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.
Incredible! Paint can pouring, engine oil furnace but remarkable work! Seeing him running a hand on the chuck while turning reminded me of watching dad decades ago, never saw a cleaner lathe.
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.
@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...
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.
What a load of rubbish. Western manufacturing techniques are world class. That's why it's called precision engineering. These guys are doing it like it's the 1900s
@@InvisibleYetVisible Guess you fail to understand, they're making due with what they have at hand. Also, are they of the "western world"? No, they're not.
@@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.
I dunno, looking at the amount of material they melted down, it seemd they may have cast a set of pistons instead of just one. I think these guys know what they are doing.
German engineers get goose pimps when watching these incredible craftmen working without any protecting gear and solving problems with simple procedures.
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.
Piston skirts are not round as turned on a lathe but oval. And you cannot grab up aluminum and cast a piston that will work. All this work they do is for show and not meant to be used as they lead to to believe.
Right after ww2 my uncle bought a motorcycle with a broken cilinder. He did exactly the same and casted a new one from cast iron scrap. It ran for five more years without any issues.
Scrap aluminium alloy from pistons would make absolutely suitable pistons. It's called recycling. Alloy wheels can be cast in the same way. Shrinkage is around 1% so a small amount of packing around the original is needed. Why make life so complicated? Boeing can't do what these people do!
Cylinders pistons fit into are circular not oval. Piston rings are circular. Pistons are circular. Because of the way they run up and down the cylinder pistons may become oval and at that point they're scrap as often the cylinder is as well! Where people get the ideas from I really don't know!
@@t588143I would have thought he would use aluminium alloy. Steel is much too hard to cast in the way shown here. Cast steel would be difficult to machine unless very carefully melted.
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...
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.
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.
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.
First of all, great work and high skill. Good luck and more development and prosperity because you deserve this. But I have a note: Does it withstand the intense heat and high pressure in the cylinder or does it melt because some chemicals and some metals are added to aluminum to increase its hardness and its ability to withstand the intense heat and high pressure?
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.
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.
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.
This is a great example of how the parts they make are used and then break again. I’d be interested in how long it was used in the engine before it broke.
There are some smart arse keyboard engneers giving their snide remarks....But in Pakistan these Parts work and work well, the fact is they work for years and years flawlessly at a much smaller price....so whos the the smart ones? Respect and admiration for these guys
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........
These craftsmen make the best use of available tools and what they have learnt. Complaining and whining ars just out of question. They just get the job done.
A new cylinder repair kit for a truck with an I-6 diesel engine runs something like 500-700$, including the sleeve, the piston, the pin and all the rings, so a kit for the entire engine would run 3000-4000$, if it they still happen to make those. While the job is nothing short of amazing, the end product will probably not work very well compared to a proper factory one. Working somehow is still better vs not working at all.
It encourages creativity. Desperation is the mother of invention. We need more of the that in the US to spark industry again. Tell the legislature, safety "experts" and perveyers of finance go to hell.
If this piston is for a single cylinder engine, it might work if power output and RPM are not critical, but if it is used with others in a multi cylinder engine no thought has been given to balance. If this one is just a few grams lighter or heavier than the rest........
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.
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....
Newsflash. Pistons aren't round. They are cam ground because a cylinder isnt round when it's hot. They are ground slightly oval to fit the bore when running. This would not last long, the engine wouldnt run as well as it should, oil control would not be optimized. This is a mickey mouse last resort.
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.👍
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.
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.
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.
Well, guess that the guy responsible for balancing and matching that piston to the other ones in the engine and to match the compressionrate also is a full time employee…
All very well adding leather to make the outside diameter bigger to allow for machining, but they did not add anything tothe length. Hence the piston is now much shorter than the original. Very Hairy practice with the pouring of the aluminiun, no proper tools ot ladles, just an empty paint can.
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.
China is in a economic free fall...
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
Look at China now, it completely coming apart. TOO MUCH corruption in their system with apartments and highway bridge coming down almost daily.
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.
100% agree
pretty good but what about pin fit, pin boss machining, pin clip retention grooves, and oil return holes, balance? alot to do yet
Spot On Observation
No Porosity Test For Casting Either.
A lot
doing what they can but that casing is full of porosity
Had one in my car it worked very well for 17 years. The car was sold, still working perfectly.
the mechanic : those parts are not produced anymore !
old engineer : hold my cigarette !
Incredible! Paint can pouring, engine oil furnace but remarkable work! Seeing him running a hand on the chuck while turning reminded me of watching dad decades ago, never saw a cleaner lathe.
Pistons are oval and tapered to allow for thermal expansion. without this shape, you'd need huge piston to cylinder clearance to prevent seizure.
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.
I love soaking up the wisdom of the keyboard engineers in the comments.
@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...
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.
@@gvet47 hence my comment, I respect these guys.
@@gvet47make DO
What a load of rubbish. Western manufacturing techniques are world class. That's why it's called precision engineering. These guys are doing it like it's the 1900s
@@InvisibleYetVisible Guess you fail to understand, they're making due with what they have at hand. Also, are they of the "western world"? No, they're not.
Thanks for showing us part of Red Bull's new engine manufacturing facility. 😁
If it wasn't for Pakistan's import restrictions they probably could have bought a new piston for what it cost them in fuel to melt the aluminum.
The average wage in Pakistan is $300 a month and coal is cheap.
@@glennchartrand5411 But it clearly was done with Diesel fuel. Are you blind ?
@@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.
À. ,aaqllqllaAa as aaaaaaaaaaaaaa@@ntal5859
they use very cheap coal
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.
Casting a church bell is no walk in the park. Look at youtube
Поршень, в домашних условиях????? и будет работать???
звоните инженерам KOMATSU, MOROOKA, ISUZU пусть приедут набираться опыта
I dunno, looking at the amount of material they melted down, it seemd they may have cast a set of pistons instead of just one. I think these guys know what they are doing.
Ok smart guy, show us then using your computer generated materials while these people learn from mistakes and make adjustments
Everyone is a RUclips expert. I applaud these craftsmen.
What alloy are you using?
piston with a little bit of valve cover.
🙂
Hey it was a piston before, so the alloy must be right.
@@ntal5859 Yes it is. It is piston alloy. The addition of valve cover improves the casting fluidity. 🙂
German engineers get goose pimps when watching these incredible craftmen working without any protecting gear and solving problems with simple procedures.
No they don't
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.
Kudos to the skilled lathe hand.
These skills must be maintained.
Piston skirts are not round as turned on a lathe but oval. And you cannot grab up aluminum and cast a piston that will work. All this work they do is for show and not meant to be used as they lead to to believe.
Right after ww2 my uncle bought a motorcycle with a broken cilinder. He did exactly the same and casted a new one from cast iron scrap. It ran for five more years without any issues.
Piston ovality is 1/4 of tolerances for new piston. So ovality dont matter.
Scrap aluminium alloy from pistons would make absolutely suitable pistons. It's called recycling. Alloy wheels can be cast in the same way. Shrinkage is around 1% so a small amount of packing around the original is needed.
Why make life so complicated? Boeing can't do what these people do!
Cylinders pistons fit into are circular not oval. Piston rings are circular. Pistons are circular. Because of the way they run up and down the cylinder pistons may become oval and at that point they're scrap as often the cylinder is as well! Where people get the ideas from I really don't know!
@@t588143I would have thought he would use aluminium alloy. Steel is much too hard to cast in the way shown here. Cast steel would be difficult to machine unless very carefully melted.
Full of admiration for their skill with simple equipment,
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...
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.
Lot of skill and patience...
A master craftsman!
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?
0@@oo0Spyder0oo
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.
It will have big clearances and go for years , it isn't a racing piston.
What amazed me most about this video is that the guy is actually wearing shoes.
kind of petty considering what he,s doing..
I wonder how long this piston will last. Inclusions and casting defects will cause the piston to explode 😅😅
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.
These guys cam make anything, even weld broken crankshafts, stuff the western engineers cannot do.
@@dayleedwards3521 Er...You do NOT want to go there...
Long enough and at a cost comensurate to the income of their customers. More than I can say in the West.
@@dayleedwards3521 cant and wont are two very different definitions.
What is this thing called and where do you use it ?
First of all, great work and high skill. Good luck and more development and prosperity because you deserve this. But I have a note: Does it withstand the intense heat and high pressure in the cylinder or does it melt because some chemicals and some metals are added to aluminum to increase its hardness and its ability to withstand the intense heat and high pressure?
Constructive criticism or no comment or reply, thank you
Amrish puri working on lathe machine 😂😂
Wonder if it weighs the same as the others, ans absolutely love the chuck bite marks on skirt.. 😂
-Marring the work piece is not in their vocabulary😄
The chuck bites on the skirt will retain oil... improved lubrication.
Don't worry they're just love bites!
Hey Bruh, that piston you made last week didn't go 10 miles.
They got no other choice but to make their own...too many import/export restrictions. They are in a tough spot.
Hey Bruh, that comment you made last week didn't got 10 likes.
How could I say that...any reason sir?
you mean 10k miles
@@jundabu2368 10k metres
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.
Good evening. Could you do me a favor? Send me the composition of the sand you use because I need to make 3 of these but I have no idea what you use.
In 7th Grade we were casting like this....Schools in the U.S. don't teach Men SHIT anymore!
After Looking At The Finished Product 🤔, I Can Now See Why The Original Piston, Had Such A Catastrophic Failure 😂 ! ,
Just Kidding 😲 ! , Nice Work 👍 !
Lmao ...
Its not original after all 😭😭
I have used one of this 14 year used and still working smoothly
What is the liquid they add to the sand for the moulds ?
anything that can bind the sand do work, in this case it looks like engine oil
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.
Boomer spotted 🤡
And it will run just fine and the truck will do another 200000 miles.
I wonder if the original piston wasan invar strut pistion ?.
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.
does his dress get caught in the lathe?
Was that canola oil?
We probably see the same piston at the beginning and end of the video. Clever.
I thought they were going to weld the broken piston together. Good casting solution.
They wear shoes 👞 in this one ,,, must be osha makein changes
Que mezcla de arena usais
Kum+kullanılmış motor yağı
Carry on guys you're the bests.
All you judgemental doors get lost could you do what this dear man does you should be ashamed of yourselves this man is fantastic 😢😊
Molten Aluminium gets gassy and porous, didn't see any de-gassing stage, weak castings. See how the sprue just cracks off at 15:00
This is a great example of how the parts they make are used and then break again. I’d be interested in how long it was used in the engine before it broke.
There are some smart arse keyboard engneers giving their snide remarks....But in Pakistan these Parts work and work well, the fact is they work for years and years flawlessly at a much smaller price....so whos the the smart ones? Respect and admiration for these guys
These guys are very clever😅. They make good money from RUclips though the viewers and comments. Of course not from making pistons 😂😂
This piston is never going into an engine, it's just done for the video, ie click bate
Can you give us a reason why
Well done good work guys...
Always amazes me to see the use such old technology to set a form and cast a new component
hmm I wonder whats the reliability of this component.
Reminds me of high school shop class. Too bad they don’t have that anymore.
Again, good skills but where are the safety boots and glasses?
I love how they sized the groove for rhe rings!
Fantastic ingenuity, but I KNOW that you also heard Gru's minions. Banana!
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........
Can anyone confirm this but that piston looked like a cummins piston ... plus the engine block at the end as well ??????
These craftsmen make the best use of available tools and what they have learnt. Complaining and whining ars just out of question. They just get the job done.
Will it work? Yes. Will it last? Don't know, probably not. But who cares? Replace it again.
Using old piston as casting material seems perfect.
Ich habe Respekt vor diesen Menschen die alles reparieren, und nichts wegschmeißen.
A new cylinder repair kit for a truck with an I-6 diesel engine runs something like 500-700$, including the sleeve, the piston, the pin and all the rings, so a kit for the entire engine would run 3000-4000$, if it they still happen to make those.
While the job is nothing short of amazing, the end product will probably not work very well compared to a proper factory one. Working somehow is still better vs not working at all.
It encourages creativity. Desperation is the mother of invention. We need more of the that in the US to spark industry again. Tell the legislature, safety "experts" and perveyers of finance go to hell.
Good repaireng house pistone
If this piston is for a single cylinder engine, it might work if power output and RPM are not critical, but if it is used with others in a multi cylinder engine no thought has been given to balance. If this one is just a few grams lighter or heavier than the rest........
Botas de seguridad???😮 Felicidades!!
Pistons need to heat treated and they are oval and tapered so when the expand they become round and straight.
I am pretty sure that the cost of this piston now exceeds the value of the whole car...
Nope
That piston due to its size is probably from a transport diesel engine
Nah. Sand labor is cheap. They also sound like minions
I want to know how long that lasted
Ainda bem que tem inspetor de qualidade, para tirar minhas duvidas
Pakistani the best mechanic
no coolant any where ????
these genalmen are amazing, very talanted!
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.
The concept is amazing
I see a market opportunity for locally made safety shoes and other protective equipment
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....
Newsflash. Pistons aren't round. They are cam ground because a cylinder isnt round when it's hot. They are ground slightly oval to fit the bore when running. This would not last long, the engine wouldnt run as well as it should, oil control would not be optimized. This is a mickey mouse last resort.
I wish I knew what each step was!
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.👍
Километров на 500 должно хватить
хотя бы на 100 и то если не заводить..
🤣🤣
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.
А если бы они залепили на холодную сварку тот поршень, который им чувак принёс, в начале видео, то хватило бы на тыщу, без этих танцев с бубном. ))))
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.
Someone should teach them pistons are not round they are oval for heat expansion
It’s gona be a rattla or seize lol
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.
Si rompió así el pistón entonces es muy seguro que rompió perno, biela, cigüeñal, probablemente el block del motor 😅
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.
Держитесь, ребята!, я перестал выкидывать пивные банки. Скоро будет легче с отливками😂😂😂
Well, guess that the guy responsible for balancing and matching that piston to the other ones in the engine and to match the compressionrate also is a full time employee…
Metal shrinks when it is cast, the old piston is too small to be a pattern for a new piston
I guess they can get those abandoned black hawks flying easily enough.
Yeah, I wouldn't trust that to last very long before failure
Nice to see safety shoes being worn well done standards are rising
they keep breaking because they are made the same way. Making a piston is complicated.
Great effort though.
I adore how they sound like minions.
All very well adding leather to make the outside diameter bigger to allow for machining, but they did not add anything tothe length. Hence the piston is now much shorter than the original. Very Hairy practice with the pouring of the aluminiun, no proper tools ot ladles, just an empty paint can.
Oil holes are missing in piston
Wow these guys have real skills not seen much in this so called modern era