How exactly does an engine work? What is the difference between a gasoline and a diesel engine? What is an EGR cooler?

When it comes to training people on the common principles and uncommon details that every single engine contains, nothing beats a full size cutaway of an engine. Whether on a moveable piston engine, a static turbine engine or any other kind of engine, training departments across the globe rely on the realistic detail of an actual engine cutaway to best relay standard and model specific information to students.

At CalCo, you can be sure that widest viewing angles for the most cost effective prices can be achieved with the same high level of attention to detail as found in trade show floor displays. The finish level may be a bit subdued, but the longevity of the training equipment and quality of craftsmanship is just as high.

Training engines highlight the areas you want to teach and give a working knowledge of how the engine functions. Whether an entire engine or just a few key components, CalCo puts together just the right model to help you describe the part relationships and stories behind new or complex technologies.

Add color coded passageways to clarify the function of each section, custom cutaway areas exposing internal parts and paint to emphasize the parts of the engine you want to draw attention to.

A professional photography shoot of the training engine can be included to add to the training materials provided to students as well. Employees, distributors or anyone in the training session can follow along with the materials, make notes and leave with a visual reminder of the session. These trainees will have an easier time remembering the parts when they are color coded, they can remember the key points of the product when they are highlighted and they will remember the training when this unique engine is used.

A recent article in Industry Week discussed the importance of assessing your needs and using relevant materials. To access the article click here.

Training is more dynamic when it is hands-on and with a visually stimulating and interactive product it can be even more exciting. Let CalCo help to make your training sessions memorable!

Call CalCo at 847-639-3858, click here for contact information or visit CalCo’s Facebook page.

CalCo has been around as long as the Corvette and WD40. In 1953, most Americans were enjoying the first issue of TV Guide, now that television was becoming a common electric appliance in the home. Ernest Hemingway received the Pulitzer Prize for ‘Old Man and the Sea’ and Elvis Presley had just graduated from High School.

Since that time, the cutaway has remained practically unchanged as a valuable tool for:

• Equipment training
• Sales presentations
• Trade show/lobby displays

RegO regulator cutaways, 1971

RegO regulator cutaway, 2011

It was once said that the Polaroid camera, the fax machine and even email were each going to spell the end of the physical, real-life cutaway. Even today rapid prototyping and lightweight modeling technologies seem to threaten the need for this specialized service.

The fact of the matter is that nothing can replace the understanding and sensory communication that a true cutaway offers. “This cutaway is an actual product; the same one you will be buying, maintaining or investing in”, they seem to say.

“THIS is the actual casting quality. Touch these seals yourself.  These gears mesh together as smoothly as when you turn this handle”. What can possibly take the place of an experience created only by a unique and custom version of your product, made by experts that know how important this experience is to your audience?

Only a company that has evolved alongside much of the technology that comes through the door can fully understand the subtleties and unique characteristics included in each one.

Do you want quality? CalCo craftsmen average a staggering 11+ years of experience

Do you want reliability? CalCo stands behind all promises of cost and timing

Do you want dependability? Many current clients have been using CalCo for decades, some since the very beginning

Do you want flexibility? Every day CalCo handles custom requests for everything from signage and lighting to animation and sales kits. What do you have on your plate that you’d like to see come to life?

Let’s step back for a moment:

How can you tell a do-it-yourself wall painter from a professional? The edges. That place where the new paint stops and the ceiling or unpainted wall begin. That place where a clean, straight and even line running the entire length of the corner is the simplest to imagine, yet most difficult to achieve.

CalCo has been working on the ‘edges’ for almost 60 years, and the magic of a CalCo cutaway is not in how even the paint is, or how all the cuts line up perfectly, or even how simple but very effective the cut design is. . .

The magic is in how much conversation the cutaway spurs about your product and its many benefits and advantages. The magic is in how many orders are placed within viewing distance of a cutaway. The magic is in knowing that this process works year after year after year after year. . .

Contact CalCo at 847/639-3858, click here for contact information or find us on Facebook.

Navistar Booth at MATS 2011

Spring and Fall have traditionally been the busy months for manufacturing trade shows and this year is starting off well.  We attended the 40th Anniversary of the Mid-America Truck Show in Louisville, Kentucky which was held March 31-April 2.  The auto industry problems of the last few years seemed to be a thing of the past.  With over 1000 vendors, 71,000 attendees and all the latest trends and products on display the MATS show showed great promise for the future.   There were many large displays, engine manufacturers including Navistar had large booths with all the latest technology on display.  There was a lot of conversation over the latest emissions filters for trucks.  All in all the show was a great opportunity to see new products and meet new people.

We also visited the ConExpo/IFPE show in Las Vegas,  which is always a big show due to its occurrence only every three years.  This year there were over 2400 exhibitors and 120,000 registered attendees of which 24%  were from international destinations, including 150 different countries.  While the attendance didn’t break records it was still impressive given the tough times the construction industry has endured over the past few years.  Large crowds gathered and there were some big, impressive booths with monstrous equipment. Manufacturers went all out to ship their equipment to the show in hopes of delivering big sales.  Time will tell but those exhibitors we spoke to were happy with the results. The next Con Expo/IFPE show will be held in Las Vegas again on March 18-22, 2014.  See you there!

At the beginning of May we attended the OTC Show in Houston.  This years Offshore Technology Conference was the largest exhibition since 1982 in Houston, TX with over 78,000 people in attendance. The energy levels were cautiously high and new products and developments were on display from all over the world.

CalCo sees many of their cutaways and displays end up at this show year after year, and with the high profile attendees and press coverage, it is easy to see why. With more than 2,500 companies on display, it is important to catch the eyes and attention of the right people in a way that spurs healthy conversations and ultimately attracts more business.

From working models to engine displays to hose cutaways, CalCo’s work was all over the 2 massive halls. Whether its in the oil and gas industry, the automotive sector or even the military, the importance of high quality displays is a must. CalCo has been creating the highest end product displays for almost 60 years, and all that history works for you in showing your expertise by leveraging and outsourcing to true experts in the industry.

When the details are important, the service is a must, and the show goes on with or without you, turn to CalCo and get it done right.

Hopefully the high attendance at these trade shows indicates that the lagging economy is recovering nicely.  We came away with a more positive outlook on the future of the automotive and construction industries.  If you have any information about a recent trade show you have attended we would love to hear it!  To contact CalCo call 847/639-3858 or click here.

Small Engine Cutaway

Car Engine Cutaway

Truck Engine Cutaway

**click on any image for a closer look

Engine cutaways make great showpieces, tools and displays, and are very complicated to create with the intricacy and precision that makes them look effortless.

From small engine cutaways to turbine jet engine cutaways, CalCo Cutaways has been leading the industry in expertly crafted displays for close to 60 years,  CalCo’s senior technicians are familiar with multiple types of engines and will put their 75+ years of combined experience to work for you!

Some of the engine cutaways that CalCo has created include:

• Diesel Engine Cutaways
• Outboard Engine Cutaways
• Automobile Engine cutaways
• Inboard Marine Engine Cutaways
• Helicopter Engine Cutaways
• Motorcycle Engine Cutaways
• Jet Engine Cutaways
• Small Engine Cutaways

Jet Engine Cutaway

Diesel Training Engine Cutaway

Tractor Engine Cutaway

Semi Truck Diesel Engine Cutaway

Forklift Engine Cutaway

Gasoline Engine Cutaway Slices

Outboard Marine Engine Cutaway

Engine Cutaway Closeup

Before and After Photos

of Engine Cutaway Transformations

A few of the uses for your engine cutaway include:

• Education and Training
• Lobby Displays
• Trade Shows
• Sales Purposes

If you are looking for a proven engine cutaway specialist – Call CalCo at 847/639-3858, email news@CalcoCutaways.com or click here for contact information.

Ever wonder how CalCo can continually make first class cutaways and always seems to know just what you wanted? We owe much of it to our production supervisor, Dan Fierla. Dan started at CalCo as part of a high school cooperative work program and has been here ever since. In his 32 years, he has moved up the ladder from high school intern to Senior Supervisor, in charge of production and managing our facility and workers. If you have worked with CalCo you may have spoken to Dan and you most likely learned that he has high standards for the work that we do. If it doesn’t meet Dan’s expectations, it is not going out the door. Customer service and satisfaction has always been a key component at CalCo and Dan is one of the reasons why. Another of his famous attributes is his dedication to time commitments. We pay close attention to deadlines and work hard to meet every one. While we always try to work projects into our schedule, we have turned away business because we could not have maintained our high standards and met the delivery date.

According to Dan the most important information that you can give us about your project is……

“information that will help me to make your project have that just right look.  Details like, what are you trying to show with this cutaway/display?  Is it the size/type of the internal parts you want to showcase? Or is it something special that separates your product from the competition? This information helps me to design the cuts to show what the customer needs and wants to see.”

His favorite project that he has completed is…..

“I had the honor to work on and am very proud of a Double over head cam V6 marine engine for a large engine manufacturer. This project from start to finish was done right.  David Meeler from their marketing department, came to Calco, told me all of the features he would like to show, which helped me to machine the engine and give it that personal touch.  Colors and color coding were all picked out by the customer. When the engine made its maiden voyage at the Florida Boat Show it was a big hit.”

Something you should know about him is……

“I get great satisfaction out of working with the other members of the CalCo team.  I am driven to make CalCo the Best it can be for both employee and customer. When I see pictures of  trade show booths like Navistar, DeZURIK and Kimray, and all of them use Calco cutaways/displays to show case their products,  I have a great sense of pride in knowing I played a part in helping them project a positive image.”

Dan’s level of experience and overall knowledge of products helps you in terms of deciding the best way to display the internal components of your product. Chances are great that Dan has the best and most cost effective way to show your products key features.  He can assist you in creating your ideal cutaway/display.  He also has innovative ideas to show off large products, create working models or design custom stands.

If you have a project that you are interested in discussing, give CalCo a call at 847/639-3858, email us at news@calcocutaways.com or click here for our contact page.

CalCo likes a challenge! We have been in the business of solving our customers problems for almost 60 years.

CalCo started in 1953 as a cutaway shop taking products and cutting away a portion to show the internal parts since they can be a valuable selling tool.  We have come a long way over the years by adapting to customer needs and changes in product displays.  In that time, we have become a turn-key solution for our customers by adding new services.  Did you know there is a place you can go to get all of your product display needs performed at the same time?

In addition to cutaways,  CalCo provides :

• Working Models with or without a cutaway
• Product Displays
• Sales and Training Aids
• Lighting
• Custom Basemounts
• Custom Shipping Containers
• Acrylic covers  and Displays
• Point-of-Puchase Displays
• Custom Cases
• Scale Models and Rapid Prototyping
• Three Dimensional Printing
• Animation
• Sales Awards
• Corporate Gifts
• Plating
• Training Programs
• Professional Photography
• Waterjet Cutting

CalCo can solve your trade show or product display problems with just one phone call!  A typical project now involves creating a cutaway, attaching a brushed aluminum base or custom rolling basemount, building a custom shipping container and a shooting a professional photography session before the project is completed and shipped back to the customer ready to go directly to a trade show or presentation.

If you need help with your trade show, sales or training needs, call CalCo at 847/639-3858 or click here for our contact page and let us make your idea a reality!

It’s what’s on the inside that counts…

How many times have truer words never been spoken?  When recently introducing our newest outboard engine, this was truly where the story lie…on the inside.

I immediately thought of using a cutaway of this new engine to show prospective customers the game-changing thinking and technology inside it.  Having used CalCo’s services in the past, the cutaway they expertly prepared helped greatly by allowing me to both show and explain the internal technology that makes our new V6 outboard powerhead so one-of-a-kind.  In fact, numerous customers commented on the cutaway’s ability to help them see and understand the features that created the benefits, as discussed in various product introduction presentations and materials.

It should be noted that, at the time this cutaway was created, the product had not yet been introduced anywhere in the world, so strict confidentiality measures had to be followed.  In addition, the actual powerhead that was used for the cutaway was one of only four in the world at the time, so a replacement was not available.  Add in the fact that we only had a few weeks to get this fully prepared and on-site, and it’s plain to see there was absolutely no room for error!

You’ve heard it said that “a picture is worth a thousand words”.  Having this cutaway as a teaching tool was equally as invaluable.  In short, the level of detail shown in the cutaway Calco prepared stole the show, and made my job a lot easier.  It’s why I’ve used them 3 times previous, and will call them again next time I need cutaway services.

David Meeler

Product Marketing and Information Manager

To contact CalCo for your project needs call 847-639-3858 or click here for the contact page.

And finally, some believe that 2009 was a year down the toilet, although that was not the case at CalCo we still spent some time with one….

CalCo looks forward to another interesting year!

To contact CalCo call 847/639-3858 or click here for our contact page.

Much of the beauty of an engine is in the details. In order to see all of these details, such as the pistons, crank shaft and valve train components as well as how they function together, a cutaway is an ideal solution.

With a cutaway you can not only see how the individual parts function but you can see how they relate to each other.  From the exterior many engines may seem similar; but once the interior is exposed with a cutaway, you can see the unique attributes of the individual engine inside and its configuration.

These are the important elements that can mean all the difference in power, performance and efficiency.  Using a cutaway will clearly show where the advantages and benefits are and how a particular model can outperform the competition by showing the internal configuration and how the parts interrelate.

Even some of the external components, such as the fuel pump or alternator, can contain hidden features that benefit from a cutaway as well.

“Hands on education has always been, and will always be the best way to inform and educate an audience on products and mechanical relationships.”

View the gallery of engine cutaways below and you can see that CalCo knows engines and how to make them a work of art.

For more cutaway photos please visit www.CalCoCutaways.com and look in the Cutaways Gallery.  If you would like information on having your engine or any other product cutaway, please contact CalCo at 847/639-3858 or click here for contact information.