SPEAR MOTORS TRAINING INSTITUTE.

KAMPALA (UGANDA)

DEPARTMENT OF AUTOMOTIVE MECHANICS

PROJECT TITLE : ENGINE OVERHAUL REPORT

NAME :MAKUMBI GERALD

YEAR OF STUDY : 2023 YEAR 1

DATE : 30 /03/2023

INSTITUTE NAME:SPEAR MOTORS TRAINING INSTITUTE

SIGNATURE:.............
DECLARATION
I HEREBY DECLARE THAT THE CONTENT IN THIS REPORT HAS BEEN
DONE TO THE BEST OF MY KNOWLEDGE AND HAS NOT BEEN
SUBMITTED TO ANY HIGHER INSTITUTION OF EDUCATION OF ANY
AWARD.

NAME: MAKUMBI GERALD

SIGNATURE: ……………………………………..
3/04/2023
DATE: …………………………………………………..
APPROVAL

This report is submitted in parental fulfillment for the award of national

certificate in mechanical engineering of Uganda business and technical
examination board (UBTEB). Under the supervision of;

SUPERVISOR’S NAME: ……………………………………………….

SIGNATURE: ………………………………………………………….

DATE: ……………………………………………………………
DEDICATION

I hereby dedicate this report to Mr NYANZI MATIA who have really worked
hard to see that I study this mechanics course…

I Dedicate it to my friends and teachers at spear motors training institute

who have always been of help during this course study.

I finally dedicate this report to the almighty GOD who has been guiding me
from the day I first joined the spear motors training Institute up to date…
ACKNOWLEDGEMENT

This project was started and concluded under the supervision of all the
lecturers at spear motors training institute. I'm grateful for their time and
guidelines that saw this project to a successful end.

I'm also grateful to Mr SAKIBU FRANCIS who looked into

the report and corrected the mistakes I had made … Finally

I thank the Almighty GOD who enabled me finish this

report…

ABSTRACT

During this welding project, i have been able to learn new ideas and
techniques i never knew before

CHAPTER1 welding tools

CHAPTER2 Materials we used

CHAPTER3 Measurements ,markings and cuttings we used

CHAPTER 4 Welding techniques and joints we used

 CHAPTER 5 procedures and preparations

CHAPTER 6 Spraying and painting

CHAPTER 7 challenges

CHAPTER 1
TOOLS WE USED
Welding machine/transformer;
provided power for welding

Welding rods;
for joining material surfaces

Grinding machine and key;

provides power to run the discs
Cutting and grinding discs;
for cutting and grinding material

Tape measure;
for measuring length of the materials

Scriber;
we used it for marking material surfaces
Chipping hammer;
we used it for chipping cool off flux

Square;
we used it to join material at an angle of 90

Welding glass;
we used it for the safety of our eyes
Flux;
a courting formed on top of a welded point
Wire brush;
we used this for cleaning welded joints

Spirit level;
we used this for finding the ground level of the workpiece

Vice;
we used a vice for holding the workpiece during cutting and filing
Pillar bench drilling machine;
We used it for making drillings on locks

Power hacksaw;
We used for cutting pieces of metal
Hand shearing machine;
We used it for cutting metal sheets

Safety boots;

Welding torch
Stainless steel metric ruler
 CHAPTER 2
Materials we used
Angle line steel
12 piece 40cm each for partitioning the cubicle vertically
3 piece 200cm each partitioning the cubicles horizontally

steel plate 3mm and 1mm

Base plates 1mm
Cubicle partitioning plates 1mm
body/frame plates 1mm
Door plates 3mm
square tubing 1x1
CHAPTER 3
Measurements ,markings and cuttings we used
Height 200cm
Width 52cm
Length 200cm

CHAPTER
Welding techniques we used we used
Spot
Weave welding

Types of weld joints we made

We used corner joint for joining the frame
We used tee joint for joining square pipes and angle bar separators

We used welding rods 6013

 CHAPTER

The following were some of the factors we considered before weldinding

Current,

Polarity,

Voltage,

weld groove,

travel speed,

distance between electrodes,

electrode extension,

angle and diameter

 CHAPTER
The following were the procedures and preparations we followed during welding
i)Pre- welding processes
The metals that are to be conjoined should be prepared – this involves ridding the metals of
unwanted grease, dust and rust and filing a slanting edge out of the metal sides. The latter
process allows an increased room for penetration, forming an even stronger welded joint.

ii)Wearing proper safety gear

Any process that involves electricity and produces sparks calls for strict adherence to safety
guidelines. Welding gear primarily includes welding robes, safety shoes, safety gloves and
safety glasses. Welding robes are made of fire-resistant materials to prevent potential fires or
holes from being burnt into your clothes; safety shoes provide protection against welding
sparks; safety gloves protect your hands from burns and safety glasses protect your eyes from
being damaged by the fierce glare emanated from the metal whilst welding. Welding blankets
are often used to smother small fires, preventing them from turning into infernos. Firetex is
famous for its welding blankets.

iii)Setting up your work area

It is equally important to set up a safe workspace. The table or platform you are going to keep
your workpiece and welding paraphernalia on should be made up of fireproof material. Often
sparks from welding fall on the ground; thus it is imperative to clear the workshop floor of any
flammable substances such as grease and oil.

iv)Securing your workpiece

Clasp the metal pieces to be joined until they are welded. You could make use of clamps to
secure your metal pieces.

v)Striking the arc

An arc is established by touching the workpiece with the electrode for a few seconds and lifting
it back. When the electrode is in contact with the metal workpieces, the electric circuit gets
completed, producing heat which melts and begins the formation of the welding joint.

vi)Correct rod position and movement

While welding, it is good practice to keep the rods tilted at an angle of ten degrees or twenty
degrees from the vertical. The rod motion should be such that it traverses a straight line. Arc
length, which is defined as the distance of the electrode from the pool of weld, must be kept
neither too small, nor too long. The characteristic to look for in the perfect arc length is that it
would cover up a large portion of the light emanating from the weld and keep the rod from being
shoved into the slag pool at the same time.

vii)Forming the bead

When the space between the pieces of metals being conjoined is filled with the molten
consumable electrode and molten base metal, a bead formation is said to have taken place. For
getting a bead of the envisaged shape, it is best practice to refine your arc movement .

viii) Cleaning and painting weld

Clearing your weld of any slag will help you examine it better for any defects and faults that may
have happened whilst welding; an angle grinder can be used to perform the job. Painting your
newly welded workpiece will ensure it has a longer, corrosion-free life.

CHAPTER5

Spraying and painting

Tools

Spray gun

We used this for spraying

multi-effekt 11-e330

We used this for painting the exterior

plascon paint smoke gray

We used this for painting the interior

Thinner
We used this for dissolving the paint

We used this for filtering the paint

air compressor
This provided compressed air we used to spray

sand paper p120

CHAPTER6

Spraying procedures

We mixed the paint as follows

We added 125mm of thinner to 250mm of multi-effekt 11-e330

Mixed and filtered it

We also added ½ a cup of thinner to plascon smoke grey paint

Mixed and filtered it

We the added the paint to the spray gun and sprayed

CHAPTER 7

Challenges we faced during and after welding

We faced problem of eye irritation due to the smoke from welding since we had no gas masks
Carrying the locker was also another problem after welding since it become heavy
Some accidents such as cuts and burns
Paint fumes during spraying