Diary

Grading

-will be creating presentations on every section of the bike in detail

-participation during class

-workmanship while in the lab

Shop Class Chapter 4 p72-88

From the reading

-Disposition of humans in terms of how they work and respond to what they’re working on

-Certain types of humans are attracted to certain types of work

-Major discussion surrounded the conflict of whether to go to a prestigious school to learn classes you’re not very interested in and get a prestigious degree, or to go to a school where you can learn, specifically, what you love and have a passion for

-The irony is that the author got his Ph.D. from Chicago and hated his job.

New Key Ideas

Transaxle-The part in a car where the axle contains the differential

Spindle Carrier-The casing for needle bearings

Ball Bearings-Apparatus to allow proper movement of shafts and wheels-Contains an outer race, an inner race and a shaft that goes through the inner race.

Match Porting-Matching the openings of two separate parts (intake valve to the cylinder) without proper match porting, causes turbulence and compromises flow of the fuel system.

“Speed Costs Money”-Performance engines that are frankenstein engines of different companies’ parts and people who tweak engines are compromising the health of the engine. Engine designers have functions in mind for certain designs and parts and the use of different parts from other makes can ruin the engine and force the engine to fail.

Force equals mass times acceleration-By decreasing the mass in the flywheel, you can gain acceleration, however the engine won’t run as smoothly

“Heavy Clutch”-With a heavy clutch(tighter tension between the friction plates) can allow you to “ask a lot” from you engine. There won’t be as much slippage with high torque. However, in the case of engine failure, the real wheels can lock up.

Thursday Feb. 28th

Education of a Gearhead:

Major Motorcycle Ideas to Consider:

Matchpotrting-defined above

Galling on the cam lobed-wearing away of material from rubbing(happens with tighter springs on the valves, cause high friction on the cam lobes, can throw off timing)

Journal-Part of the shaft in contact with the bearings

Titanium Nitride-Coats the journal, or any part, to increase the hardness of the metal and improve performance. Can be applied to piston heads.

Stochastic Art-Surgeons and Mechanics (different from builders and designers) They improve and fix things. Builders and Designers build things from scratch for an intended purpose

Objectivity (How it is) vs. Subjectivity (How you imagine it is, how it should be) In terms of level of detail

We saw the example of drawing upside down-Artists are more likely to draw an image more properly upside down because it is more objective.

Measuring the spring constant-In Shop Class as Soulcraft, the author uses a bathroom scale and a vice to measure the springs. Springs that are too stiff will cause the the lobes to gall and parts to mushroom with the increased friction and pressure. Stiffer springs improve the engines efficiency when working at higher RPM.

Friction and Clutch Plates.

The use of larger clutch plates versus more plates. Larger plates increase surface area for more friction and so do more plates. (the triumph uses a basket clutch)

Plates rub against each other to produce friction. 4-8 foot pounds is good slip.

Progress reports from previous lab:

Frame & Wheel group- guest speaker Bill Becker gave advice on truing the bike’s wheels and demonstrated how to put in new spokes. Glenn showed this group how to use the C & C machine, and they observed him drawing parts and begin to make a tool they can later use.

Electrical group- this group began working with the old distributor from the bike and the new one Professor Littman ordered. They used a vice and a press mechanism to pound the center stem of the old distributor out of its housing because the original housing will be used with the new distributor. This group also learned about the centrifugal weights that have a 12 degree range of motion and spin, advancing the cam and causing the spark advance

Bottom End group- this group spent time in the lab cutting gaskets. They used the milling machine for drilling, which has a plane with a digital indicator that reads out X and Y coordinates to ensure accuracy.  Other members of this team printed out a picture to see if it would fit our bike. They reported needing to fix a curvature, and Glenn said it was a good place to start.

Transmission group- this group took the bike’s transmission apart and took inventory

Clutch- this group learned how to sandblast parts and how to use the parts sealer, which is crucial to closing the covers

Top End- this group cut valve seats and tested them at different angles. They did this by using blue alcohol-based pigment and spinning it in the valve to see if it matched all the way around. If it was not consistent, they cut more. This group also cleaned the valve seats. The tool for cutting the valve seats is a tool of rotation and cutting, like a lathe as it spins. Three rough stones are positioned around a head at a specific angle, this group used 46 degrees first, then 60.

Class discussion:

In class, Professor Littman reminded the class that there is always something to do in the shop, wether it be clean the tool chest, organize the workspace, look a presentations on Tiger Cubs from previous years, or learn how to use the software available to us in the shop.

The reading for today, Ch. 5 in Shop Class as Soul Craft, brought up further discussion regarding the philosophical and mechanical elements of motorcycles and mechanics.  One interesting point discussed in class was the different interpretations of the word “scholar”, specifically, if it means a highly educated person like the narrator, or if it applies more to the expert mechanic Frank in the reading. The class also discussed the difference between “liberal arts” and “servile arts” and what it means to feel free in your work.  In terms of mechanical discussion, we picked up references dealing with the “engine not bleeding”, meaning the hydraulic system in a car cannot be flushed out, potentially because of air bubbles. We also learned the author’s clever trick of finding oil leakage, which is to spray athletic foot spray on the area with the leak and the oil will show.

We began looking at the ratios of teeth on the sprocket for the primary chain (Engine and Clutch) and the drive chain (Gear Box and Rear Wheel). We will look at the equation in more depth later this week.

No reading assignment for Thursday 

Reading Assignment: Chapter 4 in Shop Class as Soulcraft

New Terminology

• Drive Chain: transfers mechanical power to the wheel
• Staked: when a tapered pin is whacked, deforming the metal to lock the nut in place
• Arbor Press: a machine used to apply pressure. Can be used to stake.
• Swing Arm: part of the suspension system, allowing the rear wheel to swing up
• Gasket: seals the cylinder together
• Motor-Generator: converts DC power-> mechanical -> DC Power
• AC vs DC: in DC, electrons flow from negative to positive. Batteries are DC. In AC, the current alternates. AC current can step-up or step-down in voltage with the help of transformer. This helps it travel over long distances. Different applications of DC and AC current, but generally DC is specialized
• Feed and Return Line: feeds and returns oil in and out
• Crank: two gears on transmission with a nut
• Cast-Iron: a metal that absorbs oil well

Recaps from 2/19 Lab

• Clutch: Removed everything from the engine casing. Used 1 1/2 inch wrench and a strap-wrench to remove a staked nut. Took out the drive sprocket and the gear from the transmission.
• Frame: Finished disassembly, removed sleeves holding ball bearings. *need to count the number of balls. Removed a pin from the swing arm. Washed parts in solvent WITHOUT GLOVES.
• Top-End: Removed 2nd valve spring from rockers. Used a telescoping rod to measure the inside of the cylinder. Going to have to sand-blast the inside.
• Electrical: Worked with circuit and rotor. Made an electrical diagram
• Bottom-End: Got all the components out. Cleaned parts with orange oil

Book Discussion

*means motorcycle reference

Zen and the Art of Motorcycle Maintence

• Did an experiment with a ping-pong rocket. Showed how fuel and air can create high pressure for an explosion. Ball acted as a piston in this case
• *Porcelain insulated on the spark plug. Carbonized. This was because of high altitude led to less Oxygen and too much fuel (fuel rich). Need to readjust
• *Connecting rod fit to the crankshaft needs to be precise other wise the force of the explosion will break the rods
• The idea of steel being seen as shapeless by those who do steel work. It can be any shape when you are skilled, and any shape besides the one you want when you are unskilled
• Inductive vs Deductive reasoning. Inductive is “bottom-up,” inferring general propositions from specific examples. Deductive is “top-down,” where specific examples are derived from general propositions. Mechanics must use both
• The Scientific Method: seems tedious and self-evident, but the caution is so that you do not make a mistake. Nature will make a fool out of you. The real work isn’t physical but learning the ask the right questions
• *when removing plug, lay against engine to ground it. Start lever and see if there are blue sparks. Will let you know if there is or isn’t an electrical failure.

• Fork: Connects motorcycle front wheel to frame. Part of suspension mechanism. Sort of like a front “shock absorber”
• Gator: Rubber part
• Stanchion: long, stainless-steel tubes (approx <1m) with brass slide movers
• Suspension: allows wheel to bounce up on uneven ground, but pushes wheel back ground. Makes rider comfortable.
• Keepers: A washers that pushes against the springs
• Rotor: 6-pole magnet that spins around the stator (series of metal coils) to produce a current
• “Spark advanced:” when the spark fires before the piston gets to the top. Reverses direction of crank shaft and leads to kickback. The opposite of this is when the spark is too retarded. Then there is too little power and too much exhaust.
• Trail: Distance between point of contact of the road and wheel and the the point of rotation (defined by the handlebars)

Recaps from 2/14 Lab

• Frame: Removed forks, gator, after spraying with Yield. Gator might need replacing. Stanchion was wobbly. Suspension was very greasy. Brake drums probably will be replaced because of asbestos
• Clutch: Had trouble removing frozen bolt that was stuck in engine casing. Prof. Littman had to grind down head of bolt to remove
• Top-End: Removed rocker arms, rods were caked in paint. Removed valve and one spring using Glenn’s special aluminum tool.
• Bottom-End: Removed cam and transmission. John explained mechanism of transmission and why Neutral is above 1st gear. Glenn made a new screw with his chisel
• Electrical: Measured frequency and voltage of rotor. Graph was perfectly linear.

Book Discussion:

* means Motorcycle Reference

Shop Class as Soulcraft

• Do we have control over own technology? There exist layers of bureaucracy between us and the machine. Companies have a vested interest in your technology working to give us free time and convenience. Does this truly grant us freedom?
• What are the “opportunity costs” of fixing something yourself? Is there something else intangible gained by giving up your time to learn how something works? Discussed Crawford’s view of economists as possibly dismissive.
• Passive User vs Skilled Use: examples of steroe vs guitar, hand pump oil on old motorcycles, Betty Crocker cake mix
• *Motorcycles shifted from cast-iron pistons to alumnium because engine speed is related to mass. Metal with less mass -> more efficient engine. Our bike has an aluminum piston.
• *Model-T Engine demonstration. Able to see series of alternating intake and exhaust valves. Engine is “square,” up and down movement is equally to the size of the diameter. Plugs fire in order of 1,2,4,3. Made with high school labor. It was super cool.

Zen and the Art of Motorcycle Maintenance

• *Hot and dry chains: need lubricant, because chain can break as it rubs on sprocket due to frictional heat and erosion. When accelerating, front side of sprockets get worn. When decelerating, back side of sprockets get worn.
• *Exhaust pipe gets blue, because chrome turns blue when heated.
• *Pistons, wheels, and gears all move at once (84).
• Further exploration of the analytic knife, examples of sand and dividing it by properties
• Analysis -> Loosening; Synthesis -> putting together
• Difference between precision and accuracy. Precision: cutting or marking into many divisions (“cision” means to cut). Accuracy: correctness or closest to outside standard (“curacy” meaning correctness).
• Plot Updates: better understanding of Phaedrus as the former personality of Narrator’s body. Removed via electric shock.
• Philosophy: Buddha and Twain. Something is lost when examining something from an analytic point of view, but something else is gained too. Twain may have felt he lost the beauty of the Mississippi when he learned how to pilot it, but another beauty of understanding is also gained. Buddha “exists within analytic thought, and gives that analytic thought its direction” (81).

DZ

• Reading Assignment: Chapters 5-6 in Zen and the Art of Motorcycle Maintenance; Chapter 2 in Shop Class as Soulcraft
• Book Notes:

Soulcraft Chapter 1:

= manual trades (ie. “vocational ed”)  are no longer emphasized in today’s schools

= in college many students don’t learn anything of particular application

= used to emphasize phronesis (translated “practical wisdom”); recent transition to promoting sophia, or wisdom in “eternal objects” (ie. math, science)

=interviewers look for complacence and personality, not grades or specific skillset

= author argues that being able to react to situations as they arise is more valuable than general knowledge (ie. surgeons cannot be replaced, but x-ray technicians can)

= draws disctinction between “personal” and “impersonal” or rules-based services; the latter is much more offshorable than the former

Zen Chapters 3 & 4:

= narrator recognizes town/motel during storm; “phaedrus” had been there before

= narrator tells unconventional “ghost story” about man-made concepts like gravity (even sane people believe in these “ghosts”)

=the four continue on their journey; the narrator provides a list of all his gear

NEW TERMINOLOGY:

• Speedometer — guage which measures speed of rear wheel (in mph/kmh)
• Tachometer — guage which measures speed of the crank/flywheel (in rpm)
• Open-end adjustable wrench (has a thumb roller to adjust the size of the opening)
• Machinist’s hammer (one flat end, one hemispherical end)
• Tire iron (for prying the tire off of the wheel hub)
• Impact driver (converts axial to rotational motion
• Feeler guage (for measuring gap width)
• Cotter pin (flexible piece of metal; ends bend out to hold in place)
• Duplex chain (twice the width of a normal chain for added support) –used for primary chain

What we did in lab:

• Dismantled engine head and clutch assembly (Top End, Bottom End, Clutch)
• Removed rear suspension, examined swing arm (Frame/Wheels)
• Created and tested mock electrical system (Electrical)

• Reading Assignment– read Chapters 3 and 4 in Zen and the Art and Chapter 1 in Soulcraft
• Group Assignments–
  Top End- KN, KM, FS, PK
  Bottom End- BC, GE, AW
  Clutch- DT, AH, DZ
  Electrical- MS, SY
  Frame, Forks, and Wheel- NB, HL, OF, JZ
• Book Notes
  Soulcraft Intro = promotes manual trade as more fulfilling than “knowledge” trade and notes a dire need for needed better manual trade in the U.S.
  = disagrees with oversimplification of technology to the point that we don’t
  know how to interact with our own machines, i.e. mercedes with no
  dipstick

  Zen and Art (Intro, Ch. 1 and 2) = first person narration, can’t always trust narrator
  = instead of asking “what’s new?” asks “what’s best”?” which sets up whole
  philosophy of the book
  = introduces John and Silvia’s hatred of technology and their effort to
  escape it
  = choke– richens fuel mixture by restricting air to carburetor
  = flooded engine– too much fuel to ignite (take spark plugs out to dry)
  = points– the place where current breaks, which raises the voltage and
  makes the plug spark
  = 4 stroke engine– piston goes up and down twice every explosion
  = engine seizure– pistons heat up too much, become too big for the
  cylinder and get stuck in barrel (can even melt to it)
  = missing– necessary explosion not occurring in engine so no power on
  that stroke
  = backfire– fuel not completely burned in engine so explodes in muffler
  = tappet– clacking when engine timing is off
  = “wide open”– throttle fully twisted to open throat fully to allow the
  maximum amount of air into the carburetor