Metal Products is uniquely positioned to bring the Koenig Expander® to North America. Our expertise in motorsports and high-performance applications ensures that customers receive not only a superior product but also unmatched technical support and service.

​To learn more about Koenig Expanders get in contact with our team here  Browne & Co!