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2004-06 Production I4 & I5 blocks had a process change implemented into the 'D' slice in order to get the required glue print & joint on the 'D-C' foam assembly. The process change was a stock addition of .020" to the bottom of the D-foam barrels. This change was then carried forward into the 2007 I4 & I5 tooling. Unfortunately, with the 2007 tools this offset is now causing Defiance issues again in the 'D-C' assembly. This time however instead of being short, the D-foam barrels are roughly .010" too long. To correct this condition, add .010" to the upper glue surface on the 'C' foam by removing .010" from the cavity shape on the upper 'C' mold plate. This will require updating the process model for the C-foam (1.0155 scale only). This is the quickest and most cost effective action for Defiance to take. It will correct for the problem & still allow for tool deliveries as well as casting requirements to be made. Since many sets of tools are already built & will be modified in this manner, the CAD design should also be updated to reflect them. This will ensure all future tooling will be built & brought into the plant as the same design. THIS IS EXTREMELY HOT!!!

File Attachments:

	File Name	Description	User Name	Upload Date
Delete	ct03174.ppt	C-foam process change	Laker, Andrew (fz5q01)	2/21/2006 4:00:51 PM

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Program	Part Type	Part #	Design Phase	Location	PTE	Status
Inline 4	Block	12579139	Prod	Defiance	Laker, Andrew	Complete - Approved

Impacted Part Information:

Program	Part Type	Part #	Design Phase	Location	PTE	Status
Inline 4	Block	12583840	Prod	Defiance	Laker, Andrew	Waived
Inline 4	Block	12606095	Dev	Defiance	Laker, Andrew	Waived
Inline 5	Block	12577811	Prod	Defiance	Tingle, James	Complete - Approved
Inline 5	Block	12583846	Prod	Defiance	Tingle, James	Waived
Inline 5	Block	12606091	Dev	Defiance	Tingle, James	Waived
Inline 6	Block	12563712	Prod	Saginaw	Noga, Gregg	Waived
Inline 6	Block	12586319	Dev	Saginaw	Noga, Gregg	Waived