We build the KING’s Rolls Royce and it all goes HORRIBLY WRONG!

Well guys, a lot of you have asked about the things that have gone wrong in the workshop in all the days Iv been building engines so I open up and admit some of the horrors that have happened to me. One of which was the Kings Rolls Royse engine

[@Justsaying12347]

Said it before but " experience is something you get just after you needed it"

[@Ben-Dixey]

Like to see Johns sledge hammer grinding method.

[@Ben-Dixey]

So glad Issac is back on the camera, More videos like this please.

[@0783155]

My worst "mistake" cost 37 million. In my second week I changed a parameter in the system that controlled the assembly line of a engine production plant. After working hours we needed to reboot the computer. It never booted up and my colleagues never made a backup. Before we were up and running again we were two days later. We had car factories in Brazil, USA, UK, Morocco and Netherlands stopped because of this. We never skipped another backup.

[@robertmiddleton5663]

holly cow

[@johnabbatt2150]

One thing I always had to teach the apprentices - the difference between a vernier caliper and a digital caliper, you used the latter.

[@ambydaly5713]

One I particularly remember was machining an aluminium casting for Rolls Royce marine division. When you machine a cross bore you had to clock a right angle adjacent bore with a mandrel. Of course for got to remove mandrel and ended up all on the floor after a rapid cnc feed through the cross bores. It had happened to previous operators as the whole machine shop erupted but helped to restore setup and stopped me going home and nearly needing change of pants.

[@henktulp4400]

One nice blooper I recall…. My new chef (I never got on with him… so I left to work elsewhere) in this DAF workshop where I worked back in the ‘80s… He decided to replace a clutch assy late at night, so the truck’ld be ready in the morning…. Flatbed truck on the ramp…… 10PM….. the clutch is replaced,just need to tighten-up the propshaft… While tightening the propshaft’s bolts the truck reverses inch by inch backwards….. until the rear wheels go over the edge… The chassis was bent…. the wooden floor’s planks were broken and sticking up…. the (almost well tightened…..) propshaft was smashed on the ramp’s rear crossmember…. bending it in half and pulling the gearbox’s rear bearing through it’s casing in the process…. Aaaah yeah….. the fueltank was split too and dropped hundreds of litres of Diesel….. The call this nitwit had to make was not one anybody would like to make…(hihihihi) I got this update from a colleage* of mine just weeks after I left this place BECAUSE of this new chef, and to this day it fills me with joy….. *and we are stil good friends after over more than 4 decades we were working in this place… he left not long after me…

[@milesgoff7261]

The 'clean room' dint last very long... Someone left an old car and some scaggy engine bits in it... 😂

[@madeljacky]

I thought it was only me that used a Vernier to scribe lines where to machine to, obviously not as I can see, if it works it works, another entertaining and enlightening video lee

[@Ben-Dixey]

Its just a bit abusive of the calliper, wearing the precision ground edge down, when you need to measure something using just the very edge of the calliper you can't because it's no longer accurate. If you want to mark length then use a height gauge on a surface table. It's a similar thing to using a micrometer as a G clamp. But hey if it works it works right ?

[@edwatts9890]

Profit first, production second, safety third!

[@andyday4535]

The man who never made a mistake never made anything!

[@Nicknofish]

Ear defenders, boys, please. I suffer with horrendous tinnitus. Sends ya nuts, and there ain't no cure. Take it seriously, plug those ears. 😢

[@ouroborosirvington]

Hold your nose and blow out through your ears till they pop, then do a hand stand for 3 minutes. Works every time.

[@henktulp4400]

You are absolutely right… One thing probably unknown to many is that deafness is caused by ‘noiselevel’x’exposure time’!!! A sudden ‘bang’ can be harmful… but hours of exposure to ‘normal’ noiselevels much more so!!

[@adamyearsley1204]

@55yrs I 100% regret my earlier lack of discipline in that regard…

[@tabsqc]

He’s right or you will suffer later!

[@R6AAO]

I had it for about 3 weeks not so long ago. It nearly drove me to a tinfoil hat. Woke up one day and it wasn't there anymore. Probably a brain tumour but only time will tell.

[@dennissheridan1550]

Lee, I would bore the eugenia (sp) before cutting the rod reliefs, the interrupted cut will play hell with the bar if you do it the other way round. 😉👍

[@henktulp4400]

5:11 HaaaHaHaaa…. John:”ooops,camera!!!”

[@2strokesteve]

I used to use one of those surface grinders, it should have a spring around the shaft of the diamond dresser so when you are pushing it down and turn it anticlockwise it dresses the stones and when you turn it all the way back it springs back up out of harms way 😉

[@Ben-Dixey]

Makes sense, Barum aren't the type of company to fix things that are broken, even if it caused a major problem. Did you use a sledge hammer to adjust the griding head ?

[@2strokesteve]

Definitely not considering the machine was accurate to 0.0004 "​@@Ben-Dixey

[@Ben-Dixey]

@@2strokesteve Thought not, don't think this one is accurate to 4/10ths of a thou anymore.

[@donaldhalls2189]

If it's going to cost £8000 to rebuild the engine, and you can get a rebuilt engine for £6000, you could probably only use those engines as core returns, mistakes happen as long as people aren't hurt mainly, thanks for sharing, all the best to yous and your loved ones

[@frogandspanner]

A wonderful tale.

[@barbaraneville5036]

Worst cockup .Setting a Z height an inch lower than it should have been on a CNC machine which held two workpieces at a time taking an inch of material off the internals of an two Airbus wing Spars Luckily realised in time to stop before it became catastrophic Reported it to the night supervisor straight away Inspection and quality control came around while the machine was stopped to allow the engineering department to do a head swing round to see if I had moved the cutting heads Inspection assesed the damaged spars and decided it was OK to continue and they raised a concession on the two Spars & thankfully they were OK to be used . Saw them about three weeks later have a manual rework to blend the lower spots into a proper radiused area . I got a right telling off After that I was very careful to double check the Z height before pressing the green for go button

[@scotty6346]

I've noticed Lee and Isaac having little digs at John on a few of their video's?

[@aaronkent2940]

On the subject of things going wrong I did a Renault Laguna cam belt. Of course no key way on the crank I turned it over by the key not quite tighting it up enough just to try it and it fired up and touched all 16 valve and slightly bending them all so took the head off hammer them all back in straight black straight and cut the seats and laped them back in and it went on to do 350,000 miles without dropping a valve 🙈😳🤣 So I learnt from that mistake😂

[@JapsDmz]

That king knows now tho .....😂

[@samrodian919]

So the moral of this story Isaac is that you have to push things FULLY into the correct hole! Wonder what Lee's missus thinks of his "Cock ups" ?

[@richardhartley7094]

You learn from mistakes and it stays with you 👍

[@julianpritchard2558]

Just for the record! I dropped a nine inch grinder many years ago, caught it by the still spinning disc! Now that hurt 😢🤬😵😵

[@TheMadManPlace]

When I was an apprentice back in the 70's we had that damn stone dresser retaining pin fall out on us twice IN ONE WEEK... Solution : Drilled the hole all the way through, made up a new pin that went all the way through and on the other side drilled the pin to take a clip similar to those that you find on the bonnet retaining pins on most racing cars. Over the years that modification must have saved MANY apprentices a lot of "red carpet time" in front of the bosses and the company a lot of money. Back then it was ONLY apprentices that worked on the skimming machine (and the boring bar) because cast iron is a vile and messy thing to deal with when it comes to the fine dust it produces. Remember that back then we DID NOT HAVE FANCY RUBBER GLOVES to protect the hands. One of the guys got hold of some medical gloves but in the workshop environment they only lasted a couple of minutes and they were shredded - doctors are lucky that the human body does not have sharp stuff in it OR corrosive fluids.

[@yarrdayarrdayarrda]

Had a 7.4L IHC diesel head on the milling machine, same situation where I set it up to make a cut then went to the other side of the shop. (machine had an auto stop on the table) All of a sudden I hear this horrible noise and upon rushing back the table has lifted and cut about a quarter inch groove in the deck of the head. (head was scrap after that) It turns out one of the screws holding the table feed (toothed) bar had vibrated out and when it hit it just rode up on the body of the mill. (table was quite heavy and just floated on ways) Ooops!!!

[@T3-RIDER]

Royce* 😂

[@maxpacker5288]

a chrome plater i know left an old essex radiator in the acid bath by mistake next day there was nothing left it cost a fortune to replace

[@295walk]

Me dad leant me his Cavalier when i was 17 . Loved that car, It went well for a 1.6 . 90 in 3rd. Mum dad sis went on holiday funnily enough to Bideford . They got half way 😊 . Knocking its tits off at junction 28 on the M5 . The machine incident sounds absolutely horrendous your very lucky

[@normangaylor5959]

Is your mike off, Lee?

[@stewills9711]

Hmm Pretty sure its Rolls Royce :)

[@damianbutterworth2434]

At work someone set up a machine to drill huge crankshafts. He got the hole depth the wrong way round. Shank and collar. The inspector pasted it off. The machine ran for 2 shifts before someone spotted the mistake. 200 scrap crankshafts. :)

[@colinscutt5104]

DOH!!

[@damianbutterworth2434]

@@stevekelly5166 passed it off then if your from down South. Any more lip and I`ll block the Potato lorries. :) :)

[@damianbutterworth2434]

@@stevekelly5166 your insulting someone vastly more intelligent than you. Can you at least program in many computer codes??? kzbin.info/www/bejne/a5ndhZufpJmhnqs

[@richardhartley7094]

👍👍

[@MegaReddevil71]

He who.has never made a mistake has never lived that's what my dad.used to.say to me

[@James_Rivett]

Fred Dibnah used to say "those people who never make any mistakes, never made anything". I am very cruel to myself when I make a c**k up, its one the few times I will use 4 letter words, that a bit more rude than twit or fool lol. Unfortunately with steam engines, a lot of things are one off, so like your Rolls block, it has to be repaired.

[@a310man]

Do be careful with your video titles. Cosworth Disaster, Rolls Royce Rebuild Goes Horribly Wrong, Taken to Court etc. The impression is not a good one for Barum Engines. Just a thought - concentrate rather more on the positive. Honesty is good, but stating disasters is not positive.

[@RaggyAl1971]

Yet another click bait title😠

[@EricaMTB]

You'd already done a deal, that's why they were in your shop. Terrible look for your business reneging on the deal.

[@billybgamer5205]

When I worked in engineering as a youth, a workmate told me a story of an old guy who was putting a finish cut on a 6' plus diameter shaft bearing surface. He was watching it so closely his tie (yes it was that long ago) got caught in the lead screw of the lathe and was pulling his face closer and closer to the job as it progressed. Somebody saw it and hit the emergency stop button. The machinist went apeshit! He'd been turning that job for days and as I say it was a finish cut on a bearing surface so it had to be as accurate as he could make it and he was sure the cut would have finished before his face got pulled into the job.

[@henktulp4400]

Well that is commitment of a level rarely seen nowadays…..

[@mfree80286]

Could have handed the guy a pair of scissors.... :)

[@andrewbaron8713]

I was made team leader on the Trent 500 fan blade rework program. All blades had to be reworked prior to going into service. The certification aircraft blades needed extra inspection and I was told they would arrive with different paperwork. Several days later 9 o’clock link call. Told the first two sets of cert blades should have arrived. I was like nope not yet, on checking they had but paperwork was wrong luckily for me. Scrap bill, 2 million pounds. My biggest error, but escaped with my job as engineering didn’t annotate the paperwork correctly.

[@tonyshaw4570]

we all make mistakes .you just got to make them right

[@jaclroberts]

That's the problem with big machines, when it goes wrong, it goes wrong fast!

[@bishen67]

Have you seen the latest Car S O S with the Citroen SM ? Faults with the Maserati v6 fitted to it. Pistons unavailable, so used Cosworth racing ones, valves now modified Pinto ones. Liners fitted with an air hammer. You may find it interesting.

[@stevem7868-y4l]

If we all listed our worst F UP on here, this would go on forever, My worst is welding on a Renault 5 Gordini, and setting the interior on fire, the Blue carpet was buggered, incredibly, our local scrappie had the same colour carpet in a smashed up normal Renault 5, job took days to sort, and the Customer never knew!! as we had to valet the interior so much, it looked like a new car

[@robertmiddleton5663]

i had one doing cam belt 1600 twin cam megane i tried to improvise on locking tool for cams it turned over by hand so started it engine light came on after a minute followed by miss fire the rest you all know new gasket kit some new valves ect i borrowed the correct locking tool blood sweat tears it ran fine all at my cost as should be .i retired now but like proper engines with push rods

[@rogerbond7811]

He who hasn't made a mistake hasn't made anything. As for hearing damage after 45 years as an aircraft engineer my hearing is well damaged despite trying to remember to use some kind of protection.

[@Samppe5]

Good content! But why has the audio quality been bad ? Hiss and noise....

[@philhermetic]

Never leave a machine that is running!

[@grunewaj]

Can’t you resize the cam caps on that BMW motor rather than get a new cam carrier?

[@philipsavickas4860]

when running a business the math has to work or you lose it all it's just a #game

[@bobuncle8704]

What a badge that’d have been to have on the wall. I ruined a King’s engine. 😅

[@Jester-Riddle]

'I screwed up Royal(t)y' ... !!! 😁

[@itsverygreen532]

And just like that the engine build area is full of odd engines people have dropped off, cars that don't need to be there ...

[@Phuc_Yhou]

It was all the BMW engines pus ancillaries being picked up that day as Lee said in the video and Johns car is deserves to have its engine installed in the clean build area

[@jaredwoodward919]

In engineering if you haven't made a mistake, you must be employed just to sweep the floor. But boy you don't make the same mistake twice.

[@JohnHanson-r1z]

Built a Suzuki race engine for Isle of Man and missed doing a big end cap and engine threw the rod and went through case and wrecked the engine it didn’t do more than half a mile you can imagine how that went down

[@eliotmansfield]

“it was running perfectly - until it wasn’t - round the ‘ring” - so it’s shagged then.

[@davyboy888]

Full David Brent here today :)

[@simonquincey9315]

With the BMW engine, could you line bore the cam carrier over size to carry a bush, peg with roll pin and polish the cam? A bit expensive maybe but if there was a few to do and the part is expensive to replace, then. Thanks for an excellent series.

[@daledavies2334]

Could you find cam bearing shells from another engine and bore these cam carrier out to fit them. In North America we put SBC rod bolts in SBF rods. Increase bolt strength via diameter increase from 5/16" to 11/32". You can also step up to ARP bolts. Guys have machined Chev rods to get long rods in a Ford and also use Chev aftermarket pistons to get the required compression height. Using sortof "stock" off the shelf parts keeps cost down. I am getting Chev LS valves; 1.9" intake, 1.55" ex, into my 1966 Ford 289 heads. 8mm stems require either the powdered metal Chev guides or bronze guides. Vavles being stock replacement are inexpensive.

[@STANLIZ4]

happens in any business things go wrong, and sometimes you try and rectify it with the customer and it goes wrong again!

[@arzemagic]

Look at that sliding wooden door put a handle on it or paint it or both look at the state of it it’s filthy

[@MrSnookerballs]

never leave a machine running while you do something else, even going for a piss.