TEST YOUR SURFACE GRINDING KNOWLEDGE

QUESTION : When the general term of "surface grinding " is used what is it describing?
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QUESTION : (2) How is a cylinder head evaluated for the need to surface grind?
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QUESTION : (3) If an OHC cylinder head is bent what additional check has to be carried out before machining the face?
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QUESTION : (4) If the OH cam does not turn freely what procedure is required before machining the face?
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QUESTION : (5) What is CBN tooling and what are the advantages?
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QUESTION : (6) Apart from cylinder head-gasket face, name other surfaces that may have to be machined or ground flat during engine recondition?
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TEST YOUR CYLINDER HEAD STRAIGHTENING KNOWLEDGE

QUESTION : (1) What is the basic difference between straightening a head and surface grinding a head?
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QUESTION : (2) Describe some methods of head straightening alloy heads?
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QUESTION : (3) Some alloy heads can be straightened by surfacing both faces , top and bottom. Why can these heads be straightened this way?
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TEST YOUR BORING KNOWLEDGE

QUESTION : (1) What two general types of boring bars are commonly used by engine reconditioners?
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QUESTION : (2) Is it desirable to bore straight to the required o/s in one operation? If yes, give an explanation, if no, give an explanation.
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QUESTION : (3) What is the recommended depth of the final cut when boring a cylinder?
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QUESTION : (4) Does a boring bar tool with a larger nose radius or with a smaller nose radius achieve a smoother finish?
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QUESTION : (5) What size should this tool nose radius be to achieve the smoother finish?
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QUESTION : (6) Draw a plan diagram of a 6 cylinder block, number the cylinders 1 to 6. If boring number 3 cylinder first, work out the boring sequence that will achieve the best boring conditions. (Less heat and distortion)
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TEST YOUR HONING KNOWLEDGE

QUESTION : (1) What is the purpose of honing a used bore that is being re-rung?
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QUESTION : (2) What is bore glazing?
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QUESTION : (3) What is bore polishing?
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QUESTION : (4) Why can't we run the new rings on the re-machined bore without honing?
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QUESTION : (5) How do we know if our hone pattern is ok?
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QUESTION : (6) What amount of material should be left for honing after boring?
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QUESTION : (7) What grit stones should I use?
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TEST YOUR RE-SLEEVING KNOWLEDGE

QUESTION : (1) Dry sleeves or plain repair sleeves are produced in several wall thicknesses. The three most commonly used being an "A" "B" and a "C" sleeve. What wall thickness are they?
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QUESTION : (2) What section sleeve would be (most commonly)used to repair a block where the conrod had broken through the cylinder wall? And why?
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QUESTION : (3) What is the generally accepted crush applied to a sleeve when fitted in a cast iron block?
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QUESTION : (4) When fitting a dry sleeve apart from the interference what should also ensure the sleeve cannot move in service?
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QUESTION : (5) What has to be checked in the adjacent cylinders when sleeving a cylinder?
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QUESTION : (6) If a block is bored to maximum o/s what check is important when selecting a sleeve?
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TEST YOUR CAM GRINDING KNOWLEDGE

QUESTION : (1) How does a cam grinder know what shape to grind a cam lobe when they are all different from engine to engine?
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QUESTION : (2) What is the most common finish fault when re-grinding camshafts?
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QUESTION : (3) What causes these chatter marks?
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QUESTION : (4) Some cam designs require the lobe to be ground at an angle to assist in rotation of the lifter or follower. What two methods are used to achieve the desired angle when grinding?
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QUESTION : (5) Apart from finish, accuracy and concentricity what other items have to be considered when grinding a camshaft?
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TEST YOUR CRANK GRINDING KNOWLEDGE

QUESTION : (1) What type of machine is a crankshaft grinder?
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QUESTION : (2) Name two important procedures that reduce chatter and improve surface finish when grinding?
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QUESTION : (3) What parts of the crankshaft are usually used to set up the crank ready for grinding the mains?
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QUESTION : (4) What has to be checked and possibly redressed on the grinding wheel every time a different model crank is reground?
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QUESTION : (5) What is meant by stroking a crankshaft during the regrinding operation?
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QUESTION : (6) What other items have to be considered and addressed when "stroking" a crankshaft?
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QUESTION : (7) When grinding a crank is it the general practice to grind the mains first or the big ends first and why?
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QUESTION : (8) What is nitriding?
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QUESTION : (9) What depth does nitriding general penetrate the shaft to?
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QUESTION : (10) Why is it so important that the oil holes have an even and correct chamfer re-machined after regrinding?
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TEST YOUR LINE BORING KNOWLEDGE

QUESTION : (1) What is meant by line boring?
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QUESTION : (2) What other areas of an engine apart from main tunnels can require line boring?
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QUESTION : (3) As camshaft tunnels in a block are integral and cannot be closed like most main caps what is important to identify before boring the cam tunnels oversize?
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TEST YOUR ALLOY WELDING KNOWLEDGE

QUESTION : (1) What type of welder is commonly used to weld alloy heads and blocks?
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QUESTION : (2) What does TIG stand for?
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QUESTION : (3) What is the principal of TIG welding?
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QUESTION : (4) There are several gases used as a shield. What is the gas most commonly used by engine reconditioners to weld alloy heads?
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QUESTION : (5) What is the most important part of the welding process when welding corroded alloy heads?
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QUESTION : (6) What are some of the advantages of welding alloy heads with TIG?
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