1947 Imperial and Chrysler Service Book – Cam Ground Piston
imperialclub.com
imperialclub.com
Some further searching reveals that there is a whole series of these with accompanying slide films:
http://www.imperialclub.com/Repair/Lit/Films/index47.htm#194...
Imagine if Tesla made booklets and videos like these for the technology in their cars... I guess 70 years ago companies were far more open with sharing such things, and willing to spend a lot more on it too.
We are witnessing the end of ownership for anybody that isnt hyperich.
Thanks for this post I upvoted a few of your comments. That said being a bit older and in business for many years (since college) I think it's the opposite actually. When I was 'growing up' in business you didn't share your secrets or give out any information whatever that would be helpful to your competition unless it was disinformation. So this didn't start with Steve Jobs and Apple it was pretty much status quo for all business. The internet changed that and I think at least one of the reasons was the involvement of academics who were more used to sharing what they knew.
[1] http://dig.library.vcu.edu/cdm/landingpage/collection/psm
There's much more now, e.g., titanium connecting rods.
I am old enough to remember when it was ordinary (for 2 strokes single cylinder race engines - think of karts or motcross bikes) to mount the piston in the engine, do a few kms/laps then disassemble the piston and remove with a very fine ceramic file where the aluminium became shiny, rinse and repeat 5 to 10 times.
Modern car break in procedures are like "don't do anything ridiculous for the first 500 miles, then it'll last at least 200K miles"
That's the effect of computer controlled machining to a fraction of a ten thousandth of an inch on all parts vs merely to a thousandth or so in the old days.
Not only, if I were to select one single reason for the increased reliability of modern engines I would select the enhancements in tribology/lubricating oils (and to a certain extent also to "better" fuel, particularly for Diesel engines).
The secret is now out but long was not: Often the poor engine suffered that agonies of the damned. Why? Too much gas and water got into the oil, ruined the lubricating qualities of the oil, and made the engine wear out much faster. The worst situation was running the engine cold in cold weather. In particular there was that little device, the "choke": It's job was to flood in lots of excess gas hoping to get an explosive mixture from the cold air. Well, a lot of that gas didn't burn, got past the piston rings into the oil. Similarly for water from condensation.
The big step up was to have some exhaust flow under the intake manifold to heat the incoming fuel-air mixture to do better vaporizing the gas and need less extra gas from the choke.
What solved that was fuel injection, in various forms, throttle body, port, and cylinder. Then the pressure on the gas was high enough to get good vaporization.
Next biggie was spark timing: Usually it was far from where it should be again causing inefficient combustion and gas and water in the oil.
One of the most critical needs for lubrication was the rocker arms, e.g., where the rocker arm was pushed on by the push rod from the lifter on the camshaft. On a classic small block Chevy, I had a push rod go through rocker arm and the valve cover! We got a new, 'crate', engine via Chevy.
Oh wow! Seriously!? This is so crazy to me. People always talk about how things were better made "back in the days" but I was always skeptical of that. I haven't lived long enough to know this first hand but being a technology oriented person, I've always assumed things generally get better engineered over time.
Your experience is genuinely shocking because my 2013 BMW has 55,000 miles now and still runs like it's new. I looked under the hood recently just to check on it and the engine bay is still perfectly clean, no oil leaks, etc.
In the sense that why it is entirely true that cars (not only the engines, but also the clutch, and brakes) needed a lot more maintenance and much earlier repairs/replacements, the cost of them was relatively low.
The big advantage is that you can run now a car for thousands of km/miles without doing anything to it and - usually - it never stops/breaks. (but when/if it does, your wallet will notice it)
Besides the "almost continuous" oil changes and filter replacement, once upon a time it was "normal" if you were planning to make a - say - 500 km trip, to go a few days before to the mechanics and having him check the car, and anyway you rarely had a clutch go beyond 60,000 km (40,000 miles) or (drum) brakes go beyond 40,000 km (and registered/checked every 20,000 or so), and the same goes for minor components (that someone that only had "new" cars probably don't know they even exist) such as the steering rack, rod ends, wheel bearings, all of these were routinely replaced or fixed at a relatively low mileage, besides needing to be "constantly" greased manually.
But for example the water pump, that rarely lasted more than 40/50,000 km, was fixed by disassembling it, replacing the bearings and seals, with a cost of a few dollars.
Nowadays you replace it only maybe once in the life of the car, say around 100/120,000 km, and it is easily a 300-500 US$ job.
The only thing that I find has gone "for the worse" (though there are reasons for the change) is the timing belt.
Old engines had a timing chain instead that never broke in 120,000 km or more (in some rare cases it may have "jumped over" a tooth of the sprocket, going slightly out of sync) and even when it broke, the engine was built in such a way that the valves had no interference with the pistons, if the timing assembly broke the engine would simply stop working, and in any case you could "hear" that the timing chain was worn out by the typical "ticking".
New engines timing belts need (in some cases) to be changed much earlier, like 40,000 km or so, and the issue being that they break more easily and when they do they do it "suddenly", and since new engines are more compact and differently designed (for efficiency/low consumption), when a timing belt breaks it will inevitably bend some of the valves (if you are lucky) or break the engine head (if you are unlucky) in both cases you have before you a mechanic's bill of several hundreds or a few thousands dollars.
As well, a modern car very rarely leaves you in the middle of a trip (unlike old cars may have), but the difference is that in the old times in most cases any mechanic/pump station would have repaired it somehow with available pieces, whilst now - in the much more rare case of an issue - you typically need a replacement car because what has broken is a small piece (often electronics, like a sensor) that local spare parts warehouses (where they still exist) do not have in stock, and that needs to be ordered taking two working days to get delivered, and possibly the replacing needs to be carried on by an authorized dealer because a special software is needed to do the pairing with the new sensor.
Not at scale they don't
People get paid very good money to figure out how to get near equivalent results using wide open tolerances that any random supplier with run of the mill facilities could meet.
Certain parts might be spec'd to less than a thou. Nobody who wants to keep their job is going to spec out a tolerance on something that both wears over the life of the system and cannot easily be replaced to less than a thou. Ball bearing balls, sure. Crank journals, nope.
Thermal mechanical stuff is a big pain. One of my professors mentioned as a young engineer measuring expansion on exhaust manifolds by drawing faint scratches and microscope to measure how far they stretched as the manifold got hot. Important because localized thermally induced stress causes fatigue cracking.
http://blog.jepistons.com/maximizing-horsepower-with-piston-...
We attempted to model static stresses from mounting the cylinder head, thermal stresses, and mechanical stresses from mass forces, combustion forces and the like.
Our goal was to achieve low combustion gas blow-by, low oil ingress into the combustion chamber, yet low friction between piston and cylinder wall.
We used simulations (about three months worth IIRC) and measurements to generate data points for a continuous ersatz model of the physical phenomena, then performed multi-criteria optimisation on that model. The resulting shape was interesting, but not exactly earth-shattering. Kinda randomly warped.
This work was tremendous fun, and I learned a lot.
If anyone is interested (and can read German), it resulted in this dissertation: https://books.google.de/books/about/Tribo_System_Kolbengrupp...
Do you have a couple pictures of the piston handy?
Give me a few hours to dig up my old thesis. That was more than a decade ago!
I'll reply to your post again with an image link once I've found it.
I scanned a picture from the dead-tree version: https://imgur.com/vQLIQ1F
Top image is the cylinder shape without optimisation, bottom is the optimised shape.
Obviously, the contour distortion is massively exaggerated (ISTR a factor of 1000), otherwise it wouldn't have been visible; we're talking micron scale here.
Thanks very much for the follow up!
Plus, I'm curious if the economics work out at all anymore. Mechanic billed at $100/hour. How many hours does it take to rebuild anything to the piston level, versus the cost of a new (or used) replacement engine just dropped in place. I suspect they favor a replacement engine.
I do. Worked for my father and grandfather in my teens and early 20s. Water-we’ll drilling, so lots of gas and Diesel engines, as well as pump work, including high voltage AC and DC motors.
At the time, I thought it was “normal”. Little did I know.
I had to look that usage up:
‘Dope’
“information about a subject, especially if not generally known.”
I’ve personally never heard that phrase in that context. I also learned that it’s original meaning was thick soup. Fun book...
Interesting, I know the word from early aircraft where dope was used on the fabric skin to tighten and strengthen it. The dope used was a thick gloopy soup.
https://www.deseretnews.com/article/571007/Similarity-betwee...
http://blog.oxforddictionaries.com/2015/06/dope-etymology-hi...
http://www.etymonline.com/index.php?term=dopamine "1959, from DOPA, the amino acid (from first letter of elements of dioxyphenylalanine), + -amine."