Honing Department and Machine Assembly

4:53

26:36

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Rottler Manufacturing: The Unsung Hero of Combustion Engines (100 Years of Made In America)

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What happens here

The tour enters the honing department, where Rottler's H80 series machines (H85A, H85AXY) are assembled. These are automated hole-to-hole honing machines. The presenter explains that Rottler ventured into the honing business in the 1970s, starting with older swing-arm machines and evolving to the current modern era. The H85AXY, for example, is highly sensitive and uses a full computer system to detect high and low spots, allowing for bores to be rounded and straight within two-tenths of an inch. The machines feature a positive pressure electrical system with air filters, preventing cast iron dust from entering the sensitive electronics, and most components are US-made directly in Washington State.

Goal: Demonstrate the assembly and features of modern honing machines

Tools and materials

Engine block — Demonstration and testing on honing machines
H80 series honing machines — Honing engine cylinder bores with high precision

What they say

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amazes me on those is how sensitive they are like where there's like some type of measurement system in here built in to find like the high spots and low spots yeah so that's what made the Rottler unique is is with our control system and being you know we're running a full computer on this machine and so we have our current graph here and that's exactly we do is when that machine is honing it's sensing that pressure that current load on the motor and it can tell exactly like you said is it tapering is it a high spot is it a low spot and and we can get bores round and straight within two tenths all day long what is the air filter for I've seen that on other machines you're in shops you've got a lot of cast iron dust in the engine industry and we don't want that getting inside we also usually you'll see fans on a lot of our electrical boxes and they're not actually to bring air out of the electrical system we we run them the opposite direction to push air in so it becomes positive pressure uh so all of our electronics are assembled in this corner so we bring the cabinets in everything's flat packed and then he's assembling the entire control system so we build the entire control system here and then go and put all those boxes you've seen on every machine is going to get installed whatever configuration whatever circuit boards that they need for the power requirements and then this is our engineering side so this is where engineering's been for at least last 10 years testing out of bicycle suspension doesn't know we're looking at them yeah when I print things out here I'll look it all right yes that's my that's my mountain bike buddy he's like damn they just filmed me bouncing on my seat yeah he's like dang it yeah so we run a full CNC shop now um again just like anything it's evolved to keep up over the years Rottler was running manual machines in here all the way up through the 90s but Andy Rottler has always been very very into CNC technology he was kind of the one to really push this company into our own cnz controls and so scaling up and just getting everything we can to be able to do production so you got machines making machines right here machines making machines that's how you do it and we run our own like we have our own em69 ATC so that's our four axis block work machine uh come on in we run it this was actually the first one we built and you know you got to test things so we set it up in here and they've just been making Parts on it for probably…

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