I've lived in the so called third world and they are geniuses in the get it done, make it work, and within the affordability of their customers. These hard working folks in dangerous workshops with no benefits and no safety equipment will rule the world. This is how China started and look at how they have come to be an industrial juggernaut. As a foundry owner and a machinist I have nothing but respect.
This is Pakistan which is the 5 largest maker of motorcycles in the world automobiles tractors and of course an atomic power and whatever comes with it missiles planes tanks etc; these are wayside workshops strewn across the country more so in Punjab. Hard working Pakistan makes cement plants sugar mills and a lot more. Thank you for your kind comments
There isn’t a chance this piston will act the same as the rest of the piston’s, gas engine, maybe, but diesel the bowl must be precise to the hundredth of a thousandth, the wrist pin centerline, to the deck of the piston are incredibly important, the injector must fire the fuel inside the bowl, if the piston drops below the spray pattern it will melt the piston.
@firstlast-ty4di Amico mio, tra gli " ingegneri delle tastiere" nei commenti potrebbero esserci ingenieri laureati,meccanici (come me) che hanno lavorato sui motori per >25 anni e che magari hanno montato decine o centinaia di pistoni nuovi,cioè gente che di motori ne capisce sicuramente più dei "tecnici" nel video,tecnici che ignorano unità di misura come il centesimo o il millesimo di millimetro,i loro "strumenti di misura" lo dimostrano...
@@fasullodavvero Yes, many comments are valid, but many others are very uninformed. These Pakistani workers are not attempting to make pistons for a Formula I racing engine. "Hundredth or thousandth of a millimeter" (.0004" or .00004") are not needed here. I'm guessing that the tolerances on the design drawings for the original piston are much looser than that. These workers showed some very intelligent improvising. Did you notice how the broken piston was wrapped with a thick material to make a pattern for the sand mold? That was to allow for the thermal shrinkage of the new casting. Making a new pattern would be very expensive. Chucking the piston on the lathe to bore the wrist-pin hole also impressed me. Keyboard warriors tend to diminish the skills of workers in developing nations only because of their lack of access to modern machines and instruments.
@@firstlast-ty4di Amico mio,sono cosciente del fatto che quei meccanici,fonditori,tornitori fanno quello che possono con quello che hanno,ma in casi simili è solo tempo sprecato,quanto alle tolleranze,non è questione di F1 o altro,anzi,è proprio il contrario,fare un pistone che duri molto è più difficile,specie se non disponi del know-how e i materiali per farlo,io ho studiato in una scuola professionale prima e fatto il meccanico per >25 anni poi e non ci provo nemmeno a produrre un pistone,al 99,99% sarebbe un fallimento,già solo riprodurre correttamente il profilo del pistone è impossibile se non hai le misure corrette (i pistoni *NON* hanno lo stesso diamentro in tutti i punti)e le differenze si misurano in determinati punti in centesimi di mm...
@@fasullodavvero The need for precision, itself, is a vast area of study. Approaches such as six-sigma examine how tolerances and variability of finished parts influence to performance of a completed system. There is a point where increased precision will not improve quality commensurate with cost. I don't know whether the piston produced in this video will be put into an engine or whether it is only a demonstration. I do think that the method shown can be useful in situations where supply-chain delays are prohibitive and a piece of equipment must be put back into service quickly. In the USA (or Italy) mechanics and engineers take great pride in being ably to order a new piston and take delivery the same or next day. The piston will be shiny and meet all manufacturer tolerances. Of course, we wouldn't go to a foundry and machine shop with drawings and ask to have one made. We have industrial resources not available in Pakistan. That does mean that we are superior mechanics or engineers. To me "keyboard engineers" have false pride in the good fortunes of their birth places. I would liken them to those who would ridicule someone in a wheelchair.
@@firstlast-ty4di Perfetto, vedo che *NON* hai capito quale sia il punto,cioè che il lavoro che vediamo in questo video è semplicemente inutile,la fortuna non c'entra,quando non ci sono ricambi, si butta tutto,quello che vediamo nel filmato è "accanimento terapeutico" , è come voler curare la peste con l'aspirina,non solo non guarisci,ma spendi denaro per curarti...
@@ntal5859 Diesel under forced air burns blue , not orange. It was either used engine oil or coal. Since you can see a coal pit and a beat up drum next to the forge , they probably use whatever's available that day.
Hmm.... great effort with little resources, but way too much wrong here--- casting a viable working piston isnt as simple as casting a church bell - theres very specific metallurgical design and physical properties that have to be met, expansion, contraction and friction co-efficients, pistons have a very specific skirt shape, weight must be in line with other pistons its used with, if its for a diesel it must be forged not cast or it will fail in a big way - I just cant see this yard casting holdiing up to the loads imposed by a diesel engine especially in an environment where oil is probably filtered through a cloth and re-used many times.
Drilled pin boss, no pin retaining clip, no brass shims on the lathe jaws, no balancing.....all in all, a sorry piece of work.... but they still got the engine back together, temporarily.
but they work , sides can be filed, and as its old pistons its lo expansion alloy heat them up to operating temp try in bore and see what areas need relieving
I have Machined and ground hundreds of pistons and have never ground an oval or tapered piston be they alloy, cast iron or composite, oval pistons are a result of ware or bad machining not design, piston technology is a science you will get stepped pistons around the ring area and side clearances in casting or forging reliefs around the wrist pin area, as well as scalloped skirts but never oval or tapered, think about what you claim is for thermal expansion, and take a look at the engine designers specs for cylinder material expansion and why they use a particular piston material and specify in some cases quite anal tolerances, oil grades, coolant, types, and most importantly fuel types , I have done pistons from 20mm up to 450mm from running speeds of 150 to 25000rpm, seizures occur as a result of friction created by failure of adherence to specifications or by some people thinking they know better than the engine designers or deliberately exceeded the limits of the engines for whatever reason usually resulting in a much shorter serviceable life. These Pakistanis' don't have a choice but they do an extraordinary job with what they have to work with, I worked on new million-dollar machines and know firsthand at what they are achieving with nothing more than junk machines in a 4-jaw chuck and primitive metal casting.
@@FladFlidington Sorry, but your assumption of them being round and not tapered is so very wrong. Pistons are tapered from bottom to top to allow for thermal expansion and growth. This design allows the piston to move freely in the cylinder bore, even when the piston head is heated. Pistons are cam-shaped instead of perfectly round to achieve a good fit with the cylinder walls at normal operating temperature. Some pistons are elliptical, which means they are oval-shaped with one half being a mirror image of the other. When cold, these pistons are elliptical, but become more circular as the engine heats up. This improves the seal and combustion efficiency.
@@FladFlidington WTF? Pistons are deliberately machined elliptical for a reason of thermal expansion. If everything you've ever machined is round, then good luck standing next to one of your abysmal efforts....no thanks.
@@stevo184 Hey How about you show me the MANUFACTURERS specs for piston machining, any mainstream engine manufacturer, even Ford or GM mass produced run of the mill tolerances, and you are talking tapers and ellipses, not undercuts two entirely different things.
It will last just as long as the one your local parts dealer imports, why do you think they can supply you with a piston for few bucks, because they are made in 3rd world countries.
We used to make pistons from semi finished ones and they had a taper smaller towards the crown a nd a cam grind as they expand more across the gudguon boss. The crown was round where the rings go. That will seize.
If they seized these guys wouldn’t be wasting their time making them daily would they? You lot are negative nannies about everything these guys do, if it’s not pointing out a thousand times about their footwear, safety or other, the you attack their product. Go watch some other channel then.
I think what they do is amazing with what they have at hand and am not rubbishing them that is why I enjoy watching them. What I am saying is what I know from making pistons and am intrigued as to how they will last. Ps you know more than I do after having been in the industry most of my working life?
It’s also easy enough to make them oval in a 4 Jaw chuck and harden them as well the only other issue I can see is that the original would ofhad strengthening steel plates cast in and sometimes alphan inserts made of steel for the top ring to stop wear. But they do their best.
Making due with what you have, we American's and the rest of the world could learn something here... Excellent job on that piston, great video, cheers :)
It is interesting how this video brings out so many experts. Not one has lived in a country that has very little. They do have the skills to make due that those posting do not.
Looks like a Piston for a bigger Diesel Engine. Probably a bit older Design as I think the deep Dish isn’t Standard anymore since some Time. Possibly not even Turbocharged, which would mean comparatively low Power/Volume. Quite possible that there is no Support for Replacements anymore and even in Regions with Access to old Stock it’s not cheap. They aren’t going to scrap their Equipment over such a Problem… Also Efficiency or dirty Exhaust Gases from Bypass Oil are of no Interest if the Machine is what finances your Life. Since 1923 there are Diesel Engines in Trucks. For sure a forged and CNC machined Part would be preferable, but it’s not going into a modern Sports Car. This Piston just needs to keep the Engine usable and survive as long as the other old ones in the Cylinders next to it.
Incredible! Paint can pouring, engine oil furnace but remarkable work! Seeing him running a hand in the chuck while turning reminded me of watching dad decades ago NJnever saw a cleaner lathe.
nice valve pockets, I think they are a bit too deep, but on the whole a very good job considering the lathe has seen better days, At least they carry out servicing on their machinery.
I've seen this method of indicating where they just stick a wire ground to a point on the lathe bed and eyeball runout to that. I wonder what tolerance you can achieve this way? I bet for this particular application it's all you need to dial in a rough casting.
Notice how they need to melt at least 5 other pistons in order to cast a single new one. Sure, you need some extra for the casting ports and the slag losses, but it seems too much still.
After the engine is started up, then 5 minutes after the piston maybe is seized in the cylinder due lack of the tapered piston crown due expansion of heat. Same weight as other pistons?.., propably high vibrations...
Газануть под нагрузкой в одну горочку и хватит. Кольцо от теплового расширения никто не заливал, спав тоже нанотехналогичный, наверно из таких же поршней. Так что все это дело быстренько размажет по цилиндру и компрессия тю-тю.
Top ring land liner? Skirt reinforcement? Cam grind? BALANCE? Warranty expires as soon as it starts up. This "repair" is about as "good" as the welded heat treated axle they did.
This is trial and error, not specialist knowledge. Instead of a feeler gauge, just a sense of proportion. Measure the bolt hole with the meter measure. Holy compression. Hands on the jaws........
Unfortunately, those pistons need to be forged at high pressure and not cast, they definitely won't last long. But I have to say that they have a lot of initiatives at what they do.👍
Wont last long, no expansion control plates no steel ring lands not barrel shaped. Measuring wrist pin location with ruler. Cutting pin hole on lathe. Cast piston in extreme conditions. All recipes for disaster.
I remember a guy who made a wood piston for an emergency repair on his morris 1000 … forgot about it and some 50 years later during an engine rebuild there was the piston still going strong
When Habib the engine rebuilder takes a hammer to a piston so his brother, Ackmed, across the street, can make a few rupees off the YT content provider....
Hmm, safety concerns aside, I'll focus on the actual cast pistons, the actual casting looks to be on the same level as what I have seen done professionally, though there are some small things that made me look twice, the first is the paint bucket used to transport the molten alloy? seriously? The second is the actual head of the piston. I would have covered that like the sides, to fill it in and allow the machinist the opportunity to machine the new head to spec. Lastly, water cooling a newly cast alloy part? the outer layer will cool faster than the core and that could lead to crcking. I would prefer to see it air cool naturally. As for the material? They salvaged old heads and used those to make the casting, so in my mind, that means they should be of the same alloy mix, which should be good. The casting? As far as I could tell, it was done as professionally as I have seen elsewhere, used the correct moulds and sand etc. I didn't initially realise they wrapped it in leather to make a new LARGER piston, that was a clever trick and one I'll remember! The new piston looks pretty darned good, though I would have preferred to see the small number of pinholes drilled out and tig filled with fresh metal before turning the piston to final size. It'll work and if you can't get replacements, it'll do the job.
Sadly, here in the uk, the health and safety squad have killed this countries industry. These hard-working men deserve a medal. And the women at home feeding them.
