Broken crankshaft? No problem Sir. It'll be ready after lunch...

[Rkweld]

I think on a scale, if you think allan millyard is good when he turns out similar quality, in his environment with the tech and info he could have at his disposal, then these guys are amazing.

 

[minimutly]

A little info from some modern equipment. cranks are not matched like they used to be, I can only assume it is because of the time saved helps profits. For example, strip an isuzu and the engine components are colour coded shells, liners and pistons and the components are stamped with a relative code. They fit a different size shell or liner rather than re machining.

Engines are balanced electronically to the lowest preforming cylinder.

I am not saying its the best way but it works.

"Fitting" components is nothing new - Rover were doing it in the 80's with the k series, the Japanese with bike engines also. Not so sure about "electronically ballancing cylinders", maybe diesel common rail stuff?

 

[Stueeee]

Exactly what happens - it cracks and those cracks wreck the oil film - borrowed image of a Lancia crank from some random Italian stallion forum from some time, some where.

Lancia OE English language workshop manual for my 1991 integrale mentions the steel crank is nitrided.

View attachment 328204

That looks pretty terminal. How many times has the crank been ground? the guys who've done my cranks have always said that they're good for one regrind. The usual manufacturing process is that the cranks are ground slightly oversize before nitriding, then they're ground to size afterwards. This cleans up the bearing surface, covers any slight distortion, and also hits the point of maximum hardness which is (IIRC) 8 thou' below the surface. Total depth of hardness on nitrided EN40B steel is about 25 thou'

 

[Rkweld]

"Fitting" components is nothing new - Rover were doing it in the 80's with the k series, the Japanese with bike engines also. Not so sure about "electronically ballancing cylinders", maybe diesel common rail stuff?

Yeah thats right, common rail diesels i have experience of it with. It does not surprise me that it has been happening since the 80s, time is valuable in mass production. Ill have to have a read up on k series etc!

 

[prepman]

I've seen some amazing footage from the Indian sub-continent, but this takes the biscuit. I love the slag hammer and the protective shield for his right hand safety sandal

Bit of STP in the oil...no problem.

 

[Robotstar5]

"Fitting" components is nothing new - Rover were doing it in the 80's with the k series, the Japanese with bike engines also. Not so sure about "electronically ballancing cylinders", maybe diesel common rail stuff?

I remember that when I worked on the K series production line, the blocks, liners and pistons had letter stamps to get the best match.

 

[8ob]

I remember that when I worked on the K series production line, the blocks, liners and pistons had letter stamps to get the best match.

I would like to think that with modern production machining they can bore a block and grind a crank these days without the need for graded pistons. I remember the days of four pistons sizes for a standard bore with about half a thou difference between them and Ford V6 blocks with a plate on the side to indicate bearing housing diameters, they would cockup a few thousand blocks and get bearings made to fit the bigger OD. Nightmare come rebuild time but they dont really care about that

Bob

 

[ajlelectronics]

As the old question ‘what is accurate’?

A man who helps the vicar.

 

[pressbrake1]

A man who helps the vicar.

That’s shocking!

 

[brightspark]

Well you call it what you want, we know he used a short piece of emery cloth in it...

its still a form of lap

 

[pressbrake1]

"Fitting" components is nothing new - Rover were doing it in the 80's with the k series, the Japanese with bike engines also. Not so sure about "electronically ballancing cylinders", maybe diesel common rail stuff?

Been going since the beginning.
Any proper fits have to be selected

 

[awemawson]

The rollers in the Gamet headstock bearings were graded and selected for final fit. There is a Colchester Lathes promotional film showing a girl doing it, and throwing the graded rollers into totes by size. And that was probably early 1950's.

 

[Rkweld]

It makes sense if it is financially more viable. By chance it was the relatively late isuzu engines which seemed to have this where i experienced it first. The many perkins, cummins, cat, mitsubishi etc. were not. I suppose its just at what point or for which projects each manufacturer decides to do so.

 

[minimutly]

It makes sense if it is financially more viable. By chance it was the relatively late isuzu engines which seemed to have this where i experienced it first. The many perkins, cummins, cat, mitsubishi etc. were not. I suppose its just at what point or for which projects each manufacturer decides to do so.

This is when engines changed from 50,000 miles wrn out, to 100k, still like new. Sure, oil development and fuel injection played a part too.

 

[Blobber]

This is when engines changed from 50,000 miles wrn out, to 100k, still like new. Sure, oil development and fuel injection played a part too.

Isnt it whats basically blueprinting, like we used to do with the 70s engines to make them a bit more pokey?

 

[highseas]

I like how in all thease eastern videos everything is done on the floor and theirs always some random old guy in the background sitting on the only chair doing nothing

 

[highseas]

I like how in all thease eastern videos everything is done on the floor and theirs always some random old guy in the background sitting on the only chair doing nothing

Having watched it all....he is going to end up like that Russian bloke! Just a red rag wrapped round his lathe and a strawberry jam on the wall

 

[redlig]

seen the trailer planed to watch....
have u seen the one where they weld up a heavy truck front axle.....it had a broken king pin eye....
I hate to be driving that truck fully loaded when it breaks again.....

Life is cheap.

 

[redlig]

I like how in all thease eastern videos everything is done on the floor and theirs always some random old guy in the background sitting on the only chair doing nothing

As for the guy in the background doing nothing in UK they are known as Managers. usually with a degree or two in man management.

 

[redlig]

A little info from some modern equipment. cranks are not matched like they used to be, I can only assume it is because of the time saved helps profits. For example, strip an isuzu and the engine components are colour coded shells, liners and pistons and the components are stamped with a relative code. They fit a different size shell or liner rather than re machining.

Engines are balanced electronically to the lowest preforming cylinder.

I am not saying its the best way but it works.

When I first started with a Japanese manufacturer I was really impressed to find the different colour coded shells for the crank. Having been used to the British M/Cycle industry . One of my colleagues was racing a cb750 engined sidecar outfit which he revved to the limit plus. I asked him about the coding system. He replied " don't bother just use the brown ones it saves P*****g about with Plastigauge" . He never had any crank problems just piston failures.