Welding Day 2

Continued learning my welds today, finished the last two I needed to do which were the lap weld and the T joint weld. Had a couple of goes at the lap weld before I got the hang of it but I got there eventually. The T joint weld was alot more difficult to get the hang of, trying to get the two surfaces molten and keep feeding the rod on this one was proving a bit of a challenge.


Close-up view of the T joint weld, its a bit messy cause I had trouble keeping both surfaces molten.


Another view of the T-joint.


The lap weld after a couple of tries.


Close up of the middle of the lap weld, took this photo to show what a proper weld looks like; A little row of coins.

Welding Day 1

Today we started learning about gas welding, steve took us into the workshop and we began to weld Steel so that we could learn and begin to understand the process of welding, we began by melting the two pieces of steel to join them together, then we used the welding rod which I found alot more difficult, but just have to continue practicing until i get the hang of it.


First attempt at welding two pieces of steel together, not enough heat on the metal to get the weld through to the other side properly


Second attempt, this weld is alot cleaner and has penetration the entire way through the weld


Corner joint, the hole is because the welding torch I was using had something stuck in the nozzle and was causing too much oxygen so the torch was acting more like a cutting torch than welding torch


Inside of the corner joint showing the penetration to the inside of the weld


First use of the welding rod, this is where I had the most difficulty trying to move the rod forward as I was putting the rod into the molten pool and dragging forward, It's a bit messy but as steve said its all about practice.

TTEC 3203 Engineering Technology

Micrometer Task

A task of micrometer measurements we received from Dave to fill out.

500hp Mazda Fe3 turbo

Engine Stripping Day 3

Today in the workshop we learnt about measuring the cam lobes and the crankshaft, I measured four intake and four exhaust valves to get an understanding of the difference in size. I started to measure the bore, measuring the TDC, middle and BDC of each bore to check for Ovality and Taper. We also learnt about Core Plugs and how to check for coolant in the engine, as well as touching on the workings of the starter motor and flywheel. Tomorrow I will finish measuring the bore and then continue on to measure the piston rings. Really enjoying this course, the information intake is a bit full on especially the paperwork, but I'm getting through it and thoroughly enjoying every minute in the workshop.

Jack and Secure a Car Safely.

Last week on Monday the 30Th of June we went into the workshop to learn how to Jack and Secure a car safely, taking health and safety into account. We jacked up the car on the cross-member using a trolley jack and then placed axle stands under the car. We then repeated this process on the rear of the car, we removed the wheel covers and the wheels and placed the wheels, covers and wheel nuts underneath the car to prevent anyone tripping over them. After we had taken the wheels off we had a look at the front disc brakes and the rear drums, Rob then went on to teach us the basics about how the brakes work.

Stripping an Engine Day 2

Today in the workshop we learnt about compression inside the compression chamber, pistons and piston rings, as well as taking the measurements of the bore (Ovality and Taper), piston rings and valves, no pictures today but will take some tomorrow when i am taking measurements.

JSF e28 BMW 545 Turbo 951hp/1063nm

The Four and Two Stroke Engine Cycle

Stripping an Engine.

Today we worked on stripping down engines and learnt about the four-stroke engine cycle. we aligned the timing with the TDC (Top Dead Centre) and the BDC (Bottom Dead Centre), Removed the rocker cover and then dismantled the head, followed by the engine block. We learnt about internal combustion and how the fuel and air mix in the Combustion Chamber reacts when the spark is fired. All in all a good day and learnt alot of new things and can't wait to get back into the workshop tomorrow to begin rebuilding the engine!

Timing the engine to align with the TDC


This is the timing for the crankshaft, shows the notch aligned with TDC


The head with rockers removed.


The rockers, Top is the intake side and bottom is exhaust side.


Removing the head bolts, I started from the center and worked my way out.


Using the valve spring clamp to remove the valves from the head.


Valve seals, used to prevent oil from leaking into the combustion chamber.


The crank shaft after i removed the pistons.


Oil catch can.


Pistons, crankshaft brackets and thrust washers, ready to remove the crankshaft.


The crankshaft after removal.


The oil pump which I removed so I could take out the crankshaft.


oil sump, Had to remove to get to the pistons and crankshaft brackets


The valves from the head, top is intake and bottom are exhaust, separated to make sure I don't get them mixed up when i rebuild the engine