Bulkhead insert for an internal combustion engine

An engine main bearing structure comprising:

• a bulkhead insert for connecting a main bearing cap column to a head column and having first and second ends connected by a pair of straps, each strap having an I-beam cross-section, each end defining at least one protrusion having a surface normal to engine combustion and reactive loads, the first end shaped to support a crankshaft main bearing, the second end configured to receive head bolts.

A method of forming an engine comprising:

• providing a bulkhead insert in a tool, the bulkhead insert configured to connect a main bearing cap column to a cylinder head column, the bulkhead insert having first and second straps, each strap having a flanged beam cross section, the insert defining protrusions having surfaces substantially normal to engine combustion and reactive loads;
• and
• forming an engine block having a bulkhead containing the bulkhead insert in the tool.