October 25, 2009

Hello,

Thank you to those parents/guardians and students that came out to the parent/teacher interview.

Congratulations to last years seniors as they participated in their commencement ceremony. Special mention to Matt D. and James R., good luck in your future career plans.

I will be calling parents/guardians of at risk (marks below 60%) students, in the coming weeks. All parents/guardians are welcome to call or drop in. I am not in class between 12:30-1:30pm. I always stay in room #131 (trans. tech. shop) till 4:30pm.

Remember that all students must neatly print their full name and full date (10-25-09) on the line provided at the top of the supplied "Daily Note & Log" sheet. All students must copy the note from the blackboard in the top space provided. All students must take time at the end of every class to print their effort in the shop in the bottom space provided. All notes must be printed neatly, lots of details, step by step, and including tools/equipment used. Please, give facts regarding the safe use of equipment when used. I will only mark the supplied sheets when kept in order of date in a duo-tang.

In the shop:

• 1988 Ford Mustang GT (student); the brake system hydraulic master cylinder was reinstalled. All hydraulic brake steel lines were reinstalled to master cylinder. Master cylinder was bled of air, then front hydraulic brake calipers and rear hydraulic brake cylinders were bled of air. Vehicle was removed from shop.
• 2003 Saturn LW200 (customer); engine oil (10W30) and filter (cartridge) change. Also, check tire pressure (35psi); hydraulic brake fluid (OK); engine coolant (-45 F/C, clean, OK); power steering fluid (OK); battery (water/OK, clean/OK, install washer to positive battery cable to tighten); windshield washer fluid (add/OK); engine air filter (OK).
• 1999 Honda Accord (customer); check for reason of red brake light on dash and low and soft brake pedal. Brake system hydraulic fluid reservoir very low (reservoir cap has a 12 volt fluid level that lit red brake lamp on dash). Under vehicle inspection found leaking brake system hydraulic main steel line from front of vehicle to rear left/right wheel brakes. Removal of steel bolts and plastic brake and fuel line mount under vehicle. Fuel system steel feed/pressure line, return line, and vapour line also require replacement. I called two Honda dealerships for a quote, $2650.00 (including parts, labour, and taxes).
• 1999 Ford Windstar (donated); steering system hydraulic return and pressure power lines installed to power steering rack and pinion assembly; left and right front front wheel drive axle shafts installed into trans-axle; left and right steering knuckles installed onto lower ball joints, McPherson struts and FWD shafts (right front FWD shaft outer Center Velocity joint threads were damaged with a hammer and had to be disassembled, filed, and grind with hand file and electric angle grinder to repair threads and reinstalled), (lower ball joint bolts are missing and are temporarily held together with grade 5 bolts).
• 1989 Ford Aerostar (donated); removal of steering system power steering hydraulic pump (required cutting of hydraulic pressure and return lines); removal of plastic dash panel (use of pneumatic/air cut off wheel to remove rivets); removal of plastic trim at drivers door interior (use of pneumatic/air drill to remove trim screws); removal of left front steering knuckle (removal of castle nuts from upper and lower ball joints, separate ball joints from knuckle with use of hammer and ball joint pickle fork); cut off top mount of left front shock absorber (use of electric angle grinder); cut in half left front stabilizer link (use of electric angle grinder).
• Push lawn mower (donated); disassemble of engine shrouds, flywheel (sheer key was partially sheered, indicating mower blade hit something hard, indicating engine timing is partially out); removal of fuel tank and carburetor; components are individually washed with varsol, rinsed with hot water, dried with pneumatic/air blow gun.
• 1981 Ski Doo Citation (donated); front skis and suspension sand blasted.
• Pontiac Grandprix (donated); off limits due to broken back window glass.
• Saturn SL; removal of driver and front passenger air bags; removal and replace right rear and right front wheel/tire (use of vehicle jack and tire wrench).
• students continue to use pneumatic/air and electric tire machine, plasma cutter, gas torches. Grade 9 also use electric wood table saw, electric jig saw, and electric drywall gun/driver.

From the board:

• Safety: Lockout and Tagout
• Tools/Equipment: Plasma Cutter
• Theory: Service Brakes
• Safety: Ergonomics

October 18, 2009

Hello,

Friday, Interim report cards have been given to the grade 10, 11, and 12 students. I forgot the grade 9's during period 1, so, I had the office lunch time announcement explain that the students could pick up their report any time that day (only a few were picked up), sorry for any inconvenience. Parents/guardians please read your child's report and talk with them about it. I am available after school every day to discuss your concerns in person or by phone. I will be available during the parent teacher interviews this coming Wednesday.

Grade 9: you can pick up your Interim report from me on Monday. Please bring your completed form for "Take your child to work day".

SHSM: please bring your completed form, immediately.

In the shop:

• 1988 Ford Mustang GT (student): right and left engine exhaust headers are bolted in. Engine is lowered back into engine mounts. All components reinstalled on right side including throttle body, air intake system, and engine 12volt starter. The brake system hydraulic master cylinder had to be removed, this required the use of the pneumatic impact hammer on the housing while applying side pressure with a tire bar to free the cylinder from the brake system power vacuum booster due to excessive rust.
• 1999 Ford Windstar (donated): front exhaust pipes bolted in with new nuts. The mating exhaust flanges at the intermediate pipe has been wire wheeled to clean away all old gasket material and rust. One broken stud at this flange has been removed with the use of vise-grips and gas torch (could not remove second stud due to oxygen tank for torch is empty). The steering system power steering rack and pinion is bolted to engine cradle and the steering column is also bolted to rack. We are having difficulty installing the pressure and return hydraulic fluid hoses. The electrical connections are also different from the installed used automatic trans-axle to the vehicle wiring harness. We are changing the necessary sensors from the old removed trans-axle.
• 1989 Ford Aerostar (donated): the rear wheel drive axle/differential assembly has been disassembled, including drive pinion gear and matching ring gear (hypoid set), differential case, the side differential gears, the differential pinion (spider) gears, and bearings, shims, washers, and collapsible spacer. The steering column has been removed and the steering wheel has been removed from the column. The complete dash is being removed. The engine cooling system water pump is being removed, we are struggling with the clutch fan and one bolt holding the electrical system 12volt alternator.
• 2 vehicle engines: are in various states of dis-assembly/assembly. One engine is in the process of being timed (base timing), crankshaft to camshaft. The other engine has just removed the intake manifold. All components are washed in varsol, rinsed with hot water, dried with pneumatic blow gun, sand blasted, and painted.
• 1 small engine has been completed. One way clutch for recoil starter is no longer functional, but engine does rotate.
• 1 small engine is being started for dis-assembly. Cylinder head has been removed.
• 1997 Chevrolet 1500 P/U (McIntyre): I purchased 20 new chrome wheel lug nuts. We had to cut the parking brake system rear cables (seized) with electric angle grinder to allow the installation of brake system rear brake drums. Install all wheels and torque lug nuts to 100'lbs. All components removed from box, box was swept out, replace all components back into box. Push vehicle into unused tech. room for storage.
• 1981 Ski-Doo Citation (donated): remove chain case side cover, remove drive and driven gears with drive chain. Clean out chain case. Reinstall components and fill with oil. We require a service manual to diagnose the engine electrical system, no spark.
• 19?? John Deere Liquifire (student): student has lost interest, need to remove snowmobile from shop.
• 1961 John Deere 45 combine (mine): currently on hold.
• 1997 Chevrolet Lumina (donated): project on hold due to cold weather.
• 1988 Chevrolet Caprice (donated): students remove and replace wheel/tire. The front door panels are in the process of being removed. Cold weather is an issue.
• 1997 Pontiac Transport (donated): removal of front fog/driving lights from front bumper. Lights were hooked up to 12volt booster pack to make work. Student plans to install lights in the "General Lee".
• 199? Saturn SL1 (donated): THANK YOU!
• 199? Pontiac Grandprix (donated): THANK YOU!
• "General Lee": basic 2"x2" frame bolted together with 1/8" hard board front and back to hold shape using drywall screws. One side has been drawn out on 1/8" hard board. Overall size is 48" long, 30" wide, and 36" tall.
• Students continue to use gas torch to cut up vehicle door metal, good pieces of metal are kept for future metal projects, the scrap is taken away, in my trailer, to a salvage yard for cash.
• Students continue to use the shop pneumatic/electric tire machine.
• I am slowly preparing space in the shop for our new electric Snap-On wheel/tire balancer.

From the board:

• CO carbon monoxide: deadly in 3 minutes, headache and nausea first.
• Torque wrenches: 100'lbs. for most five wheel lug nuts. Remember, use the star pattern.
• The brake system: components ...
• ...

October 11, 2009

In the shop:

• 1988 Ford Mustang GT (student); students continue to install the new chrome full length exhaust headers; remove engine mount nuts, using 1/2" pneumatic impact wrench/gun and gas torches to heat one nut, and lift engine with tripod; remove engine 12volt electric starter; remove engine upper intake plenum; fit right header; install header with new exhaust gasket and fasteners. (Bear electric/hydraulic scissor vehicle lift)
• 199? Ford Windstar (donated); students continue to replace the automatic transmission/axle; used trans-axle bolted in (hydraulic transmission jack); torque converter bolted to engine flywheel; front engine exhaust pipes and catalytic converters removed (gas torches); engine and trans-axle sub-frame bolted to vehicle; engine mounts bolted to sub-frame. (Hydro Lift electric/hydraulic above ground two post vehicle lift)
• 199? Ford Aerostar (donated); students continue disassemble the vehicle; remove front windshield (wire windshield removal tool); removal of glass from front, side sliding, and rear gate doors; removal of glass from left side of van (shattered); removal of brake master cylinder, disassemble/reassemble on bench; begin to remove power vacuum brake booster; begin to remove steering column; begin to remove power steering pump (power steering pump pulley removal tool), trying to remove power steering high pressure hydraulic line from power steering rack and pinion (gas torch); begin to remove engine clutch cooling fan (plastic fan is badly cracked, cutting off with pneumatic cut off wheel; cannot remove clutch fan with clutch fan removal tool).
• 1985 Chevrolet Caprice (donated); students continue remove and replace and test individual components; R&R&T: horn, blower motor, wiper motor, battery, and wheel.
• 199? Chevrolet Lumina (donated); students continue to disassemble the entire vehicle; removal of right front McPherson strut, right front lower control arm, right front drive axle shaft with inner and outer center velocity (CV) joints; beginning to remove left front lower control arm (mounting bolts badly seized, cutting off with gas torch); removal of stereo, speakers, antenna, wiring, then set up on bench and hook up with 12volt booster pack; removal of all seats (hot wire drivers power seat with 12volt booster pack to move forward and back to reveal mounting bolts); disassemble of seats (separate all material from metal seat frame)
• small engine (donated); students continue to assemble components including crankshaft, piston with rings and connecting rod, cylinder head, engine case covers, carburetor with fuel tank.
• vehicle engine x2 (donated); students continue to remove, clean with varsol, rinse with hot water, dry with pneumatic blow gun, sandblast, and paint; reinstall components ...
• 1981 Ski-Doo Citation (donated); students continue to assess the future of this snowmobile; removal of front skis with suspension and steering; borrow a pull start from Mr. Lane a used pull start and check engine compression, 125psi in both cylinders, OK!
• 19?? John Deere Liquifier (student); students continue to remove, wash in varsol, rinse in hot water, blow dry with pneumatic blow gun, sandblast individual components; waiting for student to install 3 cylinder studs for right engine cylinder and install right cylinder and cylinder head...
• rear axle (donated); students continue to disassemble; removal of rear axle brake hydraulic lines; removal of rear drum brake hydraulic cylinders; disassemble and clean cylinder for rebuild; threaded lock pin broke, grind away differential case with electric angle grinder to remove lock pin and removal of differential cross shaft.
• Pablo's 1969 Dodge Charger (General Lee) costume; students continue to plan and construct the 2"x2" wood frame 30"x48" for his costume, deadline 10-30-2009.
• Bath tub (student); students continue to modify a used metal bath tub into a vehicle; removal of side (electric angle grinder and pneumatic cut off wheel); grind through enamel to allow for welding of snowmobile ski; students are thinking bob-sled; I recommended that the finished product should be presentable in a Dunnville parade.
• 2002 VW Jetta (customer); students perform vehicle inspection including all fluids, lights, wipers, tires.
• 1997 Chevrolet 1500 P/U (McIntyre); students remove, test, install sealed beam headlights.
• 1961 John Deere 45 combine (Peters); on hold.

I explain theory to students as they work on their tasks and when they ask questions.

From the board:

• we continue to discuss and take notes on our three main topics including safety, tools/equipment, and theory.
• in brief; push tools with an open hand, do not pull or you risk taking the tool in the mouth; types of screwdrivers and sockets/ratchets; tire sizes; specialist high skills major, SHSM.

October 4, 2009

First, farewell to our friend, colleague, and teacher. Mr. Jim Dickhout.

This past week in the shop:

• 1988 Ford Mustang GT; replace right rear 3/16Th double flare brake hydraulic line, bleed both front brake calipers and both rear brake cylinders; remove front exhaust pipes with catalytic converters and begin to remove front header style exhaust manifolds.
• Ford Windstar; removal of automatic trans-axle; removal of 2nd trans-axle from engine on floor (no vehicle); preparing to install 2nd trans-axle into vehicle.
• Ford Aerostar; removal of front plastic bumper cover; removal of glass from sliding side door; removal of entire vehicle electrical wiring harness is in progress.
• 1997 Chevrolet 1500 P/U (McIntyre drag truck); remove right front sealed beam headlight, test with 12 volt booster pack for high and low beam working, OK, reinstall.
• Ford 1/2 ton P/U; tighten battery positive cable at starter, OK.
• John Deere Liquifier snowmobile; pedestal wire-wheel 3 (one missing) engine cylinder studs
• 1981 Ski-Doo Citation snowmobile; clean belly pan of grime.
• 2001 Pontiac Sunfire; replace left front headlight bulb, left front marker bulb, and rear license plate light bulb; use scanner to clear computer code.
• 2001 Nissan; check computer code with scanner and clear.
• ...

From the black board:

• Safety: including disposal of waste fluids (engine oil, transmission/axle fluid, P/S fluid, brake fluid, anti-freeze ... plus the hazards and risks to the environment and drinking water. The danger of drinking anti-freeze!
• Tools & Equipment: Wrenches including combination, double box end, double spanner/open end, 6 point, 12 point, offset, line, speciality, ...
• Theory: how to properly check engine and transmission/trans-axle automatic/manual fluid

Friday (supply teacher; I was at the first aid/CPR re-certification class)

• DVD "The Worlds Fastest Indian"; students watched the 2nd half of the DVD and completed 5 multiple choice questions about the DVD.