GregH Posted March 14, 2008 Share Posted March 14, 2008 Ok, so I've learned an awful lot about how some of the engines we work on are put together by studying the cutaway views. Of course, the real cutaways are just cool to look at.. But, forgiving my ignorance, how are they made? How do you cut through an injector to show how the internal pieces fit together? How do you cut through a cylinder head to show the passages around an injector cup? How did Ford cut through the 6.4 they showed off at the Texas state fair? I did a few google searches, but came up with nothing. I was hoping you guys could tell me.... Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted March 14, 2008 Share Posted March 14, 2008 Bruce is definitley the guy to ask this to. He's got some really cool cutaways. Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted March 14, 2008 Share Posted March 14, 2008 Yes, Bruce has quite a few cutaways as I understand and he has been kind enough to post several in our PhotoPost area as well as in many posts. I love cutaways myself. They give you a perspective on these engines you cant get otherwise. Actually, it would be cool to have a cutaway gallery... but there are pics as I mentioned. Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted March 14, 2008 Share Posted March 14, 2008 It is very labor intensive to build a cutaway. I've done 6 so far- 7.3, 6.0, 6.4, DT466E, DT466(EGR), and an Allison MD3060. I've also done 5-6 turbos including several VGT's. There's no "magic bandsaw" that you run the whole thing through to slice it open. Most of the time I do the teardown and mark where the cuts go. If it's a larger piece like a cylinder head I take it to my local metal fabrication shop who has a monster bandsaw where it is cut. If it's a smaller piece, I have a bandsaw that will cut up to about 10 inches. If it's a really hard part, like the 6.4 pump head, the regular fab shop can't cut it and I take it to a shop with a Bridgeport where it's done. Once the cuts are done, I take an air grinder and successive finer discs to get rid of the bandsaw marks. Start with 36 grit on an air sander, end up with 220 on a D/A like a body shop uses. Most of the paint is WalMart cans, and I use a LOT of clear paint. All of the aluminum is bead blasted and all of the iron is sandblasted before it gets the final paint. My shop is adjacent to my old repair shop, which has both a glass bead cabinet and a sand blast cabinet. I also have a 10 gallon siphon fed sandblaster for engine blocks and large stuff that are done outside. These engines look terrific, but they will never run again. There's so much sand in crevices, cam followers, oil galleys, etc, that the groan when you turn them over. There's also a lot that goes on behind the scene with getting a cutaway to the class site. I have two trailers, both built to spec- a 5x8 single axle and a 5x10 tandem. Both have options such as double floors, extra crossbeams, bigger brakes, electric winches, custom ramps and holding fixtures to support the engine once it's in the trailer. I had 6 custom carts built that are all the same size so that the holding fixtures inside the trailer can accept any cart. The cutaways weigh from 400-1400lbs depending on which engine/trans it is. I can haul 3 in the 5x10. Both Anthony and I have V8 SUV's that are set up with trailer brake controllers and heavy hitches. He just got back from St. Louis today with a DT. The best part of building a cutaway is how much you learn as you're doing it. Opening up passageways and seeing inside says volumes. I've also built a bunch of demonstrator boards- DT466 fuel system, IH multiplex dashboard, Bendix ABS braking system, etc. All of these are fully functional with all sensor inputs etc, and electric motors to run the CMP and WSS sensors. All of them interface with PC software and have fully bidirectional controls like you're hooked to a truck. Here's some pics that were already up, I'll add some more when I get a chance. BTW, I love cutaways too. Techs are hands on people- they would much rather have a cutaway in class than any book. My books are loaded with full color cutaway pics, too, which really helps out. Have a great weekend! /forums/images/%%GRAEMLIN_URL%%/grin.gif Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted March 14, 2008 Share Posted March 14, 2008 2005 DT466 (EGR) 2000 DT466E 7.3 PSD 6.0 Carts: Here's a shot of a DT in the trailer when I was setting up the mounting fixtures: Demo Boards; IH NGV Multiplex Board DT466E Demo Board: These are fully functional and have complete bidirectional control with a laptop and MD Fleet. Those HEUI solenoids are NOISY! When you activate the motor spinning the CMP, it sounds like a frigging machine gun in a quiet classroom! Here's a shot of Anthony teaching using Diamond Logic Builder (IH's multiplexing software) in a classroom. He normally does not sit down, but was using his laptop to control the dash functions. Note the dash projected on the screen: The best thing about building those demo boards was what I learned in the process. If I had taken a thousand classes I still wouldn't have learned as much. Wiring those from scratch and figuring out all of the little subtleties was incredible. More incredible is learning firsthand the errors in IH's schematics! /forums/images/%%GRAEMLIN_URL%%/grin.gif Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted March 15, 2008 Share Posted March 15, 2008 Bruce you may very well be the Leonardo de Vinci of diesel cutaways, very cool.... /forums/images/%%GRAEMLIN_URL%%/readthis.gif /forums/images/%%GRAEMLIN_URL%%/thumbup.gif Quote Link to comment Share on other sites More sharing options...
eastendpowerstroke Posted March 15, 2008 Share Posted March 15, 2008 Bruce you may very well be the Leonardo de Vinci of diesel cutaways, very cool.... /forums/images/%%GRAEMLIN_URL%%/readthis.gif /forums/images/%%GRAEMLIN_URL%%/thumbup.gifI love to see them but Bruce has !!WAY TO MUCH FREE TIME!! Quote Link to comment Share on other sites More sharing options...
Shlep Posted March 15, 2008 Share Posted March 15, 2008 You definately have the coolest job /forums/images/%%GRAEMLIN_URL%%/notworthy.gif Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted March 15, 2008 Share Posted March 15, 2008 Bruce could do a exhibit for it... He could name it something like... DIESEL RENAISSANCE FOR THE WORKING MAN Or maybe David is right to much time on your hands. /forums/images/%%GRAEMLIN_URL%%/poke.gif Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted March 15, 2008 Share Posted March 15, 2008 The Bendix air ABS board is also fully functional with faults that can be put in and diagnosed either with the LED's on the module or the A-Com software (which is free from Bendix, BTW). The board hooks to a laptop and has full functionality just like a truck would. If you ask a tech what training he wants, he'll almost always tell you advanced drivability, fuel control, or other high end topics. The problem is, if you hand him a DVOM he can't use it. I wrote an electrical class several years ago that's 16 hours in length and one of our best sellers, Anthony's doing it in Orlando this week for an electric company. (Funny, eh? Teaching electric company employees how to use a DVOM!) The demo boards are an old industry standard. This is the third set I have built. The first were plywood, but I wanted a better look and lighter weight so I built 15 of them from aluminum and ABS plastic. They are light and easily shipped in a crate. The focus of this class is basic DVOM use- volts, ohms, and amps. (Right, Jim?) Learning the K and M scales. Voltage drops. Relays. LOTS of hands-on. We wire circuits with light bulbs and relays in the class, and spend a few hours doing the proper methods of starting and charging systems diag including slow drains. This is a really fun class to do. Even experienced techs give great reviews on this class. Average age of all of my students is probably about 40. Many of them are older than me. Anthony just turned 40, so some of the students are old enough to be his father! I hope I haven't bored you or turned this into a Turbo Training ad... Have a great weekend! /forums/images/%%GRAEMLIN_URL%%/grin.gif Quote Link to comment Share on other sites More sharing options...
Joey Kaylor Posted March 15, 2008 Share Posted March 15, 2008 i will attest from first hand experience that the 6.0 on a stand is one heavy bitch. and it is like driving a 4ws vehicle, it goes where it wants to! did you put those injectors on baking pans!? Quote Link to comment Share on other sites More sharing options...
Jim Warman Posted March 15, 2008 Share Posted March 15, 2008 Bruce... that stuff is simply marvelous.... the amount of patience it takes to create it must be astounding... My hat is off to you.... For the DMM, I'm starting to wonder if most guys should have just saved their money... they get so confused way too easily.... I always have to chuckle when a tech gets a B+ drop across a light that isn't lit.... and he has to take the bulb out and squint at it to see if it's good or not.... Or if he actually falls for Fords hokey test procedures. <mumbling something derogatory about checking grounds with an ohmmeter> Come to think of it... don't teach anyone how to use the DMM... that is one of the very few things that sets me (at least) apart from the mainstream.... Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted March 15, 2008 Share Posted March 15, 2008 I hope I haven't bored you or turned this into a Turbo Training ad... Bored? It's fascinating and the more I learn about you and all that encompasses your training the more I am impressed. As for sounding like an ad for Turbo Training, you are a DTS sponsor so, um, like, ahhhhhhh... you are fine. The diagram with the multi-meter gives me an idea for a shortish 10 question on line test. If only I had software to create interactive stuff instead of just tests, ohhh the stuff I could do with this site! Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted March 15, 2008 Share Posted March 15, 2008 i will attest from first hand experience that the 6.0 on a stand is one heavy bitch. and it is like driving a 4ws vehicle, it goes where it wants to! /forums/images/%%GRAEMLIN_URL%%/hahaha.gif You're a weenie. That 6.0 is only 700lb with the cart because the crank, rods, and pistons are gone. The DT's weigh 1200 and 1400lb! Did you put those injectors on baking pans!? They're bolted to 1/4" aluminum plate, which resonates like a bitch! /forums/images/%%GRAEMLIN_URL%%/grin.gif Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted March 15, 2008 Share Posted March 15, 2008 If only I had software to create interactive stuff instead of just tests, ohhh the stuff I could do with this site! Don Schnell of Smoghouse drew that picture (I have permission) and he has interactive software for using it. It is REALLY cool- you take the DVOM lead and put it on the points, flip the switches so there is voltage available, and the DVOM reads the correct voltage. He had it on his website a while back, but now I can't find it. http://www.toolsforeducation.com/index.php He writes some really cool interactive software for diagnosing cars, perhaps you've seen it. It starts out with a work order and a garage, you get the keys and test drive the car to verify the complaint, look up applicable TSB's, perform tests according to the WSM, and repair the car. The steps are so similar to real life it's funny. It's a lesson in following the correct steps in the WSM and you have to do it in the right order or you fail. You may want to e-mail him and ask for a demo disc of what he does. Perhaps he would be generous and allow you to put it on your site. Another source for great pictures is Ralph Birnbaum. He's a graphic artist from Akron and I've known him a long time. You may recognize his art from large corporations like Napa and others who he draws for. He is very prolific and has drawn thousands of high end pictures. He sells some of the older stuff on his website for the amazing low price of $6 each. I've bought hundreds and use them in my programs. Take a few minutes and browse his site: http://picsellation.com/~picsella/Auto_Electric_g74.html Here's couple of samples: Soooo, how much bandwidth am I allowed? I've been doing a lot of uploading lately..... /forums/images/%%GRAEMLIN_URL%%/grin.gif Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted March 15, 2008 Share Posted March 15, 2008 Bruce, the toolsforeducation.com site is pretty much busted. Most of the interesting links are broken or don't work. This topic just planted the seed. Give it time and see what I can conceptualize. The test software I started using has a companion program for creating demonstrations but I would prefer something with a little interactive ability. I should download the trial version and really play with it before I make my mind up on it. I found something else that looks promising but it is a little more expensive. Remember, I am on a budget. Quote Link to comment Share on other sites More sharing options...
dieseldoc Posted March 19, 2008 Share Posted March 19, 2008 Bruce your training sounds extremely thorough and helpful. How does a guy go about getting into some of them? I have visited your site and looks like you do training for independant shops and fleets. I am the only one at my shop that works on our ford fleet(when they dont take them in for warranty, our fleet has gotten updated lately and we only have one that isnt in warranty). These engines are extremely interesting to me and the fleet wont be in warranty forever. I try to learn everything I can wherever I can find info. But tough to know if you can trust it or not. Thats why I love this site so much. Hats off to you keith Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted March 20, 2008 Share Posted March 20, 2008 Bruce your training sounds extremely thorough and helpful. Thank you. How does a guy go about getting into some of them? This is a very difficult question to answer. Although Anthony and I are very busy, 95% of the classes we do are closed to the public. These are private classes held for Departments of Transportation, government agencies, and large utility companies. We only do a few public classes per year, which are always listed on my website. The next one is next Saturday in Grand Rapids, MI, where I do 6.4 and Bendix Air ABS and Anthony does IH Multiplexing. Later on will be Toronto, Akron, WA, and PA. How do you get into a class? I really don't recommend the public classes for the most part (except for WSAFC) because they are compressed classes. Compressed classes suck because it gives you a great taste, but leaves you hungry. (How do you compress a 16 hour class into 3 hours?) Washington State Association of Fire Chiefs has me do a full week of full classes, without shortening them, in September. There you can get the full 16 hour PSD and other engine classes. I do regularly have people travel across the country to attend one of my classes. So it's tough. How do you get into a class? Contact a local ASA chapter or other industry leader and get them to hire us to come in. We charge by the day, not by the student, and it's expensive. It takes at least 15 people to make a class cost-effective. I wish I had a better answer for you, but I don't. Thanks! /forums/images/%%GRAEMLIN_URL%%/grin.gif Quote Link to comment Share on other sites More sharing options...
dieseldoc Posted March 20, 2008 Share Posted March 20, 2008 I was looking at the books you have for sale on your site. I tried to contact you in the contacts part but couldnt get it to work. Is the 7.3 tips and tricks book different than the manual that comes in the manual and dvd package? By the looks of the picture it is the same book. Am thinking about buying the both the 7.3 and 6.0 training book/and dvd packages. (sorry kieth if this reply is out of line. Let me know if it is not ok) Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted March 20, 2008 Share Posted March 20, 2008 sorry kieth if this reply is out of line. Let me know if it is not ok It's cool. We are about learning and sharing information here, right? Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted March 20, 2008 Share Posted March 20, 2008 on your site. I tried to contact you in the contacts part but couldn't get it to work. ? The phone number and e-mail are both there and correct when I pull up the "contacts" page. (I do have a new web design to be put up very shortly.) http://www.turbotraining.com/new/contact/contact.htm Is the 7.3 tips and tricks book different than the manual that comes in the manual and DVD package? No, there is only one book. By the looks of the picture it is the same book. Am thinking about buying the both the 7.3 and 6.0 training book/and DVD packages. I'll cut you a break since you're a DTS member- $299 gets you both book and video sets. That's $60 more off the package price. There's no link for that on the website so either call me at 440-846-3885 or e-mail me your CC info in a file attachment. That goes for other DTS people, too. Thanks! BTW, I'm now a "Tinker Toy Engineer"? What the hell is that? Keith, what do you do, stay up all night dreaming up these wild titles?!!!! /forums/images/%%GRAEMLIN_URL%%/rofl.gif /forums/images/%%GRAEMLIN_URL%%/grin.gif Quote Link to comment Share on other sites More sharing options...
dieseldoc Posted March 21, 2008 Share Posted March 21, 2008 Wow bruce that is an awesome deal! thanks I will definitely give you a call in the next week or so. The trouble with e-mailing you was probably my computer, Its had issues lately. Once again thanks for deal on the package sets. Quote Link to comment Share on other sites More sharing options...
Shlep Posted March 21, 2008 Share Posted March 21, 2008 That goes for other DTS people, too. Thanks! More like thank you for that offer, I'll be putting my order in within the next 2 weeks /forums/images/%%GRAEMLIN_URL%%/cheers.gif BTW, I'm now a "Tinker Toy Engineer"? What the hell is that? Keith, what do you do, stay up all night dreaming up these wild titles?!!!! /forums/images/%%GRAEMLIN_URL%%/rofl.gif That title almost suits you don't ya think, just look at all the cool things you get to do /forums/images/%%GRAEMLIN_URL%%/thumbup.gif Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted March 21, 2008 Share Posted March 21, 2008 Yeah I was the first to be the T/T/E and now I'm the Diesel Fitter whatever the hell that is...Although I think I figured it out, seems to be every 100 posts you make you get to be somebody else. Jim leave it alone...as well a couple of you other guy's. Quote Link to comment Share on other sites More sharing options...
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