Uploaded May 2025 | Updated September 2026, 3 hours ago

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The whole process of making motorbike pistons in a single video.

I forgot to include how I ovalised the pistons. The pneumatic pressure of the tail stock against the mandrel distorted the pistons enough that after round turning they settle oval. The conical taper was easy to program on a CNC lathe, I just programed a larger end diameter.
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00:00 - Chapter one - Introduction
00:53 - Chapter two - Design and modelling
02:42 - Chapter three - Core moulds and patterns.
05:51 - Chapter four - casting flasks.
11:15 - Chapter five - Which alloy?
12:42 - Chapter six - Casting the pistons
16:58 - - Pouring the castings
19:38 - Chapter seven - degating and inspection
21:50 - Chapter eight - machining strategy
23:50 - - Mailtime
24:43 - Chapter nine - Machining the pistons
24:47 - - First OP
27:05 - - Second OP
28:09 - - Third OP
30:36 - - Fourth OP
32:19 - - Fifth OP
33:13 - - Sixth OP
35:22 - - Seventh OP
35:45 - Chapter ten - conclusions
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Music:
Florian - The Stomp - Instrumental Version
Higher Land - We Wont Survive - Remake - Instrumental Version