L Hot Rodding_1 Systems Engineering HOT RODDING AND SYSTEMS ENGINEERING Combine Disciplines And Create a Great End Result!

L Hot Rodding_2 Who the Heck Are You? Systems Engineering Im John D. Knapp! Im an Eastern Montana kid! Degrees: A.A. (1965) Pre-Engineering, B.S. (1967 in Mechanical Technology, MBA (1975). Ive worked in nuclear reactor operations and nuclear QA (7 years), commercial nuclear QA (6 years), aerospace and supplier/subcontractor quality engineering (29 years). My Emphasis is in Procurement Quality Engineering! Working with people to get a quality product is my goal!

L Hot Rodding_3 Who the Heck Are You? Systems Engineering Im a Gear Head! Ive been interested in cars since 1955! Im always learning new skills and applications. Taking welding (Arc and MIG welding) and auto body repair CCOC in San Jose. Will be taking machining, automatic transmission repair, tune-up, electrical, suspension, brakes & steering classes. I dont plan to retire – Ill just continue to learn and apply, until I wear out. Boredom is a slow, painful death.

L Hot Rodding_4 Systems Engineering Systems Engineering (SE): An approach AND a discipline. Identifies new methods/opportunities like other engineering fields. Note: SEs approach is holistic (i.e. concerned with complete systems) and interdisciplinary (i.e. works with other applicable disciplines). Integrates work-processes and tools to handle projects, (large or small). It overlaps with technical and human-centered disciplines. SE helps meld technical contributors into a unified team effort, forming a structured development process that proceeds from concept through production to operation. Its hot rodding (integrating subsystems into a system or car). Systems Engineering - Definition !

L Hot Rodding_5 Premises of This Presentation Are: Systems Engineering 0. Eighty (80) Percent of All Hot Rodding Projects Never Get Done! Why? 1.Work Isnt Done, Isnt Planned/Funded! 2. Inadequate Preparation/Education! 3. No Commitment To Learn AND Do! 4. Inadequate Facilities/Tools/Expertise!

L Hot Rodding_6 Systems Engineering Hot Rod - a car with an engine modified for linear speed. - typically a roadster or 2-door coupe that was modified for speed. - a roadster was light; the windshield could be removed. - burning out connecting rod bearings (hence the term, hot rod) was a very common failure in modified four-cylinder Model T, A, B and Model 18 (i.e. V8 Ford; particularly Model Ts and As with 4-cylinder engines with babbitted main bearings). The term hot rod was adopted in the 1930s or 1940s as a car that had been modified in various ways to achieve higher performance. A Little Background!

L Hot Rodding_7 The Classic Hot Rod!

L Hot Rodding_8 Systems Engineering Original hot rods were old cars that were modified to reduce weight, improve aerodynamics and performance. Typical modifications were removal of windshields, lowering the chassis, and modifying and tuning the engine for more power/torque or replacing it with a more powerful one for top speed.windshieldsengine Top chopping (i.e. removing vertical parts of the cars roof to lower the aerodynamic profile) occurred. Sectioning (the removal of a vertical section of metal from the body) also lowered wind resistance came a little later. Wheels and tires were changed for improved traction and handling. Hot rodders modifications may or may not have improved the appearance. Show cars in the 1950s replicated these modifications, added distinctive paint jobs and all kinds of interior/exterior modifications. Still More Background!

L Hot Rodding_9 Systems Engineering In 1930s, the Southern California Timing Association regulated top-speed dry lakes in California. The Bonneville Salt Flats became the home of top speed records in In the late 1940s, NASCAR originated from moonshiner cars that used modified engine and suspension. Also, the National Hot Rod Association (NHRA) is born in the 1950s! In the 1960s, the Muscle Car emerged (i.e. the Hemi- Dodge; Ford Thunderbolt; Chevrolet Camaro with an aluminum 427 cu. in. engine). Even MORE Background!

L Hot Rodding_10 Moonshiner Cars! Systems Engineering

L Hot Rodding_11 Systems Engineering The requirements placed on him or her are: 1.Skill Set – Current and Needed Skills & Experience. 2.Tools – Whats Needed? 3.Place(s) to Work – Size(s) and Facilities 4.Knowledge & Education – What Do You Know? Is Your Education Adequate? 5. Mentor(s) – Who Has The Skills That You Need? Who Will Work With/For You? Will They Train You? 6. Financial Commitment - Whats the Dollar Budget? Whats the Time Budget? Do you have both or just one? 7. What Kind of Record-Keeping System Will You Use? Lets Discuss The Hot Rodder

L Hot Rodding_12 Skill Set(s) / Abilities 1.Skills Needed: a. Welding – Metal-Inert-Gas (MIG) Welding Is the Minimum Requirement. Are you MIG/ TIG/ Gas/ Arc/ Stitch/Hammer Weld certified? b. Metal Fabrication Skill(s): 1. Cut Metal 2. Bead Roll 3. English Wheel 4. Shrinking/Stretching 5. Metal Preparation (Planishing/Hammering/Shaping/Hammer Weld) 6. Sanding. 7. Priming. 8. Painting. 9. Bend/Shape Tubing and Piping. 10. Machining 11. Heat Treat 12. Make Patterns 13. Do Metal Body Work? Have you taken any classes in the above subjects? Are you going to buy these skills? Will you buy some services and do some of the work?

L Hot Rodding_13 A Place To Work Do you have a place to work that will: 1.Store all the needed tools? 2.Give you access to the needed tools? 3.Place the needed tools effectively? 4.Store the tools and supplies? 5.Store ancillary tools? 6.Discard and buy new or other needed tools? 7.Handle all the throw-away items legally/effectively? 8.Is it a legal place to do this work? 9.Or do you have access-to-use the needed tools?

L Hot Rodding_14 Tools That Are Needed! 1.MIG Welder - a 110v or 220v unit (just for starters)! 2.Metal Fabrication: a. Bead Roller (Powered or Manual). b. English Wheel. c. A Shrinker and a Stretcher. d. Body Hammers/Dollies/Clamps e. Sanding Boards. f. Sandpapers – all types. g. Metal sheer, brake and bending tools. h. Drill press, milling machine, lathe. i. Grinders, sanders, profiling tools.

L Hot Rodding_15 Knowledge – have you done real work? Skills: Can you: 1. MIG weld? 2. English Wheel? 3. Bead Roll with or without templates? 4. Shrink and Stretch Sheet Steel/ Aluminum/Other Metal(s)? 5. Do all the metal cutting? 6. Can you do the metal preparation, welding, sanding and painting? Knowledge and Education #1

L Hot Rodding_16 Knowledge and Education #2 Do you have the knowledge to put this car on the road? a. Can it be licensed? b. Will it comply with smog requirements? c. Can you obtain a legal title? d. Will the title that you get be transferrable? e. If not, will it become a trailer queen/show car/race car? f. Why are you doing this project?

L Hot Rodding_17 Systems Engineering A. Complete the following reviews: 1. Systems Requirements Review 2. Systems Design Review 3. Preliminary Design Review 4. Critical Design Review 5. Start The 1 st Build !!!!!! One Path – There Are Other Paths!

L Hot Rodding_18 Systems Engineering The car must: 1. Operate (legally) on the street. 2. Accommodate three (3) people maximum. 3. Have > 400 the flywheel. 4. Use a 4-,5- or 6-speed transmission. 5. Have a top speed of 140 mph. 6. Have the look of an American hot rod. 7. Be improved as-needed by the owner. 8. Be as presentable as a car show!. SYSTEM REQUIREMENTS REVIEW

L Hot Rodding_19 System Design Review The Design Will Be a 32 5-Window Ford Coupe! Rumble Seat Will Be Optional! V8-Powered with a 4-speed Automatic Transmission. All components shall be American Manufactured.

L Hot Rodding_20 Identify the sub-systems (and requirements) in the Design: 0. Accessories (Power Steering, Brakes, Windows, Seats; A/C) 1.Body – (Steel Body, Fenders, Hood, Doors, Trunk, Bumpers). 2.Brakes – (4 wheel discs) 3.Electrical – Retro Gauges with Modern Head & Tail Lights. 4.Engine Type (V8 – Chevrolet) 5.Exhaust System – Straight Thru Mufflers. 6.Frame – Modern Manufacture. 7.Interior – 1950s Tuck and Roll (two colors). 8.Rear End – Quick Change for variability. 9.Suspension-Front – Standard I-Beam or Coil-Over 10.Suspension-Rear – Four-Link or ? 11.Tires and Wheels – Aluminum (Big and Littles) 12.Transmission – automatic w/overdrive. Preliminary Design Review

L Hot Rodding_21 Critical Design Review – Compliance w/Subsystem Reqmts. Identify the Make or Buy Subsystems: 1.Body – Make the Body, Fenders, Hood, Doors, Floors from steel. Buy the Trunk, Radiator Shell and Radiator) (Use Lazzes Metal Classes). 2. Brakes – Buy the Splindles, Rotors & Calipers After Market (Heidts). 3. Electrical – Buy Gauges (S&W), Make Wiring Harness (w/Custom Fuse Block). 4.Engine Type – Chev V8 block; parts from Gromms – YOU Assemble the Engine) 5.Exhaust System – Make the Pipes (Quick-Way Muffler) ; Buy Mufflers (Thrush). 6.Frame – Buy a Modern-Made Frame (Heidts; Fat Man/ Chassis Works). 7. Interior – Buy Interior Fabric (Diablo) ; Make Interior Panels; Buy the Seats (?) 8.Rear End – Buy a Quick Change or Buy a Ford 9) 9.Steering – Buy after-market (Fat Man Products). 9. Suspension-Front – Buy Coil-Over System (Fat Man Products). 10. Suspension-Rear – Buy Four-Link System w/Build-In Rear End (Fat Man Products.) 11. Tires and Wheels – Buy Aluminum Wheels & Retro Tires (Stockton Wheel) 12. Transmission – Buy a manual or auto (Chev 200R4 – you rebuild).

L Hot Rodding_22 My Supplier Base! Can my suppliers provide any or all of the hardware/ parts that I need to build this car? Do my suppliers have the knowledge and/or access to the knowledge to help me? To support their product? Do my suppliers have access to other suppliers who will also help me? Have you created the supplier base that you need?

L Hot Rodding_23 The Money – Do You Have It? Have you: a. Identified the parts sources AND costs? b. Totaled up the cost of the parts? c. Committed to spending that amount? d. alternative parts w/lower costs? e. Identified cost(s) of tools and facilities? f. Identified educational & experience costs? g. Figured the time it will take to get good enough (experience-wise) to do the work? h. The cost(s) of buying the work? i. Hesitating? Why? j. Do I really want to do this? k. Whats my real goal? Got A Hidden Agenda? l. Will you finance the car? Got the cash?

L Hot Rodding_24 What Plan(s) Do I Really Have To Build This Car? Do I have a written plan or just an image in my head? Will I use my own planning method or use a s/w tool? Where do I want to start (or must I acquire skills)? Can I start now or later? Is this a Career, Family, Friends Limiting job? Will I use it once its done? Or is it a one-off or?

L Hot Rodding_25 Youll Get To Run YOUR OWN Quality Program! Youll Create: 01. An Organization 02. Your QA Program 03. Design Control 04. Procurement Control 05. Write Procedures 06. Document Control 07. Control Purchases 08. Identify Parts 09. Control Special Processes 10. Do Inspections 11. Do Testing. 12. Control Measuring & Test Equipment 13. Handle, Store Hardware 14. Status the Project 15. Disposition Defects 16. Use Corrective Action 17. A Records System 18. Audits

L Hot Rodding_26 How Are You Going To Document the Build? Photos (Incremental or Sub-Assembly or Assembly?) Will You Prepare an Incremental Traveler or Shop Order or a Master- Build Traveler/Shop Order? Will You Integrate Photos and Steps in the Build? Will You Document/Proceduralize the Use of Your Skills in the Incremental or Master-Build Traveler/Shop Order to Do Each task or only certain tasks? Will This Be The Only Build of This Vehicle? Is there software available to prepare/document/ integrate this build with or without photos? Will the build paper track time, progress, costs, each try, re-try, failure and success? What record(s) do you want, after the build is done?

L Hot Rodding_27 Maslows Hierarchy of Human Needs – Part 2. Youve probably guessed this: 1. Youre not building a car, youre going to have an experience and build YOURSELF + a Car. 2. You have a choice – use your own design, someone elses or a totally new design! 3. One idea of this build is to challenge your understanding and your point-of-view (i.e. what I see and how I see it) through experience(s) and application(s). This challenge will build, grow, mold & polish you. The car is the by-product of this experience!

L Hot Rodding_28 Whats Not Mentioned In Maslows Hierarchy? Weve talked about building a person and a car but weve missed a VERY important point! We havent talked about TRANSCENDENCE! Youre going to transcend your: a. Point-of-view. b. Current knowledge. c. Current understanding. d. Previous experience(s). e. The experience(s) of others whove also done this work. f. Our previous self-actualization.

L Hot Rodding_29 Then You Get Into the Real Stuff! The Real Stuff is THE KNOWLEDGE that you find out about the hardware, the build and the insight that you get from this experience – THAT NO ONE ELSE BUT YOU AND A FEW OTHERS (WHOVE DONE THIS WORK) ACHIEVED!

L Hot Rodding_30 Lessons of Previous Automotive Work! 1.The De Saxe Principle in Ford Flathead V8 and 1920s Ford Four-Cylinder Engines! The crankshaft is offset to the left of engine center! Why?

L Hot Rodding_31 The Side-Oiler Ford OHV V8 Block! The main bearings get the oil first, in a side-oiler Ford V8! Why? What was the application?

L Hot Rodding_32 The SR-71 Engine Experience! Lockheeds gearbox manufacturer had NO experience with metals or materials that would see the temperatures of the flight regime of this aircraft. Neither Did We – But, We Were Already Committed To Learn! Bill Brown–Pratt & Whitney Program Manager for the J-58 Engine (1981/82 Lockheed Magazine).

L Hot Rodding_33 What Did You Know About Threaded Fasteners?

L Hot Rodding_34 Get Ready – Youll Learn What Others Dont OR Wont! 1.Why are torque wrenches an ineffective way to preload (i.e. torque) threaded fasteners? 2.Whats the most effective installation method for T/Fs? 3.Why is a stud (a bolt with each end) much more clamping than a screw? 4.Why was the first thread that was standardized, more effective, in its time than other types of threads that were developed later?

L Hot Rodding_35 Youve Been a GREAT Audience! Thank YOU for attending and allowing me to share my gear head experience(s)/insights with you. Your Attention is VERY MUCH appreciated. Please continue to be an eternal student – a continual learner AND share your knowledge with other students (i.e. be a genuine (i.e. agape) teacher, with no strings on your sharing your knowledge). If youd like to provide feedback about this presentation, please call John (408) or send an e- mail to

L Hot Rodding_36 Last But Not Least……… A Hot Rod Should Be Constantly Improved or Changed. Why? Because Technology Changes/Improves. ****************************************************************** Change (not necessarily improvement) is the law of life. And those who look only to the past or present are certain to miss the future…..John F. Kennedy You must do the things that you think that you cannot do…..Eleanor Roosevelt. Knowing is NOT enough. We must APPLY. Goethe.