Well guys we finally get the Cosworth engine stripped and as per usual we fine it’s all been done recently. But I’m afraid it’s the usual story. Also we start the Figaro engine machining and it’s a good job we refaced the blocks
Safety: I worked in a coach-building shop. None of the guys would use safety glasses, or welding gloves, because they thought that the safety gear "was for girlies', until one guy had a shard of hot aluminium from ACROSS the workshop, go into his eye. It took three of us to hold him down until the ambulance arrived. The next day the Workplace Safety Inspectors arrived and closed the workshop down for a week until the safety standards were brought up to date., including safety cages on the equipment, portable welding screens and safety training for everyone. The owners were prosecuted, and copped a huge fine,
Most ironic thing I ever saw: contractor was engaged to build guarding for some old machinery. Cutting & grinding without glasses, long hair not tied back, no gloves, no hearing protection, and no guard on his grinder.
Lee you’ll be spending time in the big house if Isaac has an injury due to your lack of discipline regarding PPE. Also agree with the comments about the clutch housings, if they’re not coaxial with the flywheel they’ll judder like buggery. I don’t know if it’s an effect of the video but the flywheel looked to be turning way too fast. If you’re using tungsten inserts and aiming for a maximum of 600 ft per min on a 18 inch flywheel (outer circumference circa 5ft) then you should be running around 120 rpm.
Great content and banter. But I'm always concerned about the eye protection being hit and miss! I had a piece removed from one of my eyes years ago at the hospital. Very painful and it went on for weeks. Stay safe guys!
Great stuff as always lads, love the video's keep it coming... but please Isaac wear your safety glasses young fella when working with machinery, as a paramedic I've seen too many eye injuries finish young lads off...
When i did my apprenticeship in the early seventies 1 year was spent in the machine shop. Working on the lathe a piece of hot swarf hit me in the corner of the eye socket and stuck to the skin.hurt like hell and left a lovely blister so wear your safety glasses or suffer the consequences.
100 percent, if I was drilling a hole in peice of metal in a vice I wear safety glasses after a near accident years ago . But look at the speed that material is rotating the shards could be flying anywhere
Wow Lee and Isaac .... Those Flywheels ..... ?????? ..... Now That is Super Bad Engineering .... I Wonder IF Perhaps it isn't best to 'Plug' the Original Holes ( Just Sothat Nobody can get confused ) and have them Redrilled/Tapped on the Correct PCD .... Let a GOOD Engineering Shop do them on a CNC Mill and Save the Program after ALSO building a Jig for Location on the Crank Boss Face/Diameter. This should Hopefully Greatly Reduce the Balancing Issues and have a 'Half Descent' end result without having to removes Massive amounts of weight. They SHOULD Have come in Correct in the 1st Place... Those Bad ones should Actually be Rejected and Returned to the Supplier .... Best to ALL from ChCh, NZ
Surely those flywheels need to be re-drilled then. Even if you balance them as they are to leave the clutch running off centre sounds like a no brainer to me.
Correct. The pressure plate will be moving eccentrically to the friction plate/gearbox input shaft if they're not corrected. I foresee snapped gearbox input shafts and damaged shaft and spigot bearings if that's not corrected before balancing the assembly.
@@TonyRule I'm surprised they are not addressing this or at least saying it needs to be done! Surprised as they seem pretty thorough in every other respect.
I worked with two separate guys who lost eyes, one had a screwdriver that slipped off the wing of a transit as he was under the van. One from a nail that was in a curtain as he pulled it down whilst clearing a property. Both of them were fanatical about safety after the event. Come on guys let’s get a toolbox talk in about safety. If you need help bring in a specialist to risk assess it all for you.
I have used both an angle grinder (with an adapter to use a 6"x1" stone) and a manufactured unit, both gave excellent results but the manufactured unit was quieter to run, 3600 rpm motor, belt driven to arbor. When flywheels put on surface table, less than 0.0001 deflection measured compared to approx 0.0004 using carbide or ceramic tooling with no hard spots. I would rough cut using a tool and finish with a grind, starting from center and working out.
There are times when safety glasses make it hard to see properly, usually about five minutes after they are new! As the Boss it is Lee's responsibility to make sure safety protocols are followed.
There are a ton of safety glasses on the market you don't have to buy cheap, some are tinted and look designer, you apparently take pride in your work, take pride in your health too.
We have had problems with hard spots and I made a grinding jig that mounts on the toolpost for facing the flywheels and rotors (jigged and held between centers). this gives a superior finish and perfectly flat but you have to use a hard grinding wheel and diamond trim periodically
Lots of comments on safety goggles and rightly so, accidents happen so quick, Isaac you are a young man dont risk your eye sight. On building sites theres policy no safety boot or hard hat then no job, Perhaps a new policy for Barum safety goggle worn at all times in workshop along with no lose clothing (hoodie cords etc) could be introduced, lee you are a great guy and care and look after Isaac consider looking after his and your own safety, can not even think what you would feel like if Isaac lost an eye?
This 👆 I work on loads of building sites and I question their OTT H&S like long sleeves and gloves, but safety glasses when your face is next to a spinning lathe??? No questions!
We used to call those hard spots on the flywheel clutch surface "diamonds" back in the day. We used to do a lot of truck diesel motors and they ALL had diamonds which cost us a shit ton of tool bits. So we made ourselfs an attachment that fitted onto the lathe tool-post bolt, had a cup grinding wheel and a 3/4 hp motor. Wound up not having to take nearly as much material off of the flywheel to get the face true again. Of course for this operation the chuck was spinning A LOT SLOWER. And the customers LOVED the fact that it was a ground finish. A number of fleet owners used to pull the flywheel when they were doing a new clutch (even though the surface was not too bad) and have us just lick it clean again to make sure that the surface was as good as it could be to lengthen the life of the clutch plate. Funny thing is that those fleets are still in business almost 50 years later. A good maintenance ethic can save you down time and expensive emergency repair bills which makes for a profitable and long lasting business.
Wouldn't it be a better solution to re-pitch the clutches on the Subaru/VW ? Balancing it out,sort of works until new clutch time then it's game over ...
Of course it would, that's the correct way to sort it out, or return them as faulty. But this is Barum engines. If I'm the customer watching this I'd be extremely annoyed
Lee, put in a safety gear "swear box". Spot anyone without the right gear on, they put £5 in the box. Everyone's in friendly competition to dob each other in. At year end, the boxed £ goes to the Xmas bash, or an appropriate disability(?) charity?
Doing a great job, I wonder how many of those off drilled flywheels have been fitted and come back? suggesting the long bolt on the cosy is a great idea, save trouble later, thanks for sharing, all the best to yous and your loved ones
I never comment but I felt I had to come on and ask Isaac where are your goggles and why is Lee the boss stood there saying nothing . seems to be plenty saying the same thing. Isaac you have been blessed with a pair of eyes, look after them mate.
Isaac you go to college so there's no excuse for not wearing safety glasses because they drum it into you! Health and safety doesn't seem high on the agenda at your company Lee.When someone loses an eye like my old man did or an arm from the elbow down like a lad I went to college with did at his firm you'll know about it then.
so if the holes in the flywheel are drilledoff center doesnt that mean the input shaft runs off-true then? seems like you would be tearing up transmission bearings.. the balance isnt the only thing to think about...
I am not a fan of the open deck blocks, especially on the major and minor thrust sides. The siameses cylinders helps stabilize some, but that produces a bit of a cooling issue.
They say the cylinder is never truly round and now it makes sense what Lake at Total Seal says about rings needing to flex to conform to the cylinders and their out-of-round dostortions
Very thoughtful of you to provide the Health and Safety Executive with all the evidence they need to prosecute for PPE infringement... and a quick Google will show they dont mess about ..bye bye Lambo, jet ski .. maybe house .. and that's after the distress of someone getting disabled for life...guys, WTF!!!
Come on guys , start using safety equipment.... it's there for a reason and i personally don't want to see anything going wrong .. pieces of metal flying off a lathe while standing watching 👀 it with no safety glasses 🥽, absolute madness .
the 205 doesn’t have extra pad feet ie more meat in the bottom of the block that’s why ford made the 200 block as the 205 was cracking from to much boost pressure
@@damianbutterworth2434 yes. The customer was complaining about clutch judder and they are trying to solve it by balancing. Balancing won't do anything to solve the clutch judder. Having a clutch that is running out of true could certainly cause clutch judder though. The problem is they don't know how to drill new holes in the flywheel, ask them to work out the X and Y pcd coordinates from clocking in the bore. No chance Lee could work that out, that's why they are going the bodge it route and hoping for the best.
Would of been nice to have a quick look at the little thing out the front and I don't mean the skip. lol . Anyone of H&S please do not watch this video.
