Progress Photos for January, 2003
Packer Eng. Replica Engine Progress
Back to Photo Gallery page.The following photos represent (P.E.) Packer Engineering's progress in fabricating the Wright Flyer Replica engine. They show some of the many processes and activities that Packer Engineering, their employees, interns and many associates have preformed over the past many months. The Wright Redux Crew is proud to be associated with such a skilled and talented group of professionals.
1. Patrick McCormick (College Intern) Steve Meyers (P.E.), Ian Kay (AFS), Joe Santner (AFS), John Nowicki (P.E), Dr. Ken Packer (P.E.) -- Meeting at American Foundry Society (AFS) regarding patterns for the flywheel and combustion chamber core box.
2. Joe Santner (AFS), Dr. Ken Packer (P.E.) John Nowicki (P.E) -- Verifying the flywheel and combustion chamber core box wood patterns with the drawings.
3. Going around the table starting at the top left: Jordan Hill (STEP), John Nowicki (P.E.), Mike Ulszewski (STEP), Patrick McCormick (College Intern), Kyioshi Martinez (STEP), Jamey Fenske (STEP) -- Meeting with the Students in Technology and Engineering at Packer (STEP) students and college interns decide what types and quantities of alloys were needed for the bronze, cast iron, and aluminum castings.
4. Tom Kuhn (P.E.) -- Tom is machining the valve seats at Packer Engineering.
5. Gary Hansen (P.E.) -- Gary is machining the magneto housing at Packer Engineering.
6. Val Skawinski from Packer Technologies International (PTI) -- Val is machining the ignition parts at Packer Technologies International, in Lombard, Illinois.
7. Dennis Collins (Intern Teacher at P.E.) -- Dennis is drilling out the exhaust baffles. P.E. supports a program called Professional Resources - Industry Science and Mathmatics (PRISM). This program assists teachers in finding summer jobs in Industry so they can take their Industry experiences and knowledge back into the classroom.
8. Gary Hansen (P.E.) and Tom Morrison (STEP) -- Gary is teaching Tom how to setup the machining equipment.
9. Packer Technologies International Lombard Facility -- 160 lb. steel plate for crankshaft
10. Jeff Ball (STEP) -- Jeff is shaping the crankshaft.
11. Packer Technologies International Lombard Facility -- Final machined crankshaft. The original plate weighed 160 lbs. The plate was drilled out, put in a shaper, run through a milling machine, finished on a lathe, put into a surface grinder and finally placed in a journal grinder (at Auto Machine in St. Charles, Illinois) which, all totaled, took approximately 300 hours of time. After all the cutting and grinding, the final crankshaft now weighs 22 lbs.
12. Patrick McCormick (college intern) -- Patrick, at AFS, is making a mold for the combustion chamber cast iron parts.
13. Matt Jacobs (AFS) -- Matt is cutting the gating into the combustion chamber mold.
14. Jamey Fenske (STEP), Matt Jacobs (AFS), Bogdan Perkowski (AFS) -- Matt and Bogdan are training Jamey on how to add the parting powder to the flywheel mold.
15. Catherine Korinek (STEP) -- Catherine is making a combustion chamber mold.
16. Kyioshi Martinez (STEP), Jamey Fenske (STEP) and Patrick McCormick (College Intern) -- Kyioshi is pounding the sand down into the combustion chamber flask.
17. Jamey Fenske (STEP) -- Jamey is removing the excess sand from the combustion chamber flask.
18. Matt Jacobs (AFS); Patrick McCormick (College Intern), Bogdan Perkowski (AFS) -- Patrick is sealing together the cope and drag halves of the molds while Matt and Bogdan observe.
19. American Foundry Society (AFS) -- Melting the cast iron metal in the furnace to pour the castings.
20. Matt Jacobs (AFS) Bogdan Perkowski (AFS) and Kyioshi Martinez (STEP) -- Bogdan is tilting the furnace to pour the molten metal into the ladle while Matt and Kyioshi hold in place.
21. Matt Jacobs (AFS) Bogdan Perkowski (AFS) -- Bogdan is tilting the furnace to pour the molten metal into the ladle while Matt and Kyioshi hold it in place.
22. Matt Jacobs (AFS) Bogdan Perkowski (AFS) and Kyioshi Martinez (STEP) -- Matt & Kyioshi pour the molten iron metal into the flywheel mold while Bogdan looks on.
23. American Foundry Society (AFS) -- Pouring the molten metal into the flywheel mold.
24. Matt Jacobs (AFS) and Kyioshi Martinez (STEP) -- Matt is trying to stop the metal from leaking out of the sides of the flywheel mold. While Kyioshi dumps off the slag from the pour.
25. John Kidd (P.E.) and Tina Kidwell (College Intern) -- John & Tina are taking the aluminum metal out of the gas fired furnace at Jim Packer's hobby foundry.
26. Tina Kidwell (College Intern) -- Tina and John pouring the aluminum metal into the mold for the main & cam shaft bearing caps.
27. Bill Crothers (College Intern), Jim Packer, John Nowicki, Jr. (College Intern) -- They are melting and testing the metal for the bronze connecting rod ends.
28. Ignition Parts -- Ignition parts made from mild steel at the Packer Technology International facility in Lombard, Illinois
29. Combustion Chamber -- Combustion chamber rough castings with gating still attached. It was poured at the American Foundry Society (AFS) in Des Plaines, Illinois.
30. Combustion Chamber -- Combustion chamber rough castings with the gating removed.
31. Flywheel - Flywheel rough casting poured at the American Foundry Society (AFS) in Des Plaines, Illinois.
32. Cylinder -- Engine cylinder being cut from a solid blank of cast iron round on a lathe. This took place at Wheatland Machine and Repair in Naperville, Illinois.
