Making a Merlin Engine Part 2

This is a continuation of the Part 1 series on Making a Merlin. To read Part 1, click here.

Jane Wales measures the lengths and parallels of a camshaft bush on a Comparator, which registers an error of 0.00254 mm. The inspection area of this aircraft factory is attached to the machine shop and checks all diameters, lengths and other dimensions with various tools. They also perform hardness tests of pistons, gudgeon pins, pumps and boost controls.

A worker at this factory adds information to the progress chart. Each section of the factory has its own chart and a check is kept on the number of parts produced. Too many of one part and too few of another would upset the balance of production and delay the finished job.

Factory worker Lena Ralston machines clutch carrier plates for operating the boost mechanism at this aircraft engine factory. She is profile-turning the face which carries the clutch plate. Metal shavings can be seen around her work area.

A wide view of the crank case assembly bay at this aircraft engine factory. In the foreground, the cylinder studs are being fitted, these will hold the cylinder in place.

A worker checks the alignment of the pinions in the reduction gear at this engine factory. This gear will then be fitted to the crank case.

Female workers attach the inlet manifolds to the cylinder blocks, prior to the blocks being fitted to the engine.

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Two workers gently lower the crankshaft assembly into the crank case. The piston connecting rods can be seen dangling below the crankshaft.

A factory worker makes the final adjustments to the supercharger, which is now ready to be fitted to the Merlin engine.

An engineer stands at a control panel in the test bed. Through the window an engine can be seen being tested. Many tests are carried out, including coolant temperatures, oil temperatures and pressure, petrol pressure and consumption and boost pressure from the supercharger to the engine.

An engine is lifted off the test bed after being tested. It will now be stripped, reassembled and given a second test before it is ready for dispatch.

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