How to Repair & Fix Cracked Cylinder Head || Rebuilding 4 Cylinder Leak Head of Cummins Generator #crackedcylinderhead #howtorepaircrackedcylinderhead #leakedcylinderheadrepair
WOW!!! I'm sure most viewers won't appreciate the trickiness of this task. 25yrs I had a friend whose head cracked on his XS500 motorcycle. We looked around for a replacement but due to the relative rarity of the machine one could not be found for love or money. At the time I worked in a well equipped fabrication shop so I was asked if anything could be done. There was also a well equipped machine shop right next door. I had a look and said "No way". Due to the brittleness of castings, the heat stresses involved,.the concominant distortion and the precision required the job was seen as almost impossible and even if successful it would be likely to crack again soon after. I asked several of my coworkers and they agreed with my opinion. But as there was NO other option we tried it anyway. One of our most experienced welders tried it and the head just cracked somewhere else as soon almost as soon as the torch was applied even though we had carefully preheated the head. So, even in our first world hi-tech fully equipped workshops this job could not be done. Yet here they are actually achieving it on the backstreets of Pakistan, and with primitive equipment. I believe the trick was to do the welding while keeping the head in the 'oven'. Ingenious, I really take my hat off to these guys.
I haven't seen anyone using cast iron fusion welding in the last 50 years other than myself and then I only used it twice. It's nice to know that someone somewhere is still using it. In todays market it had been largely displaced for faster are welding methods. Dumb thing is it was still better than anything out there today.
This is people using what they have to try to make shit last . But that crank shaft Video was the equivalent of using blue devil head gasket sealer . In the states we would have scrapped that crank shaft . In a second
Большой привет! Много месяцев подряд смотрю ваши видео! Это по сути пособие для ремонта, да и просто информация о том что для человека, думающего, преград почти нет! Реально преклоняюсь перед теми людьми что на видео, хотя сам всю жизнь связан с техникой и именно ремонтами авто, в том числе и при ситуациях когда мало денег в кармане либо у клиента либо у себя любимого, но всё равно поражён. Не унывать и не скулить, прям реально готов пожать руки мастерам! Продолжайте снимать ваши видео, очень они правильные! Корень.
Très bon travail sur cette piece (culasse) qui chez les gens comme nous soit disants civilisés et adeptes du recyclage serait envoyé à la ferraille mais chez eux, non, elle va reservir et vu le travail, longtemps. BRAVO
@james 26 Over here we call it working from home! I worked briefly in China and there I have seen a complete family live over the top of the office in the corner of an engineering lock up barely bigger than a double bed. Baby bathed in washing up bowl. Until you see how Asia live you can have no idea. Many of the tools in use were probably factory throw outs from GB. I have helped dispose of a factory and could not believe what Asian dealers were buying but it all has a market over there and the barely teenage boys assisting will have similar skills in a few years time. A very old fashioned apprenticeship.
Beautiful job It Is very interesting, In Italy they make this work only for ancient engines because It costs very much.For modern engines they Say: you have to purchase a new engine head. Greeting from Rome 🤝👍
@Omero Nardoni Your cost not working in asia coz we have different gaps labour price etc...thats why europe cars too expensive for us.. comparing product asia cars vs america cars.. everything cheap here equal with local labour and food/day
You Italians seem to have incorporated a similar manufacturing process into the queen of roadside assistance trucks that is ALFA ROMEO!!! It's a good thing that your other car companies didn't follow this direction, because today you would be a country of the 3rd world
As a chartered engineer I am truly in awe of the skills being exhibited here. Health and safety regulations not even considered and the cleanliness of the workplace could be better 😂but by god this fella is talented.👏👏👏🇬🇧
Yes, a lot of talent in making a boat anchor! There's water jackets throughout that head, some inside that you can't see & could be cracked. It's always best in cases of cracked heads like that to replace them.
@Bohappenstance Click a water jacket in the head is for coolant to flow through the block, through the heads, to cool both. If a crack in the head gets by a water jacket, it could crack through the water jacket. I understand about parts availability in some places, but some things can't be fixed back to be used
@@timothygeiger8271 Your comments are typical of todays fitters, not real mechanics and unable to do the job these guys are doing daily, just fit a new part without consideration of cost to the customer. Believe it or not, it was done like this when I was a lad when we had mechanics working in the garage.
@@jimlepeu577 guess what you ignorant jackass. If you bothered to read my actual comments, you would see where i said the technology they are using was first invented 75 to 100 years ago in the developed countries. Of course you can't understand what i actually say. By the way, when i first started doing repairs 35 years ago, we actually fixed what we could, but we took pride in our work & didn't believe in someone bringing something back. Some things are just better to be replaced, it's been like that for several decades.
Good skills, don't know how long the repair will last, but nice to see people able to do it with limited means and without genuine parts! Congratulations, in our (too much) "rich" countries we throw away and replace things instead of trying to fix them, and I think we are definitely wrong.
Beautiful amazing outstanding well done. It's a machine shop and all things are possible. If you don't have the parts, but tools and knowledge nothing is impossible. You learn to make them yourself. Thanks for the outstanding video. From a master mechanic and Machinest from Germany.
Bardzo dobrze wykonana robota. Podziw dla wiedzy i umiejętności. Ktoś wymyślił tą technologię i realizuje w takich warunkach jak widać. Czy działa? Jestem przekonany w 100%, że tak. Nikt by nie poświęcili takiego nakładu sił na darmo. Wnioskuje, że głowica żeliwna więc podziw dla sposobu spawania na gorąco (na grillu ,)),nawęglania płomieniem z niedoborem tlenu, sposobu ustalenia pasowania na cieśni cyrklem i mikrometrem. Wielki szacun. Brawo
@@avotihook Ta linia technologiczną nie miałaby racji istnienia gdyby było tak jak piszesz. Druga istotną sprawą: jeśli prze grzejesz niereperowaną głowicę to też ją niechybnie uszkodzisz :/
I got a demonstration video with my Henrob welder showing a cast iron piston ring being used as a filler rod using no flux. Finish up with a machinable weld. Arc welding can work on some cast iron parts too using high amperage and manganese electrode. Have also used chromium electrode for repairing valve seat. What they used here I do not know but it turned out great !! Well done !!! Skilled hands are a blessing !!
Самое забавное, это потом работает. Не важно что дерьмого. Но работает) значит ремонт был удачный)) главное правильно отжечь головку... и микрометром ловить миллиметры)))
@@user-ib4wh2yq8d В советской мтс была приличная зарплата и рабочий день восемь часов, а эти трудяги чем больше наклепают, тем больше получат. Ихним станкам по восемьдесят лет, что остались от американцев. Печально, конечно. Трудолюбивые люди, с детства приучаются к ремеслу а не протирают в школе штаны двенадцать лет плюс пять в институте, а потом их надо ещё и переучивать на производстве.
У меня вопрос КАК ОНО РАБОТАЕТ???? То что наварил это хрен с ним. Но гнездо пихать кувалдой и на эбокситку это же жопа. Оно же ставится с нагревом головки и охлаждением в жидком азоте гнезда, да забивается молотком при этом. + расточка с биением +/- см. Типа газы не пустило, а всё остальное пофигу. Как его не прибили ещё? Эту лажу ещё кому-то впиндюрить без последствий нужно😱😱😱
Excellent engineering skills. A perfect repair. Just shows you don't need a fully kitted out shop to do this work. Very good acid dipped finish. Love how the workshop is by the roadside like this.. ❤️
@@monera9675 Not at all. These guys are doing just as good a job as any other workshop anywhere in the world. A mechanic takes parts off a vehicle and replaces it with new. An engineering shop pulls an engine apart, machines various components with grinders/ lathes ect and reassembles. To say a shop that does this kind of work (all over the world) are not engineering works is ridiculous. The only difference is a lack of Snap On power tools, no pristine metal benches and no immaculate flooring. They may work on a dirt floor, wear sandals and have very little else but theyre still engineers whether you like it or not...
@@Draxindustries1 Machine shop is what you call this kind of skills Enggineering is the guy who design the item you you fix. Created the blueprint for the engine ports, the size of the chambers.
And the bill was $19.99! How much for a new head? Easy to be critical, but you have to hand it to these guys; amazingly skilled work with very ordinary resources. Well done.
@@farmerpete5936 I would guess the repair will last longer than we would think otherwise the business wouldn't be in business for very long. This is the way most repairs were handled in the USA until it became easier to purchase a new part instead of attempting to perform a repair. I remember the garage where I grew up in the 50's would patch tire tubes and tire side walls with good results but somewhere along the way that fell out of style in favor of toss it & replace it.
Ummm, boys have skills only problem I see is ridiculous amount of work for 1 head. What's labor? 2 thousand? It should be for as much effort there was. I think buying new or head that wasn't cracked would be better. Good job though
i agree amazing work..it easy to say throw it away and get a new head...but thats how we ended up with this throw away society we have today...im sure these guys could turn shit into gold
Siete bravissimi con i pochi strumenti che avete a disposizione fate cose incredibili, bravi meritereste di avere attrezzature migliori in futuro, buona fortuna per il vostro avvenire .
Mis felicitaciones y además admiración pues están demostrado que nada es imposible sigan adelante ayudando con los de escasos recursos pues un repuesto nuevo vale mucho dinero
That alignment stub that goes into the valve guides to enable the valve seats to be concentric is a little bent and the cylinder head should not rock as it does when doing that operatio0n now and later on when cutting the valve seatings. I do not like how he pushes on the head at 16:21, and I shivered at some other actions he took during other operations, but then perhaps I am too fussy and a cylinder head need not be coaxed and treated with gloves as I thought it should. The welder was brilliant in every way and that man knows the phase diagram of that metal he was handling. He is not only intelligent and feels his way through, but he is also a very brave man to handle that little bit of welding procedure!!!!! It is such a pity that our education system does not give enough credit to these people who have the ability to " process" an issue rather than remember information. Most people these days are the proud owners of what they buy and operate and not what they can process and diagnose an entity that needs to be repaired and guaranteed. Such craftsmen do not need any examiner to judge their caliber as the result is in the guaranteed working of the item they produce. Many schools run curriculums where the school thinks that its own examiners will decide the caliber of its students, but real life is not like that........................... our real value is what we can produce and guarantee to work without nature nor luck ever giving us a hand!!
we were taught cast iron welding at trade school , but you had to peen the weld after welding.the run out on some of the machines amazed me.i can see pre comps and valve seats falling out.and i forgot the after cooling in a bag of lime.
They call that runout... it appears to be a requirement with their machine tools. t least here there's a guide to keep the tool sorta centered. But the guide is extremely bent, so... smh
I have to “like” b4 watching these videos, as I’ve not been disappointed to date for the creativity and persistence to get the job done. Just wished the work grounds were a tad neater.
Marshallah! Incredible Job from the so called third world. Nothing is impossible when we have limited materialistic resources and mindful youth. And if I can add something I would say it's great for the environment to refurbish a car to the limits. Marshallah 🤩🤩🤩
@@seadog158 well I praise the western technological achievements without shame and with all honesty but I'm not stupid enough to think narrowly as we are in a western era and so it's too easy to only see this side. Trying to see the broader picture during human known history and you'll understand Europe us very small compared to that. Plus I have to add that most of the technical achievements attributed to Europe as actually not. Please have a look at the Baghdad battery, Ibn firnas flying machine, antikitera mechanism, mesure of time, ... So I have to strongly and respectfully disagree with you sir
If you have this cracked cylinder head to be fixed at local America dealership, They will replace entire new Engine for your pocket $7000.00. I assumed this Cave shop will do for you only $30 bucks to fix filling cracks. Thats a great to have those to do for us.
@@dennisyoung4631 is it because if we weld it at temperature room, the cast iron will not merged to the welding? Any quick explanation perhaps? Much apreciated
@@rrezaputrap2862 cast iron tends to be brittle. If it cools abruptly, it will crack or break. Same for any sudden changes in temperature. Hence, one wishes to heat pieces of it well - say, 8-900 degrees F, or 500 or so C - and keep it at that temperature while being welded or brazed - and then cool slowly, so that the stresses will *hopefully* equalize in the part as a whole. The ductility of “brass” is why brazing is often favored. Cast iron welding, however, has its advantages, which is why some still attempt to do it.
In todays high tech western society these guys wouldn't even qualify to start a course. But in the real world I'd back these guys all day long. In the west we've lost the ability to ask What If?. Everything nowadays has a procedure to follow,
I have never heard of gas welding cast iron. I would be very interested in the filler metal and gases and pressures. Excellent work especially in the crude shop judged by western standards.
I've heard of using pure nickel, nickel-iron alloy rod and cast iron rod. I'm guessing they're probably using cast iron as that would be the cheapest option. It is crazy to see them barbequing the head like that but it probably does a great job of heating it evenly and allowing it time to cool evenly and slowly.
Peterson #2 High heat flux, green. Filler is used piston rings. I have welded steel to cast iron with good results. But my results were not machinable-- could only be ground.
This is how cast iron welding was done in the old days,-Grind or chip out the crack, preheat the job in a charcoal furnace.Using a cast iron welding rod with flux (usually borax), fuse the rod into the hogged out crack, it's absolutely crucial that you let the job cool down SLOWLY- 6 hours at least,If you don't, unequal contraction will cause the metal to crack again, I've repaired many cast iron jobs and I still have a couple of rods in my garage. Nowadays, people use electric welding, using nickel rods, and peening the repair as it cools, to prevent cracking, but cast iron welding is still very risky,due to the of cast iron. It also is porous to a degree, and oil in the matrix will prevent a successful weld being performed. , ;
Mechanics with advanced precision tools are salivating on the engenuity of these crftsmen who are drooling on your state of the art machining ang mechanical equitments and tools.
Esa culata hay que ponerla nueva,,,esa estalladura seguirá por mucho que le hagan ,,,,,y se lo digo por experiencia de arreglar antiguamente culatas y no duraban mucho....ese daño es profundo
Coming from a mechanic this is what’s wrong with most of the rest of the world people have forgotten how to do things the hard way by hand. Now they just log on and get what they want. That head will probably seal better than any new head you can buy offline. Keep the forgotten arts alive guys.
watching these blokes do fine work in primitive conditions reminds me of the quote "do you need a $5000 barbecue to cook a steak when it tastes the same on a wood fire"
