Anybody want some high performance aftermarket pistons?

[nova_robotics]

It's an interesting video of how they make them, but good God.

[Toolmaker51]

I was convinced, despite rough setting, doing well and efficient (though labor intensive) job. Until the lathe chuck and hack saw cutting off sprues, turning in a 3 jaw instead some manner of fixture, until scattered die castings went in with used pistons (and of course the usual sandals and flannel pajama pants) a modern thriving enterprise! Cough, cough. It's hard not being judgemental holding other circumstances up to the wrong environment.
Watching is an eye opener. Motorcycle side covers are not equivalent aluminum to what makes pistons. The perma-mold and cores used were not all that crude, no one sitting around, and the volume says they're selling.

[nova_robotics]

I was convinced, despite rough setting, doing well and efficient (though labor intensive) job. Until the lathe chuck and hack saw cutting off sprues, turning in a 3 jaw instead some manner of fixture, until scattered die castings went in with used pistons (and of course the usual sandals and flannel pajama pants) a modern thriving enterprise! Cough, cough. It's hard not being judgemental holding other circumstances up to the wrong environment.
Watching is an eye opener. Motorcycle side covers are not equivalent aluminum to what makes pistons. The perma-mold and cores used were not all that crude, no one sitting around, and the volume says they're selling.

That drill press was just painful to watch. I didn't like cutting the grooves for the rings either. But my main complaint is machining out the bores for the wrist pin. There was absolutely no attempt to make the wrist pin bores square to the piston.

[Toolmaker51]

That drill press was just painful to watch. I didn't like cutting the grooves for the rings either. But my main complaint is machining out the bores for the wrist pin. There was absolutely no attempt to make the wrist pin bores square to the piston.

The engine compensates for the off-position of wrist-pin, the connecting rods [of equally poor quality] adjust by bending.

Can't help but watch, envisioning how to boost output and quality with proper fixtures, via exact equipment in use.

[IntheGroove]

This is why I use forged pistons...

[mansworld]

Eyeballing the ring grooves!

[Toolmaker51]

Eyeballing the ring grooves!

Definitely, not following the science. As a classroom, high school drafting class, visited Venolia Pistons in Long Beach, CA. Looking back, on a quite non high-tech environment, they were meticulous about locations/ size for wrist pin and ring grooves.

[Jon]

How it was done eighty years ago.

Aluminum casting. A woman’s place in this large Midwest aluminum factory is on the inspection line. She’s giving a final checkup on these aluminum pistons which are destined for use by America's armed forces. Destination of the finished aluminum products is kept secret. They’ll probably end up as jeep or airplane engine parts. Aluminum Industries Inc., Cincinnati.

Fullsize image: https://s3-us-west-1.amazonaws.com/h...n_fullsize.jpg

[IntheGroove]

I wonder how many of those pistons still go up and down...

[Toolmaker51]

Anyone notice what isn't in the photo, in concert with non-disclosure what they're for?

Have an inkling the piston domes had some revolutionary contours.