TOOLS OF CFR TRADE

Presented by TOM KOSIK

October 12, 2010Pictures taken by Cory Weberg and Jinfang Wang

Disclaimer

■ The recommendations, advice, descriptions and methods in this presentation are solely for educational purposes. The author assumes no liability whatsoever for any losses or damage that results from the use of any of the material in this presentation. Use of the material in this presentation is solely at the risk of the user.

■ The opinions expressed herein are those of the author, and do not necessarily reflect the views of the fuel symposium organizers.

Presentation topics

■ Introduction■ How many tools do you need ?■ What type of tools do you need ?■ Power Tools■ Hand Tools■ Measuring Tools■ What should the tools cost?■ Specialized Tools■ Care and maintenance of Tools■ What happens if you do not use the right tool

Introduction

■ Tom Kosik■ Work for Alberta innovates Technology

Futures (Formerly Alberta Research Council)■ 27 years in the Octane testing industry in

an government research facility ■ Have trained engine operators for 25 years

Finding the right tool

■ Some people believe that a hammer is the ultimate fix it tool

Finding even a better tool

■ Other people believe that a bigger hammer is the ultimate fix it tool

Be Patience no hammering

■ Some times you have to just relax and use the right tool

Number of tools

■ How many different tools do you use on the CFR test engine?

■ 78 ■ 100■ >150

Types of hand tools

■ Safety glasses■ Gloves■ Combination wrenches ■ Box end sets■ Crows foot ■ Pliers ■ Screw drivers■ Allen keys

Types of hand tools

■ Hammers■ Chisels■ Socket sets ¼” and ½” drive (standard and

deep)■ Letter and number sets■ Files

Types of hand tools

■ Scrapers■ Taps and dies■ Torque wrenches■ Pry bars■ Locking pliers■ Pipe wrenches■ Snap ring pliers

Types of hand tools

■ Picks for o-rings■ Hacksaws■ Flaring tools■ Strap wrenches

Types of hand tools

■ Cutters scissors, tin snips and Knifes■ Drill bits■ Electrical crimpers■ Adjustable wrenches■ Spanner wrenches

Types of hand tools

■ Pullers ■ Seal drivers■ Brushes and wire wheels■ Feeler gauges■ Punches ■ Gloves■ Safety glasses

Power tools

■ Drills ■ Grinders■ Impact tools?■ Jig saw

Questions that you may ask yourself

■ Will My company give me a budget for tools?

■ Do the inexpensive tools last?■ Can I use the tools?■ Will I do a good job?

■ The answer is yes, yes, yes, and maybe

Measuring Tools

■ What type of accuracy do you need? ■ What will the cost be for tools?

Measuring Tools

■ Some of the engine specifications are to very exacting dimensions.

■ Cylinder bore is measured to 0.0001”■ Piston pin is measured to 0.0001”■ Valve clearances 0.001”

Measuring tools cost

■ It almost goes with out saying you get what you pay for.

■ Tool quality does somewhat rely on price but not always.

■ There are some very good quality tools at a reasonable price especially in measuring tools.

So what does it cost?

■ If you tally up the cost of all the tools in the Waukesha brochure the cost is over $43,000.00 dollars

■ Unfortunately there are still more tools required

■ So you can add another $10,000.00 easily■ Now that you have them you need some

kind of training and this adds some more cost

What does it actually cost?

■ These previous costs would be for a new setup.

■ Most company’s have a lot of these tools the engines have been around for ~80 years.

■ Usually there is someone one that knows how to use the tools but not always.

■ Training is often the only cost.

Measuring tools accuracy

■ For some places this is the only measuring tool that they have

Popular measuring tools

■ Bore gauges

Measuring tools

■ Dial gauge (eccentrimeter)

Measuring tools

■ Dial gauge (eccentrimeter)

Measuring tools

■ Dial gauge (eccentrimeter)

Measuring tool

■ Dial bore gauge

Measuring tools

Measuring tools

■ Dial bore gauge

Measuring tools

■ Dial bore gauge sensing tip

Measuring tools

■ Dial bore gauge

Measuring tools

■ Dial bore gauge and setting ring

Measuring tools

■ Bore gauge

Measuring tools

■ Bore gauge

Measuring tools

■ Hole gauge

Measuring tools

■ Telescopic gauge

Measuring tools

■ Micrometer and Telescopic gauge

Measuring tools

■ Expensive hole gauge versus an inexpensive one

Measuring tools

■ Digital Vernier gauge and Micrometers

Measuring tools

■ Valve face runout gauges

Measuring tools

■ Valve face runout gauge

Measuring tools

■ Valve face runout gauge

Measuring tools

■ Valve face runout gauge

Measuring tools

■ Feeler gauge

Valve guide

■ Valve guide height is 1”

Installation tools

■ Valve guide installation tool

Installation tools

■ Valve guide installation tool

Installation tools

■ Valve guide installation tool

Overhaul Tool

■ Intake guide and alignment tool

Overhaul Tool

■ Intake guide and alignment tool

Overhaul Tool

■ Holding wire for valve guides

Overhaul Tool

■ Holding wire for valve guides

Removal tool

■ Valve guide removal tool

Engine assembly tools

■ Piston support block and ring compressor

Engine assembly tools

■ Piston support block and ring compressor

Removal Tool

■ Roll pin punch set

Removal Tool

■ Roll pin punch

Removal Tool

■ Roll pin punch

Overhaul tool

■ Valve lapping tool

Overhaul tool

■ Crankcase breather removal tool

Overhaul Tool

■ Crankcase breather valve

Overhaul tool

■ Valve guide brush

Overhaul Tool

■ Brush and extension

Overhaul Tool

■ Flexible magnet

Overhaul Tool

■ Straight flat bar

Overhaul Tool

■ Ring removal tool

Overhaul Tool

■ Big hands cutter removal tool

Overhaul Tool

■ Big hands cutter removal tool

Overhaul Tool

■ Valve guide pilot installation tool

Overhaul Tool

■ Valve guide pilot installation tool

Overhaul Tool

■ Valve refacing cutter

Overhaul Tool

■ Valve refacing cutter

Overhaul Tool

■ Valve refacing cutter

Overhaul Tool

■ Tools to remove the cylinder head

Overhaul Tool

■ Tools to remove the cylinder head

Overhaul Tool

■ Valve spring removal tool

Overhaul Tool

■ Valve spring removal tool

Overhaul Tool

■ Cleaning brush

Overhaul Tool

■ Nylon brush

Overhaul Tool

■ Cleaning wipe holder

Overhaul Tool

■ Ring groove cleaner

Overhaul Tool

■ Jet removal tool

Overhaul Tool

■ Snap ring pliers

Overhaul Tool

Overhaul Tool

■ Small hole gauges

Overhaul Tool

■ Engine overhaul stand

Special tools

■ Overhaul stand

Overhaul Tool

■ KWIK WAY DRIVER

Overhaul Tool

■ Compression gauges

Overhaul Tool

■ Compression gauge

Overhaul Tool

■ Cylinder lift

Overhaul Tool

■ Valve seat tools

Overhaul Tool

■ Valve seat runout gauge

Overhaul Tool

■ Sioux grinder

Overhaul Tool

■ Seat grinding stone dressing tool

Overhaul Tool

■ Seat grinding stone dressing tool

Overhaul Tool

■ Piston support and ring compressor

Overhaul Tool

■ Ring removal too and piston groove cleaner

Overhaul Tool

■ Valve seat remover and seat installer

Overhaul Tool

■ Cetane handwheel turning bar

Overhaul Tool

■ Injector pressure setting apparatus

Overhaul Tool

Overhaul Tool

■ Overhaul stand

Overhaul Tool

■ Valve lapping tool

Overhaul Tool

■ Crankcase breather valve removal tool

Overhaul Tool

■ Punches and drivers

Overhaul Tool

■ Newway valve seat cutters

Overhaul Tool

■ Cylinder lift device

Overhaul Tool

■ Kwikway valve grinder

Overhaul Tool

■ Feeler gauge and Torque wrench

Overhaul Tool

■ Handwheel spacer and spanner wrench

Overhaul Tool

■ Spanner wrench

Overhaul Tool

■ Taps

Overhaul Tool

■ Timing light

Overhaul Tool

■ Timing light

Overhaul Tool

■ Cylinder lift

Overhaul Tool

■ Engine lift

Overhaul Tool

■ Bead blaster

Overhaul Tool

■ Bench grinder

Overhaul Tool

■ Adjustable wrench

Overhaul Tool

■ Oil filter wrench

Overhaul Tool

■ Glaze breaker

Overhaul Tool

■ Turn over wrench

Overhaul Tool

■ Banjo fitting measurement tool

Overhaul Tool

■ Newway cutter

Overhaul Tool

■ Newway driver

Overhaul Tool

■ Nylon brushes

Overhaul Tool

■ Carbon blaster hose

Overhaul Tool

■ What is this tool used for?

Overhaul Tool

■ Low cost measurement

Overhaul Tool

■ Carbon blast unit

Overhaul Tool

■ Carbon blaster tip and blinds

Overhaul Tool

■ Valve lifting tool

Overhaul Tool

■ Handy pocket tools

Overhaul Tool

■ Selector valve poppet tool

Overhaul Tool

■ Various tools used in a cylinder overhaul

Overhaul Tool

■ Minimum measurement tools required

Pressure relief valve

■ Oil pressure relief valve

Overhaul Tool

■ Sioux valve seat grinding stone holder

Overhaul Tool

■ Valve seat removal tool

Banjo fitting depth

■ Approximately 5/16”

Overhaul Tool

■ Various tools use in a cylinder rebuild

Cylinder cut away

■ What do you mean the piston would fit

Tool Care

■ It is as simple as keep them clean■ Wipe them off after use ■ Sliding tools will require a small amount of

a light oil ■ Oil tools that have threads when they

appear dry so all threads turn easy