Connecting rod for an engine and method of making thereof

A method to modify the geometry of a connecting rod of an internal combustion engine, the method comprising:

• forming a connecting rod comprising:
• a connecting rod main body;
• and
• a bearing cap,
• wherein a first end of the connecting rod is formed by a bottom end portion of the connecting rod main body and the bearing cap,
• wherein the bottom end portion of the connecting rod main body and the bearing cap are configured to be mated at a mating surface to form a crankshaft bore therebetween,
• wherein the bottom end portion of the connecting rod main body comprises a pair of non-upset portions whose overall width is less than a diameter of a cylinder bore,
• wherein the bottom end portion of the connecting rod main body comprises a pair of first upset width extension portions whose overall width is a second width greater than the diameter of the cylinder bore,
• wherein the bearing cap comprises a second upset width extension portion whose overall width is greater than the diameter of the cylinder bore,
• pre-machining the bottom end portion of the connecting rod main body while clamping the first upset width extension portions;
• pre-machining the bearing cap while clamping the second upset width extension portions;
• temporarily fastening the connecting rod main body and the bearing cap together by bolts such that the first upset width extension portions and the second upset width extension portions are mated to each other at a mating surface;
• machining the first upset width extension portions and a first part of each of the second upset width extension portions while the bottom end portion and the bearing cap are temporarily fastened, such that the first upset width extension portion and the part of the second upset width extension portions at the mating surface have identical overall widths that are less than the diameter of the cylinder bore, and a second part of each of the second upset width extension portions on a side opposite to the mating surface is left un-machined;
• disassembling the bearing cap from the bottom end portion of the connecting rod main body;
• re-assembling the bearing cap to the bottom end portion of the connecting rod main body by bolts;
• and
• finish-processing the crankshaft bore while the bottom end portion of the connecting rod main body and the bearing cap are fastened together by clamping the second part of each of the second upset width extension portions together by bolts.