Thank you Hartzell Welding for showing us how an airplane muffler is made! hartzellaerospacewelding.com/
@oldschoolcfi38332 ай бұрын
I liked this, no voice over, no music, just people working and showing what they do.
@777CaptMark2 ай бұрын
My non-pilot wife was very impressed with the precision with which everything was made and then tested and verified, with everything being recorded as to who did what steps and who did the preliminary and final inspections. All done in the interest of safety, with the goal of reducing risks to people and machines as much as possible. It went a long way towards explaining why aviation is so expensive. I consider this video an excellent PSA.
@excitedbox57052 ай бұрын
It is expensive due to all the inefficiency you see right here. Several steps are using inefficient processes, some parts are not optimized, some steps can be combined, some could be done in 1/4 the time using simple jigs or automation. It looks like they setup their process years ago and never optimized or changed a single step. You could cut the production cost of this part by at least 50% with simple fixes. -That guy spot welding those spacer pegs one by one on that tube could be fully automated for
@honeydewholt27682 ай бұрын
@excitedbox5705 -No clue how that could be automated because they probably have different-sized shells and different parts that need to use the same setup -The FAA regulations might require a certain time underwater in the test so it can't be sped up -As far as I know, spot welders can't do butt welds and that is what they are doing -Again they use it for quite a few different things as shown in the video And finally, you forget about the slight issue of validating the new process, however many test pieces are needed to do that, retraining/onboarding new people for the new process, and we almost certainly weren't shown the more confidential requirements that might not let them change how they do it
@jimmytclem2 ай бұрын
@@excitedbox5705 it was the laser-cuts starting in the baffle and not the slugs that did it for me.
@branchandfoundry560Ай бұрын
@@excitedbox5705 I work in both wood and metal fabrication. Yes, hand hammering each end into the sleeve I was wondering why they don't press it in. Walking the parts cart around feels like a time waster. Maybe there's something we're missing. But seems like I'd setup consecutive function stations in-line right next to each other with the test sink at the end of the line just outside the metrology room to eliminate cart pushing. *These are off the cuff ideas. I could watch a few more times to nail down further streamlining.
@dr_jaymz2 ай бұрын
Now appreciate spray cans, far tighter tollerances, perfect seams, gas tight to 5 bar, less than 1 defect in 10,000 cans. And they make 6000 an hour for less than 4c per can.
@Durandalski2 ай бұрын
Really puts the high cost of airplanes and their parts in perspective. That is a lot of skilled labor, probably well compensated for their work. I enjoyed this video a lot!
@IhPost2 ай бұрын
Very nice to see this young fellow welding. I had the impression nobody is interested in learning how to do that.. Chapeau 👍🏻
@johnpoteat97742 ай бұрын
That was some nice looking welds too.
@jakebrodskype2 ай бұрын
I am impressed. Here I thought there would be more stamped metal and custom metal brakes. This is far more custom than I ever thought.
@SkipGetelman2 ай бұрын
Hard to believe how much work goes into into making a muffler
@arkiskewl2 ай бұрын
@@SkipGetelman this is why aviation is expensive!
@matthewwoods21022 ай бұрын
Skilled American workers. Nice to see it still occurring. It’s slightly easier to comprehend the astronomical cost of aircraft parts.
@jvmiller19952 ай бұрын
Not really. It explains some just because of the checks and balances to ensure everything is up to par. But it was pretty typical tig welding. I don't know what that cost but I bet it is 3 times what it is worth. The certification that the inspectors put on it with the company's license is what adds the real dollars to it.
@LegacyIndustrial12 ай бұрын
Really put it in perspective
@donniev81812 ай бұрын
@jvmiller1995 what do you fly?
@jimmytclem2 ай бұрын
@@jvmiller1995 skill would end up with a final part that doesn't have cut-starts inside it (visible or not)
@patricksteadman18772 ай бұрын
One of the most relaxing feelings is when you aren’t aware of a crack after opening the heater. “Man, I’m tired, can’t wait to land this thing and take a nap.” True story
@Room_for_1_more_fruit_treeАй бұрын
Now that's a heck of a shop and heck of a weld crew. Thanks for showing. Would have loved to work a such a place before I started a business.
@onemantwohands5224Ай бұрын
Hey guys , long time sheety here , loved the quality control going on and can see the parts are nice fitting ! It’s everything in this trade the rest is easy ❤
@kimkeam20942 ай бұрын
The quality control of the process is amazing and with the procedures in place so repeatable. Aircraft standards at its best. Thanks for showing this!
@russlavalle2 ай бұрын
What a cool video! You came up with really interesting points of view for the camera.
@thomascharlton85452 ай бұрын
Good one Jimmy. Thanks!
@gingyberrie2 ай бұрын
this video should be about the hidden dangers of those nails
@edmoore39102 ай бұрын
Growup
@JSMZeez2 ай бұрын
I thought the exact same thing!
@TheEclecticOrder2 ай бұрын
You read my mind.
@losoj302 ай бұрын
No crap! Disgusting..
@rcaddict692 ай бұрын
Just imagine pickin yur nose with them there claws!!!
@golfbravowhiskey86692 ай бұрын
$23.99 for a 12" glass pack for mine in the experimental word. Been running them for 25years.
@NW.Modern8 күн бұрын
Nice work! If you're up for making more videos exactly like this on different parts, I would definitely watch.
@LarryTaylor-l5m2 ай бұрын
Beautiful craftsmanship. I see why they are expensive.
@beandrive2 ай бұрын
Making these one at a time is expensive. Try mass-producing them.
@oneninerniner34272 ай бұрын
Probably can't mass produce them for a certified airplane tho.
@b0rd3n2 ай бұрын
If they shut off the gas purge when they don't need it, it might help reducing costs. Argon shielding gas is not cheap. And if they also use a new pair of gloves every part... plus initial inspection of a rolled piece before welding kinda defeats the purpose, specially after cutting with plasma/laser.
@LarryTaylor-l5m2 ай бұрын
@@beandrive Mass production might not be possible being an FAA-PMA Approved part.
@honeydewholt27682 ай бұрын
@@LarryTaylor-l5m Full automation is probably impossible but having one person do the same step over and over again is almost certainly possible and probably what they actually do and they just had a few people show the process from start to finish.
@Nitrohog20062 ай бұрын
This was the best Jimmy's World video I think I've seen!
@qwasd0r2 ай бұрын
Jimmy, this stuff is so interesting. More videos like this!
@Starsnu12 ай бұрын
I am amazed at how much manual labor goes into making that muffler. What a quality piece of manufacturing! Way to go Hartzell!
@Sailingengineer742 ай бұрын
Nice TIG welding, the bell gasnozzle is great for this and other complicated welds in odd positions
@ColtonRMagby2 ай бұрын
That was satisfying to watch.
@GaryLaaks12 ай бұрын
Holy smokes. Impressed. Those nails man.
@fredbugden35112 ай бұрын
Keeps her from doing any real or serious work.
@7000fps2 ай бұрын
@@fredbugden3511 Yes , was thinking the same , up to that point FAA certified then green shovels _reject the part.
@jvmiller19952 ай бұрын
yeah, that was pretty ridiculous, to be honest. when she rips one off does she fill out an accident report?
@trytolookbusy2 ай бұрын
Love these videos! I more please!
@chriscook80762 ай бұрын
Very cool!
@tjjoseph3332 ай бұрын
10:49 The Sonar Ping! 🤣
@granazis12 ай бұрын
Your plasma cuts very clean 😂😂😂😂
@mainemarin67582 ай бұрын
Love the Cracker Jacks tucked in the box at the end
@guitars9292 ай бұрын
Pretty cool!
@frankmcelroy37922 ай бұрын
Great video - Skilled people in the USA!
@JustaPilot12 ай бұрын
A little aviation ASMR. I see now another reason they are so expensive. Mostly hand made.
@THE_BaconPirate2 ай бұрын
😮And hand made by Americans, likely getting paid a decent wage, with benefits. Something to consider when you vote.
@cupwalker24.72 ай бұрын
One of my very first jobs as a young buck in the hanger was Duck taping the exhaust outlets and pressurizing and spraying soapy water all over the exhaust to check for Cracks so it dosent enter the cabin and then inspect , remove , inspect again and repclace the carbon monoxide Detector 👍
@matthewehansen2 ай бұрын
Awesome video! Great camera work too!
@earthelder20652 ай бұрын
"Airplane Mufflers and How Much Fricki'n Work To Make a one" and then your airplane burns and vibrates the shite out of it and it falls off!
@floridaripper8172 ай бұрын
2:39 wonder what the lil log is for. Only thing I can think is to block the blow thru 🤔
@BFT882 ай бұрын
To catch the rings so they don’t fall through the grate
@floridaripper8172 ай бұрын
@@BFT88na dude throws them thru the grate after . Dont need a middle man
@oneninerniner34272 ай бұрын
Yes
@oneninerniner34272 ай бұрын
@@BFT88 no
@kr6dr2 ай бұрын
You’re correct. It blocks the molten metal from contaminating the inner surface of the tubing.
Nice welding helmet. The first with curved filters.
@CrackerFL2 ай бұрын
Oohh! I just wish i had an aviation radio to tell some pilots they NEED a FAR better muffler than they have!
@mickvonbornemann38242 ай бұрын
Checkout the mufflers on the Bristol Beaufighter or CAC Boomerang
@cgtbrad2 ай бұрын
Recently bought one for my Mooney. So expensive, but had to be done! As can be seen in this video, the workmanship is phenomenal. Thanks for sharing!
@afterhourshotrods68822 ай бұрын
I've been a AMT for 40+ years I've also worked for two Aircraft Mfg's. And I have no idea how they can work sooooooo Slooooowly. Everything in Aviation is about time/ speed while maintaining safety.
@puremaga172 ай бұрын
Muffler.. On a Airplane? Next thing you know there will be dogs and cats living together.. Anarchy! Thanks Jimmy!
@cgtbrad2 ай бұрын
Right?! 310's don't have or need mufflers!
@dr_jaymz2 ай бұрын
Yeah, it's not really a muffler is it? It's a pipe with a baffle that's why they are so unbelievably loud. In some countries they have to have silencers like Germany and it makes a huge difference and done right it can improve performance. These mufflers are not much more advanced than you'd get in the 1950s and a lot has changed since then.
@cosmodog48452 ай бұрын
Very interesting stuff!
@GNaranjoN2 ай бұрын
Where´s Jimmy? No Jimmy, no video! What could possibly go wrong?! That theres no Jimmy!
@hadleymanmusic2 ай бұрын
Hell I see 700$ labor in 6 minutes
@arkbluj2 ай бұрын
How about a followup video about when you took delivery of the 421 and flew it back to Florida
@klw141Ай бұрын
Aviation parts are soooo expensive because of processes like this. This has to be the most arcane process I have seen in a long time. Unless they are only building 3 or four a year, some automation is required for efficiency, repeatability and quality!
@LawrenceBroussard2 ай бұрын
I remember seeing candy made at a factory I think at the time was over fifty years old and was amazed. This is true craftman skill at work with modern tec that explains the cost of a new Airplane Muffler.
@alanm34382 ай бұрын
Love it. I used to work in a small steel fabrication shop as a laser operator. I sure wish that I was able to work. Thanks for the video!!!!
@TerryMulhall-k5t2 ай бұрын
Now I will sit down Jimmy when you tell me the price !
@jim51482 ай бұрын
Very cool, love the silence. What are all the threaded studs for?
@danielpantalion57862 ай бұрын
The studs are simply there for greater surface area to support heat dissipation. More studs = more heat in the cabin!
@kevinhall22662 ай бұрын
That’s impressive craftsmanship. Great to see skilled workers in America
@stefanstoltz64222 ай бұрын
Geeezzz. Check those nails. Awesome vid Jimmy
@jamesburns22322 ай бұрын
Hmmmm....... 🤔See if you can find a step in the process that is non-value added. 🙄😔
@7000fps2 ай бұрын
part reject !!
@bscott4332 ай бұрын
Nasty looking fake claws...
@NvTwist2 ай бұрын
Always wondered why planes were so loud… this video answered that question. When is a muffler not a muffler.
@mikeallen2662 ай бұрын
Vary interesting thanks Jimmy
@bertruttan1292 ай бұрын
Impressive!
@scottkellogg81452 ай бұрын
I didn't know air planes had exhaust well commercial I thought the air went through the turbines and out the back but small planes I can see them having exhaust
@shaneand42 ай бұрын
You guys have to take the AWS 17.2 for this? Probably the hardest welding test I ever took.
@jim58702 ай бұрын
I enjoyed that!
@doughudgens92752 ай бұрын
Good video Jimmy! Nice content while you’re helping hurricane relief.
@johnw33792 ай бұрын
I really enjoy these how it is made videos. Very good workmanship and qc. I would hate to see hiw much it costs.
@floridaripper8172 ай бұрын
Awsome 👍
@J1mbo8882 ай бұрын
Top Craftsman 🙂
@AZAce10642 ай бұрын
And then? Can you make a video of installation and the rest?
@burpengaryjosh56142 ай бұрын
5:57 is that supposed to be on the piss like that?
@andyhipp12702 ай бұрын
Bet those welders can weld aluminum foil back together!! That’s a lot of welding and micrometer measurements!
@brucegrunewald8423Ай бұрын
I was surprised by how manual the construction was. The production volume must be pretty low or more automation would make sense. So I suspect that another thing making aircraft parts so expensive is low volume. Now we need to see how automotive mufflers are made.
@flyweldfabricate2 ай бұрын
My hangar neighbour just sold acorn welding to hartzell
@rickolson-512 ай бұрын
They must also make Glasspacks because that's all hear from my local airport...
@BobWiersema2 ай бұрын
Is that stainless?
@ildarmingazov23042 ай бұрын
Lazer dance :)
@thomasward45052 ай бұрын
So it's a muffler and the Heat exchanger?
@marynewton-e3x2 ай бұрын
I am glad it’s parts day would anybody happen to know what MTU engine an X00E50701316 wiring harness fits?
@lenlabrie44872 ай бұрын
It must be new glove day for filming
@kevinsellsit55842 ай бұрын
I'm still confused by the studs and lack of any packing, but I did learn how to use a carbon rod to keep from burning through pipe. ;)
@jimrankin25832 ай бұрын
@@kevinsellsit5584 it’s a nearly muffler! Just the perforated diffuser cone for packing. The studs are probably there for heat transfer to air for the cabin heat accomplished by an external housing around this component.
@kevinsellsit55842 ай бұрын
@@jimrankin2583 Makes sense, good call. Basically a muffler/heat exchanger like VW exhaust only 200 X the price.
@channelview88542 ай бұрын
@@kevinsellsit5584 Are those studs solid? That looks like a LOT of unnecessary weight.
@kevinsellsit55842 ай бұрын
@@channelview8854 Without watching it again it looked like they were 1/4-20 studs (solid) to me.
@channelview88542 ай бұрын
@kevinsellsit5584 Thanks for answer. Looked more like 5/16 or 3/8 to me but it's difficult to judge from a video. I use a lot of all three sizes in the machine shop. I feel I should know but guess not.
@davids.6822 ай бұрын
So I have one observation that maybe someone could enlighten me on. A laser cutter needs to perforate a metal sheet to start a cut. This is usually done just a little outside the desired cut line on the scrap (slug) part. The holes in the inner cone part had the perforations in the finished part instead of the cut out slug. Did someone make a programming error? Why would this not be caught in Q.C.? If it is supposed to be in the finished part, why?
@honeydewholt27682 ай бұрын
the disks at 0:21 are welded to the top of the cone so they start outside the disk. the disks at 0:31 start inside the cutout part.
@FlyingNDriving2 ай бұрын
The best part, watching the guy actually weld a bead and you cut over that.....
@joelinnebur2 ай бұрын
Was this AWI in Minneapolis by chance?
@danmac29252 ай бұрын
Yes. Unfortunately in my experience their products don’t last very long and they don’t stand behind them.
@hoosiercrypto99552 ай бұрын
How are muffler bearings made 😋
@rogerroger77342 ай бұрын
Now I’ve got to order one……….i don’t own a plane nor will I ever unless the tide changes a little bit. I just want some dang cracker jacks.
@almace2229Ай бұрын
Using a height gauge on the weld????????
@gcrauwels9412 ай бұрын
Cool.
@howelljaynes12922 ай бұрын
How does this muffler "work." My best guess is that the perforated cone is the only part producing muffling.....and very little muffling at that. The "porcupine" outer surface of the muffler really functions as a heat exchanger? I assume this whole assembly fits into another larger cylinder that functions as the air plenum to produce cabin heat? My guess is that this thing functions more as a heat exchanger than it does as a muffler. (???)
@Altacat2 ай бұрын
.. .. ohhhh ... this is so neat .. a simple muffler is not so simple : ) ....love it !!! ...and have cut so many apart and off cars dirt bikes ect .. .. fascinating to see how they deaden the noise
@richmiller98442 ай бұрын
Defiantly a government project. Probably the bosses plane!
@clarencewiles9632 ай бұрын
Hands on experiences 😂
@justinknash2 ай бұрын
I thought aircraft aluminum could not be welded? Or is this not aluminum?
@jhaedtler2 ай бұрын
With all of the automation, Why are their prices so high???
@thomasward45052 ай бұрын
About 1200 for a custom carbon fiber and titanium exhaust system for a dirt bike. You have to tell us how much this thing cost
@jimmytclem2 ай бұрын
you'd think an aircraft parts manufacturer would know to start laser-cuts in the LOST material and not the KEPT material.
@awcvn2 ай бұрын
Now I know why airplane parts cost so much!!
@uncletom67582 ай бұрын
I prefer without... Hear me coming... 😊😂🍻
@swooshjjАй бұрын
i would be rich enough, i would buy such factory, just to play with those machines
@HendoAU2 ай бұрын
Should be illegal for that woman to have those nails in that work environment.
@RonRijswijk-v3v2 ай бұрын
You meant claws
@ildarmingazov23042 ай бұрын
Caliper love her ;-)
@blafoobar99972 ай бұрын
Why?
@Colaholiker2 ай бұрын
I don't want to tell if it should or shouldn't be. But I can only imagine how extremely inconvenient that is and wonder how she's able to do what she does. (And how one can put putting on a look that they think is good so much higher than ease of their work is way beyond me. My job involves a ton of typing, and my nails are always as short as possible, anything else is just annoying me to no end.) The fact that I totally don't like the looks of it is just down to my personal taste so I am not judging.
@SzentiD2 ай бұрын
He's just the quality control.
@sferg95822 ай бұрын
So what's up with all of those threaded studs? 🤔
@jimrankin25832 ай бұрын
It’s also the core of a heat exchanger for cabin heat
@danielszwabiuk35242 ай бұрын
@@jimrankin2583 Thank you! explains so much
@777CaptMark2 ай бұрын
@@danielszwabiuk3524 It also explains why they had to make darn sure there were no leaks in the muffler itself. Carbon dioxide is not your friend, especially inflight.
@DavZZee2 ай бұрын
Somehow I’m thinking that’s not how the mufflers on my Maule were made
@insighteins13172 ай бұрын
1:58 How pointless is THAT??? 5:12 That was more of a break than a cut :-) I see a LOT of old technology ... i´m somewhat surprized!