Comments by "Keit Hammleter" (@keithammleter3824) on "Discovering Skills " channel.

Expensive to trim with oxy-acet. They paint over a lot of rust - that's a bit slack. Bumper bar shown at the end already has a small dent in it.
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What the heck did they weld that small tool post on the side of the main tool post for? It achieves nothing that some spacers would do, and adds extra probability of chattering, which is what is happening. At 9:06, Allen key left in tool mount screw while running - dangerous.
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Before straightening it in a press, they heated it to destroy its strength. From that point on, it is ruined and the straightening quite pointless. It could be re-hardened, but I can't imagine that these little shops have the means to do that. The cylinder is of course a write-off. The way it was bent suggests that it was bent (probably nowhere near as much) before and was repaired the same way - and didn't last.
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@WhiteWolfeHU : You obviously are not a machinist. It is slow RPM that is more dangerous. At high drill RPM the inertia of the job makes grabs less dramatic, and at high RPM less torque is transferred. Whenever sheet metal is drilled with a drill bit of diameter such that each cutting edge can project above and below the job at the same time (as is the case here), you have a risk of the drill grabbing the job and tearing it out of your hand (and perhaps into the operator).
8
That's not a worm gear, it's a straight cut pinion.
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Ed, just about. And its not even a door - its just the outer skin. Imagine Ford or GM employing old guys to hand panel beat out the defects, as this mob does, when making 300,000 units per year - a typical run that's about 1200 per 8 hour day. Even the floor area required for the panel beaters would cost too much in real estate. It makes you strongly suspect that paying a contract production engineer to re-jig their process would dramatically improve productivity and quality, giving a positive cash flow within a few weeks, even at their very low volume. Someone should replace that squealing worn out drive belt.
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Yes, it's not a gear, it's a chain drive sprocket.
4
He shuts his eyes when the arc is occurring. A lot of Pakistani welders do that. Not very safe - splatter could land anywhere on his face. Sometimes he holds his other hand so as to shield his eyes from the arc. With no gloves, skin cancer may be the eventual result.
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@alitn588 Extra tool pot welded on at 1:03. Allen key left in place rattling around at 9:05. If it jumps out and gets in the work the work may be ruined. If you click on times shown in blue, YouTube will jump to those points in the video. In most of it you can hear the chattering (it's the singing noise caused by springyness in the tooling, and you can see the resulting roughness in the turned surface of the workpiece. In this application is doesn't matter much as the hobbing removes the chattered surface, but a competent macninist will not have chattering, by improving rigidity and/or changing rotation speed and/or resharpening the cutting tool.)
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There's often something odd about these Pakistani small shop videos. In this case, it's an old guy using giant tinsnips to cut straight lines in steel sheet. The place clearly has more complex machines - so why don't they have a guillotine? Even a simple hand operated guillotine would considerably improve productivity. Door skins are far below normal quality - just a single colour coat of paint on untreated mild steel - no rustproofing of any kind. Finished door skin shown at end has a clearly visible blemish.
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@nainitalism : Perhaps. But it's certain you do not understand it either. A basic guillotine is not in any way a Volvo or Merc - its a very common basic metalworking tool. I've since watched another video of the same small Pakistani shop, and a guillotine is shown in the background. Perhaps it was broken on the day this video was shot. Or, perhaps some of the workers are too dumb to use it. The economics in any case won't be much different to a Western country. In Pakistan wages are much lower, but materials and tools are also much lower in cost too, so the relative merits of manual labour versus limited automation still stack up. A door that rusts out within a year is going to frustrate a truck owner and cost him in downtime relatively just as much in Pakistan as in any other country. You are totally wrong in claiming the market can't afford original doors. Trucks are made locally in Pakistan by the Hinopak company - they need doors, for a start. Secondly, since Hinopak have been making trucks for 40 years, there must be a substantial market that can afford factory-new trucks. And if any are involved in an accident that ruins a door, at least many of their owners can surely afford a new one. Obviously there must also be a market for shoddy substandard products. That does not mean the products are not shoddy and substandard, nor does it mean that the buyers are not ripping themselves off.
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@richardmaurer9002 : It's the extreme degree of bending. If they hit an immovable rock with the bucket while using the machine with a good cylinder and rod in place, not a lot will happen. I've done it with a bulldozer and it just stopped the hydraulics dead with no damage done. Hydraulics don't move things fast enough to build up much kinetic energy. With an old machine with worn hydraulics you just MIGHT get seal failure / fluid blow-out. To get a massive bend like this, would need something heavy hitting the actual rod side on, as might happen if you are demolishing abuilding with a back-hoe - as (say) the operator crashed the bucket into a brick wall to collapse the wall and a heavy roof beam fell down over the rod - possible but not particularly likely. In use, all the load on hydraulic rods & cylinders is longitudinal - there is no side force to induce bending. So if it bent this bad when they hit a rock, a) it must have been already at least slightly bent, and b) it was weakened for some reason, as would be the case if they heated it as they did in this video.
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Most of these Pakistan small outfits use scrap metal. In this case, they probably got a truck load of steel sheet from a surplus dealer at a low price. Buying bigger sheets can cost more than the cost of welding. Also these sheets can be manhandled. Larger sheets would require mechanical handling and attention to work flow, as they are heavy and are subject to crumpling. Also a standard size sheet large enough for the entire roof area is rather too big and would result in a lot of scrap. I've done the same thing for the same reasons. Volume manufacturers needing steel sheet buy it as coils weighing 20 tonnes or more. I'm glad to see that their guy joining the two sheets doesn't do it any better that I do - and I only do this sort of thing on a semi-hobby basis.
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Gee, that design of battery charger goes back to the 1930's, except for the use of 1960's style stud rectifiers instead of selenium. Don't these guys know you can now buy potted silicon bridge rectifiers at much lower cost? It looks like they are cutting up regular passivated steel sheet to make the core laminations instead of using proper transformer-type silicon steel - as far as I know transformer steel is only supplied already punched into laminations, bonded into C-cores or toroids, or supplied in bulk in huge coils. Using regular steel would be a lot cheaper, but the energy efficiency will be low, due to considerable hysteresis and low permitted flux density. Efficiency will be lowered more due to burrs left during their guillotining, which will short the laminations. Normally, laminations are punched first and then passivated, which ensures good inter-lamination insulation. They are grouping the laminations instead of 1:1 interleaving, which is normally regarded as poor practice in the transformer industry, but given the above points, and that it is a high leakage reactance design (desirable in a simple battery charger) it may be a good thing.
3
Now I've seen just about everything bad. What a dopey time-wasting inaccurate way to mount the gear blanks for milling! If you can't make a mandrel of correct diameter for the job, shim the shaft you have with cooking foil or even paper. That takes only a minute or 2 and then the gear is accurately centred. Hear that hum during turning the blanks? That's tool chattering due to an incorrectly ground tool, and/or wrong speed, or possibly a ruined spindle bearing. It should be corrected immediately. The interesting thing is - the operator seems to know he's doing something wrong, but can't figure out what, or is just lazy and carries on anyway. The milling cutter is cutting on only some teeth - you can hear it. Not surprising if they "sharpen" them by freehand grinding, but it may be the mandrel is bent. You can see the blank rocking as the teeth are cut - not surprising given the way they treat their tools. The old man seems to have little to do with it, other than displaying the finished product and cleaning the swarf out of the job. Perhaps he's someone's grandfather who has been found a job.
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That rounded leg style is standard around the world for these types of 3-phase transformers used by power companies - has been since there have been power companies.
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@mechanicd7562 : Only if they found a really HUGE burned out transformer. A burned out ordinary size transformer would not need cutting up - the laminations are already cut. No, they are doing a shonky - cutting up ordinary passivated mild steel sheet meant for making boxes, cabinets, and the like. Its a lot cheaper and more readily available. It would be far more profitable to rewind a burned out transformer to suit its original application anyway.
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@mechanicd7562 : I assume you mean heat, not head. I don't think eddy currents will be a problem - the sheets look thin enough. But the magnetic properties of ordinary steel are not very good. Saturation will occur at lower turns per volt, and hysteresis will be much higher, forcing them to use more turns - which in turn mandates using a larger core and/or having more copper loss.
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@dougbaker9473 : First, I told you they are not complete doors, and second, what on earth makes you think it is rust proofing? Go back and watch it again - he loaded the paint gun out (8:59) of a tin clearly marked "High Gloss Enamel."
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@lorna blewett and lee : Landrovers are hardly a much of a standard of comparison as far as dents and other defects are concerned. They are notorious for arriving at dealers with defects. However, if you buy a new Landrover and it's got a dent in it, a complaint to the dealer and he'll have it fixed at no cost to you. I wonder if that will work with these Pakistani-made doors? I've never seen poor welds on a Landrover though - had a few as company vehicles. I went to pick up a brand new one from the dealer once. I refused to take it as it had about a 12 degree list. The factory had fitted wrong springs on one side!
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Who knows! These Pakistani small shop videos usually have names that don't match the content. It's a chain drive sprocket, must likely for some factory machine.
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This is quite a worry. Hino trucks are made in Pakistan by Hinopak Motors. There seems to be a number of these small shops making all sorts of stamped, forged, and cast parts, presumably supplied to Hinopak to assemble into vehicles. Some of these shops seem more dodgy than others. The firm depicted in this video is using new steel sheet and has a clean floor - a good sign. Most use scrap iron from all sorts of sources and have floors inches deep in dirt. If you buy a Hino truck, make sure it wasn't made in Pakistan.
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@charliebaileyandloganberry7557 : You must be joking. The Far East includes Japan and Taiwan. Taiwan quality is excellent. Japan quality in the 1950's was not so hot, but they were keen and keen to learn, and for decades their quality has been among the best in the world. A lot of what China does is junk, but they are learning too - their electrical goods are as good as anyone's. But not their vehicles, yet.
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@bebertdattagre9280 : That old nonsense argument has been regurgitated ever since the industrial revolution began in England 200 years ago. It's never turned out right. As for robots - robots have been used in car body production in western countries for over 40 years. What has been the result? As a fraction of yearly salaries, you get a lot more car, a far better car, for much less of your salary. Here in Australia, in 1965 average wage was about $2500 and a car cost $2000. Today average wage is about $120,000 and cars cost ~ $40,000. So we have a lot more money left over to buy a whole house full of consumer goods - stereos, breadmakers, microwave ovens, high definition TV's, etc - so while a lot less folk work in car factories now, vastly more people work making products nobody had heard of before robots. In another Pakistani video, they show the production of hand-made cement mixers. They posted the price - it happens to be approximately the same as an equivalent capacity cement mixer retail price here in Australia, even though wages here are huge compared to in Pakistan. That's why Australia is rich compared to Pakistan - automated production. Factory automation lowers prices - better affordability - money goes further - everyone benefits and employment remains. Back in teh 1970's people were predicting the coming availability of cheap computers and numerical controlled machines would either lead to drastically reduced work hours or widespread employment. Neither happened.
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He doesn't have think or remember dimensions on a CNC machine - push the start button and its fully automatic from there on. Give him a few years and he'll graduate to abusing an old manual lathe like the best of them.
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@mathewmolk2089 : The stop , which is a bit of scrap bolted to the drill table in the foreground, probably gives him some false confidence, but the only thing holding the job down is his hand. If the drill grabs, it may wind the job upwards and past the stop before he can react. He's got the drill running at about 300 RPM (5 turns per second), so he has about 1/10 of second to get his hand clear - possible but very risky. The only safe way to drill sheet metal, with drills of diameter larger than the job thickness, is to clamp the job down with dogs and keep your hands well clear - or use a sheet-metal type stepped drill bit, which are not readily available for holes this size.
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@mechanicd7562 : And me, most of the time ...
1
most Pakistani small factories have fans and concrete floors - but they never clean them or sweep them out.
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No point in painting individual parts - the welding will destroy the paint. Incidentally the red paint is just for appearance. In use it will soon wear off. The black paint on the inside may be rust convertor/preventative as certain types are black - but it might be just black paint.
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@alitn588 : That is quite unlikely. A lathe manufacturer would not make a lathe where the carriage traverse will not cover the full turning diameter - it would be like making a small lathe for the cost of a large one. In any case, at 8:12 the video shows them using a different tool post that certainly does reach outside the full work piece diameter. The only reason why anyone would weld a small toolpost on like that would be to use smaller tool sizes they have on hand without using spacers.
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@alitn588 : No. Early in the video you see that a standard 4-position 8-screw toolpost fitted (but with most of the screws missing). Later they change to a single sided toolpost. As for cutting in small work, use spacers or where required a boring bar - this will give better results.
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@Raul mechanics : Really? That's the same as saying it can't reach the turning diameter - do you really think the lathe manufacturer was that incompetent? In any case at 0:35 and 7:05 you can see the gap is quite narrow and the ways are with cm of the workpiece. At 7:05 you ca clearly see that the carriage can bring the tool post right to the chuck, as is always the case. No, that extra tool post was welded on because some dodgy operator was too darn lazy to get a few spacers to mount a small toolbit, or get or make a proper boring bar for inside turning.
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@rosewhite--- : You need to watch more of these videos. It seems the quality of these Pakistani small shops varies quite a bit. Some are using modern carbide inserts. Some have immaculate lathes, but some have junk. Some have the floor covered in a few cm of dirt, some don't. If they can afford lathes, they can afford tooling. Your point is thus invalid - their wages may be far below what we get in Western countries, but they pay a lot less for parts, materials, and tools too. The have low taxation, and make a surprising range of things locally. There is another video showing 1/2 inch square drive wrenches being made out of scrap metal. So what would cost me $30 probably costs a Pakistani $3. Or less. The problem that causes the workers in these places to do rough low quality work, and do bodgy things like in this video is 2 things:- 1) a culture of laziness is built in to them, and 2) they don't get to go to trade school or college - they are self taught or taught by father or uncle who was also self taught. Being illiterate or semi-illiterate, they don't get to read industry publications and journals and learn better ways like we do.
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@rosewhite--- It's not racist - I blamed their culture and lack of education, not the people. Lazyiness and lack of concern about safety is a cultural thing - we were just as bad 100 years ago. And there is a good reason why I live on about $12,500 per month. It has nothing to do with my race. It has everything to do with going to trade school and university, both of which are readily available in my country. Incidentally, a quick bit of googling shows that the average wage in Pakistan is $611/month, not $40-50/month. Perhaps you are the racist one - you are certainly not very well informed, and your opinion of them is much lower than mine. You'll find, if you look, that a dollar (or the rupee) has far more purchasing power in Pakistan, so the ratio in real terms is nothing like as great as 12500:611. Consider: Pakistan makes its own trucks (and all sorts of other gear) - Hinopak Motors is the largest manufacturer. If they only earned $50/month nobody could afford the trucks. The ownership of mobile phones is very widespread.
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@roundedges2 : Probably. I have no idea how, but I've seen enough of these Pakistani small shop videos to realise they'll tackle just about anything - probably involving much use of a hammer, oxy-acet cutting and welding, and much dodgy work on a lathe..
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@bebertdattagre9280 : Where did you get your figures from? I suspect you did not read your source properly. The average salary (2021 data) for Australian males is $120,943/year; for females it is $102,965. The average personal income is about $60,000 - this includes people on unemployment benefit (which is only ~$16,000/year - below the poverty line, and about what I spend on food), disability pensions, and default age pensions ($23,155/year). We have considerable numbers on the default age pension. I retired 15 years ago as a full time senior professional engineer due to age. My salary at that time was $150,000/year. I only work part time now as a consultant, and still, due to inflation, earn about $150,000/year. Many trades people earn quite a bit more as there is a shortage of trades people. I don't know much about France, but in Australia (population about 25 million), unemployment usually runs at, and still is, about 4 to 5%. There is however a significant underemployment problem - that is quite a few people are not working in jobs that their qualifications should lead to. Never the less, average salary here is still around $120,000/year as I said. We also lost our car manufacturing, due a combination of Chinese and Korean competition and government meddling, but it made hardly a blip on unemployment statistics - jobs in other industries were created. Note that I was quoting in Australian dollars. The US dollar is worth quite a bit more. You have confused two very different factors: a) automation/use of robots, and b) transfer of manufacturing to cheaper countries. Automation improves productivity and creates wealth and thus jobs. But transfer of manufacturing to lower cost countries is having a serious impact on western counties. This is in almost all cases not due to these cheaper countries using automation or robots, as western counties have been using automation & robots in major industries for decades. It is due to several other factors, e.g.:- # The USA have priced themselves out of business by over-the-top regulations about safety and pollution; # The low cost countries generally don't worry about safety; # We for example work an 8-hour day in Australia. In China they work a 12 hour day. # The low cost countries find ways to support industry, such as low tax special regions; # Countries such as the US, Australia, UK, sometimes inject subsidies when they detect a problem, then the them away again. The low cost countries generally decide on a policy and STICK to it.
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@oo0Spyder0oo : Your points on robots are completely valid. Re salaries of who you know, it depends on who you are and who you know. All my friends except one are professionals, and no professional would be on less than $150K/year. Most engineers would be well over. The one that isn't is a police sergeant - a sergeant's salary is about $101k/year, but he gets a lot of overtime and special allowances. But my wife was an office manager (typing/filing/admin) - allowing for inflation (she retired) she would get about $75K/year. My mother (long retired now) was a hotel counter lunch cook - they get $60K/year. All her friends in the hotel industry would be similar. Since my wife died, I acquired a girl friend who is a registered nurse with extensive experience and special endorsements. She gets $97K/year and works a 4-day week. Entry salary for RN's just qualified is $74K/year. My wife's chemo oncologist was in the paper recently - an announcement that she was appointed by a government hospital at $440k/year - and she sees private patients and thus gets additional income. She works darn hard though. School teachers are about the lowest paid folk with uni degrees. According to the South Aust Educ Department website, an experienced ordinary teacher only gets $106K/year. It's well known that low salaries is why schools have difficulty getting and keeping good teachers. All this data is before tax. I was buying some bread the other day from a local bread & cake shop. It's owned by a husband and wife, and they have 7 or 8 part time employees. I got talking to her and she moaned that her car broke down. I asked what her car was - it was BMW 5-series. The bread and cake business must pay well - I can't afford a BMW 5-series. A lot of professionals would be like me: One you get to a salary level of $150K/year, your daily living costs are covered and you have money left over to invest (the 3 basic types being shares, real estate, and interest paying schemes). So our actual income ends up being well over what our day-job salaries are.
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