One Thousand Ways to Make a Living; or, An Encyclopædia of Plans to Make Money

by Harold Morse Dunphy

Cylinders for engines, having been cast in the foundry, are rough-tested, the core sand removed, and the cylinders scaled. Some of this work is done sitting down and could very well be done by men who have received injuries to their legs. However, they should have the free use of both hands. Cylinders, after being scaled and cleaned, are sent to the machine department where they are machined and ground. This work is all machine-shop work.

After being ground, cylinders are inspected for trueness and general condition. The valves are then ground to the cylinders. This operation can be done by men who have the free use of one hand and of part of the other hand. Some of this work is done sitting down, so that a man need not have two good legs. Some of the valve grinding is often done in machines, in which case it is necessary that the operator watch a number of valves on the machine at one time. This operation would require a man who could move about freely in order to inspect the machine.

Pistons for the engine, having been machined and ground, are inspected as to sizes, dimensions, etc. This operation could well be done by a man with two good hands, but he must be able to stand at a bench and move about freely. The pistons are then fitted to the cylinders so as to get a proper fit in each cylinder. They are also carefully balanced in pairs and equal weights are selected as nearly as possible. The fitting of pistons to cylinders and the balancing of them could well be done by handicapped men. The piston pins also are fitted to the piston and to the connecting rod. This work is done standing at benches, and could be done by men who have the free use of both hands.

Piston rings which are made from castings in the machine shop, where they have been ground, are sent to the inspector who carefully inspects each ring. This work is light and is well suited to a man who could sit at a bench, but he must have the free use of both hands. Piston rings are fitted to cylinders and pistons in another department. This operation requires a little more skill than some of the others mentioned and a man must have some mechanical ability to learn to do the work efficiently. There are, however, many minor injuries which would not prevent a man from doing this work.

The manifolds, both inlet and exhaust are cast in the foundry department. They are then machined, where necessary, after which they are inspected. This department could employ disabled men for inspection work.

There are a number of bolts and screws and special fittings which must be carefully inspected before they can go to the assembly department. Every bolt must be looked over as to its general condition before it can be used. This work alone offers employment to a large number of men in every automobile engine factory. It is very light and a man in very delicate condition could efficiently perform a number of these operations. In a number of positions one hand is all that is necessary. Men could either sit or recline on the bench and do the work. In fact, men in bed even could come up to production in this particular kind of work.

The oil pump for the engine, having been machined in the various departments is assembled by men who sit at benches. This work is very light work and can be handled to advantage by men with handicaps. They should, however, have the use of both hands.

We have now mentioned the various units which go to make up an engine and have come to the point where it is necessary to assemble these various parts.

In the up-to-date automobile factory, the engine assembly is done by the progressive system. The conveyor system which is used in engine assembly is similar to that used in the chassis assembly, described in another section of this bulletin. The crank case is usually mounted upon this conveyor or movable stand. The crank shaft, having been assembled to the case in another department, is now ready for the connecting rods, and the rods with the pistons are attached. The cam shaft, tappets, and tappet guides are then installed, and the cylinders are mounted. The engine moves on to another section where the manifolds are attached to the cylinders. It then passes to a section where the carburetor is mounted. Next the ignition system is attached, and the starting and lighting and such other units as this particular engine may require are installed. All these operations have taken place while the engine has been moving. Special tools are used during these operations, such as air wrenches, socket wrenches, and any tool that may save a few seconds time.

The work that is done on this engine conveyor system is considered to be hard work in that each man must keep moving at top speed in order to turn out the required production in that department. The men are well paid and they must be qualified to take care of their particular section of this conveyor. There are a number of places, however, where handicapped men can be used in this work. Very few of these operations could be efficiently handled by a man who did not have the free use of both hands. He could, however, carry on some of this work, if he had received injuries to one of his legs. All of this work is inspected and a man is carefully checked as to the work he has done.