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Hobbing
We can cut most involute splines as found on axle shafts and a few straight cut gears. Some shafts can be shortened and resplined or made from scratch.
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Hobbing Axle Shaft |
Horizontal Boring Machine
The table has 40” cross travel “x”. Moves in and out 48” “y axis” and the spindle head moves 28” above the table “z”. The table itself rotates 360° degrees. With this machine we can do large items and many can be done from all four sides.
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Horizontal Boring Mill-
Steam Locomotive Axle Bearing |
Horizontal Boring Mill-Hyd Cylinder |
Boring Mill - Repairing Large
Diesel
Engine
Timing Cover |
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Lathe -
Capacity up to 22” swing and 90” length |
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Thermal Cleaning
Blocks cleaned by this method run 3° cooler than when cleaned by hot tonking (the entire inside of water jacket is clean), all bolt holes and the ends are clean, the entire block is bright silvery clean and takes paint very well.The process is a convection oven that heats air and blows it past the block (no flame on the block) and straight out the chimney (the block is in hot fresh clean air). The oil, rust and paint turns to powder, at which time the block and heads are put into an airless blast cabinet.
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Thermal Cleaning - Before |
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Thermal Cleaning - After |
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Boring
Block is fixtured in the machine through the mainline at the precise angle to put the bore perfectly vertical to the crankshaft. When portable boring bars, and some other machine tools, use the deck at the block for a reference surface the errors of deck angles and parallelism to the main line create out of alignment boxes.
Honing
We use a “precision rigid honing head” with diamond stones for very accurate bores and proper finishes.
Guide & Seat
The head is fixtured at the proper angle in a sturdy ridged machine so that an accurate guide to value seat concentricity is maintained. After cutting the seats are hand ground and indicated to assure a high standard of accuracy of concentricity, seat width and location of seat on value face. We do not use knurling or thin valve guide liners, softer valve seats that (supposedly harden from combustion heat). We use manganese bronze or cast iron heavy wall guides. Seats are hard alloy manganese steel to assure long life with hard use. |
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Machining the seats at exactly the proper angle |
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Rod Hone
A full size floor type machine that holds the rod in a fixture, square to the hone, and power stroked to the proper size. The bore gages used for measurement are set with high precision gage blocks traceable to the National Institute of Standards. Rod caps are properly torqued, the big end is honed to size and checked for diameter and quality to within .0002 (i.e. ± .0001) at room temperature.
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Automotive Rod being resized |
Balancing
A. Imbalance is a linear function – 1 oz at 3,000 RPM produces about 100 lbs of force. At 6,000 RPM you have 200 lbs of force pounding out your bearings and robbing horse power.
(ZERO balance – a meaningless term in that inaccurate balancer taken down to zero is not as accurate as a better balance taken down to zero balance.)
The balance uses plastic “V” blocks for the crank to spin on, there are no roller bearings or other loose parts used that induce errors into the process, spun at 500 rpm the inertia in the crank is low enough that there is no bouncing. The computer then multiplies out the imbalance (a linear function) for the correct rpm, resulting in very accurate results.
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Surfacing
Machined gasket surfaces of yesterday are not acceptable on today’s engines. All heads are checked for straightness, along the cam line, and heat straightened if applicable, then surfaced using a ½” diameter. Round “CBN” high surface speed cutter to achieve the proper Ra Surface finish to make modern gaskets seal.
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Surfacing
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Welding
Aluminum MIG and TIG welding
Cast iron stick nickel – spray nickel brazing
Iron Welding MIG – TIG & STICK
We are a complete machine shop and can repair many obsolete or badly damaged parts and remachine back to Size 7 for auto, agriculture or industrial needs. |
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Weld |
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TIG Welding - Modifying marine manifold
to install sensor for fuel injection system
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EDM TAP Disintegrator
We can burn a hole through anything that is electrically conductive; i.e., broken taps, drills, and studs.
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EDM Tap Disintegrator |
Line Hone
1. To true the mains end to end
2. To have a perfectly clean bore so that the bearing shell can dissipate its heat into the block
3. Bore size is kept to a minimum tolerance to hold the bearing shell tightly to resist spinning and keep the bearing shell ends from collapsing when the crank contacts the bottom of bearing.
4. Crank shaft clearances are determined by calculating the oil spill rates to obtain a minimum while maintaining proper lubrication and oil temperature. Close tolerance provides greater bearing load area. (Proper oil viscosity and temperature enhance oil film strength).
5. Exaggerated sample:
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Same Load |
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Low Clearance -
wide arc of content pressure |
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High Clearance
Narrow arc of contact
High film pressure |
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