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Gallery, Projects and General => Project Logs => Topic started by: sbwhart on January 14, 2011, 02:01:05 PM

Title: Potty Over Crank Wall Engine
Post by: sbwhart on January 14, 2011, 02:01:05 PM
Started to cut metal for this engine: for those of you who didn't pick it up her's my thread on the design

http://madmodder.net/index.php?topic=3990.0

And a pic of the engine the model will be based on.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_0178-1.jpg)

Using a chunk of brass donated by John:- thanks John  :thumbup: first square it up and bring it to size with a fly cutter.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4512.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4515.jpg)

Then with a 18mm end mill cut a couple of scallops down the sides,

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4518.jpg)

Then set the boring bar up to cut a 12.5 mm rad

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4519.jpg)

Open the scallops out to 12.5 mm rad

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4525.jpg)

And counter bore them out to 15 mm rad

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4526.jpg)

so you've got this

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4529.jpg)

Then turn up a couple of brass spools that fit into the scallops

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4535.jpg)

And you've got your self a twin cylinder.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4534.jpg)

Well you will have when you've silver soldered them together thats a job for the week end :- if I can sneak away, our son and wife are staying with our new baby granddaughter, so we will have a string of visitors ho-ing and ar-ing,  and doesn't she look like youing.

 :D :D :D :D :D :D

Really looking forward to it

Stew


Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on January 14, 2011, 02:56:32 PM
Great to see you have started cutting metal for this engine Stew and really look forward to the rest of the build. Please keep posting and especially the photo`s of the machining methods, I always learn a lot. Looking forward to it.

Chris
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on January 14, 2011, 03:03:56 PM
Hi Stew


Aboot time  :poke:  :D  ,,,,,,,,,,,,,,,,, i can see this being an interesting  build  :ddb: :ddb: :ddb:



Rob
Title: Re: Potty Over Crank Wall Engine
Post by: Dean W on January 14, 2011, 08:55:23 PM
Potty Engineering strikes again!  You've made a good start, Stew.

Dean
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on January 15, 2011, 01:57:07 AM
A good start Stew.

There is a great advantage in making a one off, there is no one looking over your shoulder saying that you are doing it all wrong. You have total control over how it is built, and as long as it looks right and works correctly at the very end, then what you have done is right.

If you need anything else, as you know, you only have to ask.


John
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on January 15, 2011, 02:22:25 AM
Glad you started on this one Stew; looks good so far  :thumbup:

I'll be along for the ride.

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 15, 2011, 03:22:14 AM
Hi Stew


Aboot time  :poke:  :D  ,,,,,,,,,,,,,,,,, i can see this being an interesting  build  :ddb: :ddb: :ddb:


Rob

(http://www.easyfreesmileys.com/smileys/free-sad-smileys-334.gif) (http://www.easyfreesmileys.com/skype-emoticons.html)


I surender


Thanks for your comments guys,

I've bin a bit torn on this one as I got a yearning  :proj: to build a flame licker, but decided to stick to my plan and build this first not quite settled on the governor design yet though.

I've got the designs laid out for both and with most of the material set aside, just short of the ally jig plate for the bases, but I'm keeping an eye on the scrappy, as soon as he gets some its mine.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on January 15, 2011, 08:10:05 AM
Looking forward to this Stew and a great start, best to stick with your original plan or end up with multiple unfinished projects like me! Would definitely recommend a flame licker as your next build though, if I get mine running I'm sure  :proj: will return!

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 19, 2011, 11:58:42 AM
After a hectic few days I needed a bit of r and r in the shed, but it was really great having all the family together.  :D

Made a start on soldering the bits for the cylinder together, for those of you who missed it in my loco boiler thread this is the kit a I used to solder.

I hearth cobbled together from an old ally baking tray, thermalite blocks from B and Q, a propane burner with a large nozzle fitted a bucket of water for quenching, some easy flo solder and tenacity flux, the barrel is just there to keep everything at a handy height.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4539.jpg)

I solder one cylinder at a time building a little wall around it to keep the heat in.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4536.jpg)

Both ends done I just opened up the wall so that it would cool quicker after five minutes I quenched it in the water and put it in the acid pickle for 1/2 hr.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4537.jpg)

This it it all soldered up

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4541.jpg)

Then I just cleaned one end up with a fly cutter, the other end I plugged the bores with some nuggets of ally secured with loctite

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4542.jpg)

Set it back up in the mill and cleaned them all up again with the fly cutter, they picked the datum edges found the position for the cylinder centre line and centre drilled into the nuggets.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4543.jpg)

To machine the bores I'm going to set the cylinders up in an angle plate on the lathe face plate.

So first job clamp the cylinder up nice and square in the angle plate, I won't slacked the clamp bolts until both cylinders are bored this will ensure that cylinders are parallel.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4545.jpg)

Remove the parallels and clamp the angle plate to the face plate, I'm just using the centre to help hold thing in place and roughly get position. (its one of those jobs you wish you had three hands) just tighten the clamps lightly

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4546.jpg)

Add counter balance weights I've found the best way to check the balance is to disconnect the head stock from the drive remove the belt or disengage the gear which ever way your machine work, and give the face place a spin with your hand, what your after is for it to come to rest in a radome position if it stop in the same place move the weight or add more weight until you get it balanced.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4547.jpg)

Using a wobble bar between the centered nugget and a running centre clock the bar up tap the angle plate until it running true, and you've got the cylinder positioned, tighten all the clamps.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4549.jpg)

Now face plate work is probably the most hazardous job you can do on a lathe bits can fly off and do a you a real nasty, so make sure everything is nice and tight and can't come adrift, before you switch the power on, turn the lathe over by hand making sure nothing can catch, and check that you've got the speed set on slow, and stand to one side when you switch it on just in case.

OK everything nice and safe stick a drill down the bore to get rid of the ally nugget. and bore to size

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4550.jpg)

Thats the first bore done the R and R for tomorrow is the second bore to do that just move the angle plate over clock position up with a wobble bar and bore it out, the cylinders will come out perfectly parallel.

Stew









 



Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on January 19, 2011, 12:07:57 PM
Very smoothly done Stew. Well planned and executed.

I see you don't need any more instruction on soldering, that is a very nice result indeed, spot on.


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 19, 2011, 12:16:01 PM
Thanks John:-

I try listen and take in everything people tell me and put it into practice.


Stew



Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on January 19, 2011, 12:54:17 PM
 :)   looking great Stew  :thumbup:

Rob
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on January 19, 2011, 02:56:54 PM
Brilliant Stew.  :bow: When I was using the 4 jaw the other day, it was only slightly out of being central but the jaws are that heavy that I could feel the inbalance in it - Can't remember if I've even got  face plate but I'm def not ready to do anything like that!

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on January 19, 2011, 03:33:30 PM
Excellent Stew, can you tell me why you plugged the holes you had already drilled with alluminium? - just curious, I wouldn`t be asking if I wasn`t interested.... excellent pictures and write up again.

Chris
Title: Re: Potty Over Crank Wall Engine
Post by: Brass_Machine on January 19, 2011, 03:49:27 PM
Nice Job Stew!!!  :bow:

I am with Chris... why did you plug the cylinders?

Eric
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 19, 2011, 04:14:00 PM
Thanks for your comments and interest Guys.

Nice Job Stew!!!  :bow:

I am with Chris... why did you plug the cylinders?

Eric

Soldering the cylinders together is not that accurate there would be an error in the bore position, by plugged the cylinders and finding the correct location and marking it with centre drill,  I was able to clock up on the centre with the wiggler and get the bore accuratly positioned.

This is a little trick you can do with castings.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Brass_Machine on January 19, 2011, 04:17:11 PM
Soldering the cylinders together is not that accurate there would be an error in the bore position, by plugged the cylinders and finding the correct location and marking it with centre drill,  I was able to clock up on the centre with the wiggler and get the bore accuratly positioned.

This is a little trick you can do with castings.

Stew

oooohhhh. very smart move  :smart: I would have never thought that.

Eric
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on January 19, 2011, 04:21:53 PM
Sorry Stew. Late again! Only just spotted the posting.....  ::)

That's a great start you've made. Really looking forward to watching it develop!  :D

Good luck!  :thumbup:

(Going to read through again, now).
David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 20, 2011, 12:50:49 PM
 :hammer:  Got right down to doing number 2 bore this morning just a mater of repositioning the angle plate on the face plate and clocking up on the centre.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4556.jpg)

And boring it out, I like to sneak up onto the size taking smaller cuts as I get closer and run the final cut through a couple of times to take the spring out of the bar, I don't worry too much about getting exact size as long as its within 0.1mm I'm happy Its far easier to make the pistons to fit.

Her we have them both done

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4560.jpg)

Then over to the mill I left it set up with the stops so it should locate close to where I left it but decided to check bore position before I started the next op using a coaxial indicator.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4565.jpg)

It was went back within 0.2 so got it back on zero then first centre drill followed M2.5 tapping drill for the cylinder covers, be careful you don't end up with a hole where the air gallery will go, I did this on my first engine a built a few years back, you live and learn.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4566.jpg)

Tap M2.5 using the tapping stand to get everything nice and square.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4570.jpg)

Then drill and tap M5 on the underside to take the feet.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4567.jpg)

As it would make the cylinder a difficult shape to hold I left angling the valve port face till last.
I just angle the cylinder block 15 deg in the vice and milled off the meat.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4573.jpg)

At this point I was gasping for a cuppa so decided to leave milling the valve ports until tomorrow when I'll be fresh.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on January 20, 2011, 01:23:22 PM
Looking very purposeful Stew!  :wave:

Almost a Dreadnaught......  :thumbup:

Well done!  :clap:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on January 20, 2011, 03:17:43 PM
Wow, nice work stew, it's looking like the real deal already.

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: saw on January 20, 2011, 04:14:41 PM
Looking good  :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 21, 2011, 11:48:18 AM
Thanks for the interest Guys

Milling the valve ports:- this is what I call a **** or bust job its easy to get things wrong then your in it deep.

So I  like to mark the ports out this doesn't have to be dead accurate you'r just using this as a guide so that you get the wide port in the middle and the narrow ones at the ends and that the spacing is about right, I also like to make myself a crib sheet showing the cordinates I'm going to use.

I work from the centre of the valve face so first thing is find the centre and zero up the DRO in the x and y.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4576.jpg)

The middle port is 5 mm wide and the outer are 3.5 mm

Index to the correct cordinate:- centre drill and drill to depth using a number drill, thats just smaller than the slot drill, this stops the slot drill pulling into the corner and giving the port a hockey stick end.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4580.jpg)

Then using slot drill mill out the ports, as the valve face is angled each port is milled to a diverent depth, I took them considerable deeper than I planned on the drawing but with the actual job in my hand I had a brain wave on how to connect the ports up something that troubled me when I did the drawing as I was unsure how to do it.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4587.jpg)


Now the brain wave was  :smart: drill into the ports from the side, and drill through from the top of the bore to join it up, screw and plug the inlet ports to seal them up, the exhaust is left open.

Finding where to start the drill to join up with the ports.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4589.jpg)

Drilling through into the ports.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4590.jpg)


Lining up the cylinder to join the inlet port from the cylinder.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4592.jpg)

Joining the inlet port up.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4593.jpg)


And her we have the ports drilled

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4596.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4598.jpg)

I'll amend the drawing to reflect this change.

I'll put the cylinder to one side now as I want to make the valve chest and use it to mark of the fixing holes in the cylinder. But before I can do that I've got a huge tidying up job to do in the shop, I'm very much from the:- take it out, use it, put it down school of working as a result I end up with tools and bits of kit spread all round the shop.
 

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on January 21, 2011, 03:48:36 PM
Stew, I`m sorry, you replied to my question and I had not seen it until now.

Thanks for info regarding plugging the bore. I`m sure Harold Hall described a similar but crude method by plugging the holes with cork, marking the centre and then milling. I think this is what you did but more accurately with the aluminium.

Thanks again. Looks to be going great! I`ll be watching...
.
Chris
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 22, 2011, 06:02:26 AM
This is going  :offtopic: but I'd thought I'd show you how the pluging trick can work to get an awkward shape machined.

Some time ago to raise shop funds I machined up a small batch of cylinders for the Minnie traction engine.

These are the castings

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_1215.jpg)

The critical features is the position of the cylinder that is dimentioned from the centre line of the boiler the cylinder also has to lie parallel to the boiler centre line.

What you do is plug the bore and stick a bit of wood in the sadle to take the place of the boiler I used No Nail adhesive to stick the chunk of wood where the boiler goes.

Then you mark out the boiler centre line, choosing the best position for the particular casting, all three castings I used were diferent, then you can mark off the position of the cylinder and the radius for the sadle.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_1230.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_1235.jpg)

Then you pick up the cylinder position and machine it.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_1241.jpg)

Then turn up a mandril to fit the cylinder bore mount this up,  setting up on the scribed radius and machine the sadle, this ensures that the cylinder bore sits parallel to the boiler centre line

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_1264.jpg)

Her we have one of the completed cylinders.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_1447.jpg)


Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 22, 2011, 12:33:57 PM
Made a start on fabricating the steam chest, the parts are straight forward machining.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4599.jpg)

The dowels well keep everything in place when soldering, there not a particularly tight fit and I filed a flat on them to let any gas escape as the job heats up other wise the pressure will pop them out.

This is how  I set it up for solder, with the joint fluxed and rings of solder round the glands and little nuggets of solder sitting on the joint, putting it in the corner helps keeps bits in place and retain the heat, I tuch on the end of the dowels with a filler rod just to fill them in.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4601.jpg)

This is it after 5 minutes in the acid i stuck it back in for an hour

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4604.jpg)

Cleaned the outside up with a file then milled the faces flat so they will make a good seal.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4605.jpg)

Then with it upright in the vice find the centres and drill and tap the sealing gland.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4606.jpg)


Starting to look like a cylinder now.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4610.jpg)

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: saw on January 22, 2011, 01:06:12 PM
You are doing a very greate work mister.  :med:
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on January 22, 2011, 01:10:53 PM
 :bow: Thank you...great explanation!!!
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on January 22, 2011, 02:46:04 PM
 :thumbup: :clap:

 :beer:, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: Dean W on January 22, 2011, 06:54:10 PM
Wow Stew.  A lot of interesting setup work you are showing here.  I like the way you did the steam
passage ports, too.  A lot better than trying to figure drilling holes that sit in two different angle planes!
Thanks for the show.

Dean
Title: Re: Potty Over Crank Wall Engine
Post by: shoey51 on January 23, 2011, 01:03:57 AM
Wow Stew glad I caught this build I just love watching you work :thumbup:
im not game to tackle anything this intricate :scratch:

cheers Graham
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 23, 2011, 11:59:00 AM
Thanks for you kind support chaps

I had to change the layout of the holes in the steam chest, when I came to try the chest on the cylinder to see how thing looked I realized that changing the air feed hole position meant that I would break through into them with the steam chest fixing holes, not as though it would have been a disaster as the studs will be sealed in and the chest will be sealed on the cylinder but I thought it best to avoid it.

So with the new layout marked on the chest first drill them 3mm

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4615.jpg)

When I milled the steam ports and machined the chest I marked the center line with a tiny dimple from the centre drill, this is so I will have a mark to line things up. So with two way sticky type on the chest stick it to the cylinder centrally and square using the marks and the back edge of the chest lined up on the back edge of the cylinder, then with a little transfer punch made from a bit of 3mm silver steel (drill rod) mark the position of the holes in the cylinder.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4616.jpg)

Set the cylnder level using the digi level, a real handy bit of kit , carefully line up on the marks with a centre drill and then drill M3 tapping.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4619.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4621.jpg)

Then on the tapping stand and the cylinder jacked level using a sine bar tap the holes nice and square.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4626.jpg)

Now for the cover a bit of 2mm brass plate was rough cut out and the chest placed on top and a line scribed round it.

Mill to the line, the parallels are to reduce the angle of dangle and give it a bit of extra support.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4627.jpg)

Then clamp the chest to it and drill through when you've done the first hole put a clamp bolt through it do the second and put another clamp bolt through it as well, remove the clamp and drill the rest of the holes, I used a number 31 drill to give a little wiggle room.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4629.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4631.jpg)

The hole in the middle will take the air intake flange the top of this flange will be leveled off so the hole in the cover needs to go in at an angle, so with the cover bolted to the chest and set up at 15 deg, first a big centre drill followed by a slot drill this angle the hole nicely.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4632.jpg)

This is the cylinder assembly so far

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4634.jpg)

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on January 23, 2011, 12:06:56 PM
Looking top draw!!
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on January 23, 2011, 12:33:02 PM
Beautiful work Stew!  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 23, 2011, 01:48:54 PM
Thanks Guys

Nice, very nice, glad you can find time to work on excellent projects like this!
-Kenneth

Kenneth

I'm retired  :D so I've plenty of time to indulge my hobby and watch our grandchildren grow up.

Thanks

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: saw on January 23, 2011, 03:02:12 PM
This is so very nice, keep up your'e good work.  :bow: :bow: :bow:
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on January 23, 2011, 03:03:20 PM
Good going Stew  :thumbup: - top job!

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on January 23, 2011, 04:08:27 PM
Looks spot on that Stew, even more impressive that you've seen this engine in full size, done your research and now creating it in miniature.
 :bow:

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on January 24, 2011, 12:09:52 PM
Well Stew, I've missed much of this (head being in the clouds!)  But I've just read through it all and I'm very impressed  :clap:

You take a little time from your loco to relax and end up making an engine from one you saw and thought you'd like to make... Top job!   :beer: 


 :nrocks: 



I'm liking your progress so far  :thumbup:





Ralph.
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 24, 2011, 12:32:34 PM
Thanks Guys

Happy new year Ralph sorry I missed you over at Johns the other week

Ever had one of those days when you think you should have stayed in bed.

Putting the pipe coupling on the steam chest cover I turned the bit up, and soldered it to the cover, this is the set up I used to solder it, coupling sitting on a flat surface cover angled bit of heat onto the mill to clean the top of square and drill the stud holes.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4635.jpg)

This is what I ended up with.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4640.jpg)

You can see that the darn thing  has slipped and I've ended up with quite a taper on the flange

Strike 1 over to plan B

Cut it off and clean the solder off and start again this time I thought it would be more stable if I milled an angle on the coupling

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4641.jpg)

 Line it up on the cover and solder it on, square it up drill holes. Nope the double darn thing  :bang: :bang: had moved also and looked like the leaning tower of thingy.

Strike 2 over to plan C

No more piddling about and stop trying to be cleaver just solder a lump of brass on the cover mill the top off square and drill the holes.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4644.jpg)

That sorted it  :thumbup:  :D

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on January 24, 2011, 12:41:22 PM
Stew.
Some kind of cosmic learning process, I think......  ::)

Well sorted, in the end.  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on January 24, 2011, 12:44:19 PM
Hi Stew

LOOKIN GREAT  :bugeye: :bow: :bow: :bow: :bow: looks just like the real thing  :D


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on January 24, 2011, 02:49:23 PM
Shame about the first 2 attempts Stew but you got there and it looks just as good.  :bow:

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on January 25, 2011, 03:37:38 AM
Hi Stew... Happy new year to you too  :beer:

Not a problem about missing my visit... there will be another soon enough  :)     (as long as I'm allowed.... Should be? Don't want to assume. I always ask  :thumbup: )


Quote
Ever had one of those days when you think you should have stayed in bed.
Oh....     Just every day  ::)        :lol: 


Shame about the fails..... Good stuff with the recovery  :dremel:




Ralph.
Title: Re: Potty Over Crank Wall Engine
Post by: shoey51 on January 25, 2011, 02:29:22 PM
Stew these things happen to the best of men but you persisted and it worked out in the end :clap:

cheers Graham
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 26, 2011, 11:00:17 AM
Things slowed down over the last couple of days but did manage to get a little done on the cylinder end covers, these are just plain turning jobs the hard bit is dealing with the thin section when you do the second op, I deal with it by puting my back stop in the head stock and pushing the thin cover up against it this help get it concentric and keep it secure. With the piston end covers with the stuffing gland its important to get the register with the cylinder concentric with the piston rod hole I do this by clocking the cover up in my three jaw i know that if I keep trying it in diferent positions one of them will be spot on.

Drilling the bolt holes and drilled to the full depth of the flutes this was enough to do three of the covers.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4642.jpg)

A bit of fancy work

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4651.jpg)

Clocking the a cover up

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4652.jpg)

Covers done

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4655.jpg)

I'm planning on fitting a governor to the engine I drew one up but as I was unsure if I'd got the proportion correct

The first pic shows the governor against the cylinder at 1 : 1 scale

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4650.jpg)

Its far too big

This is it 1/2 size

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4649.jpg)

Better but a wee bit small I think I somthing slighly bigger would be about right, some of the parts will be a bit on the small size but still doable.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on January 26, 2011, 11:16:25 AM
Nice work on the covers Stew, if you drilled the hole and turn the register at the same setting in the lathe wouldn't they be concentric anyway?

The 1/2 scale governor looks just right to me  :thumbup:

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 26, 2011, 11:19:40 AM
Yes but you'd still have to turn it round to drill and tap for the gland nut which also registeres on the piston rod you pays your money and take your chance 

:D

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on January 26, 2011, 02:09:59 PM
Hi Stew

I do like the look of that governor  :thumbup:  ,nice bit of detail in the bracket  :med:


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on January 27, 2011, 03:26:43 AM
 :doh: Of course Stew sorry!

On the covers for the other end I presume you must have spun them around and turned the register last as well, as you did the fancy pattern on the face you can see? Do you just turn them near to size then take smidgins off to get a good fit in the cylinders or just measure them?

Cheers,

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on January 27, 2011, 05:21:46 PM
Hi Nick

I measured, then tried them for fit just a little bit of clearance.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 04, 2011, 10:56:40 AM
I bet you're wondering where I've bin with this, well had a few days out over the weekend spent in windy Cornwall.

Got a bit done over the last couple of days made the nuts for the glands.

Not much to these except try and make them in one go to get the thread concentric with the bore and to ream the bore.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4661.jpg)

Also lapped the port face nice a flat using a bit of fine wet and dry on a flat surface, this is so the slide valve makes a nice seating onto it.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4677.jpg)

I cut all the studs to length I'm just waiting for some stud lock to be delivered to fix them in place.

Made the slide valve, I made both valves in one piece saves setting up. Start by milling a bit of bar to size then as a guide mark out the recess.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4678.jpg)

Then over onto the mill I like to work from the centre out but any way you're happy with will do its really quite easy if you've got a DRO I made slide valves without the DRO and you really have to be carful how you manage the back lash or you can get it all wrong. The first cut only has to be correct as you deepen the pocket you can finish the cut short it won't matter a jot it's only the edge that does the work. Just work clock wise around the pocket so you're not climb milling.

First done

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4681.jpg)

Second done

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4683.jpg)

Flip it over and do the back

Slot for rod

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4684.jpg)

Check that depth is good

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4685.jpg)

Slot for cross bar.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4691.jpg)

Then cut it in half to make the two, and mill to length and don't forget to lap the face nice and flat same as for the cylinder.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4692.jpg)

Next I tried out my new mini vice to make the cross bar this is made from a bit of 1/4" square mild steel again make the two together.

Put the bit of bar on a flat plate put the vice over the top of it tighten vice that the bar gripped nice and level,

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4693.jpg)

Then transfer the little vice to the big vice drill and tap.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4695.jpg)

And thats the slide valve done and fitted.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4700.jpg)

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on February 04, 2011, 11:52:41 AM
Stew.
That last pic sums it up nicely!  :clap:

Coming together, and looking well.....  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: GWRdriver on February 04, 2011, 12:40:10 PM
Stew,
I haven't checked on you in a while . . . I like your work.
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on February 04, 2011, 12:54:54 PM
This project is coming along very nice Stew.

Those tiny vices are a nice bit of kit when it comes to swinging around those 'unholdable' bits that need machining. I basically got laughed at when I first showed mine being used, but I had the last laugh when I showed it being used with a cutter almost as big as the vice cutting away at a miniscule sized part.

John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 04, 2011, 01:37:13 PM
Thanks Chaps

John I was very suprized just what clamping pressure you can get with that little vice, its very well made, I want to put it to use making the small bits for the Governor.

I've just got to tidy the studs up and finish turn the piston when the stud locks done its setting thing for 24 hrs, and that will be the cylinder more or less finished, then I'll have to put this job to one side until I drop on a bit of ally jig plate for the base, I've scouted arround the scrappy 3 or 4 times now without luck.

Can any of you Guys help ?:-

I need aluminium plate:- 14 cm * 240 cm * about 15 mm thick it doesn't matter if its got a few holes in it I can soon plug those:- I'll pay postage and cost.

In the mean time I've got one or two other jobs to get on with.

Stew



Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on February 04, 2011, 02:20:15 PM
Coming along really well Stew  :clap: :thumbup: - Nice job on the valves!
I really like that mini vise as well; definitely a need-to-have on my list, as I'm currently clamping small bits on the edges of my mill vise, which is far from ideal.

Wish I could help with the ally plate - bit far though - besides, I'd also like to get my grubby paws on some  ::)

 :beer:, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on February 04, 2011, 04:21:46 PM
Stew,

I hope you realise that you have just asked for a bit of 15mm thick plate, about 6" wide by about 9 feet long.

Just how big is this engine you are building?

 :lol: :lol: :lol:


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 04, 2011, 05:00:38 PM
Bugger  :bang: decimal place wrong, thats what comes of mixing cm with mm.

14 cm * 24 cm * about 15 mm

or about 6" * 10" * 1/2" I sould stick to good old imperial.

Thanks for pointing that out John.

Stew



Title: Re: Potty Over Crank Wall Engine
Post by: shoey51 on February 04, 2011, 05:41:33 PM
easily done Stew :scratch:





Graham
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 13, 2011, 11:12:05 AM
Spent last weeks on domestick duties and finishing of a few other jobs.

Made the pistons finished the heads off on the rods griped in a collet to keep everything concentric.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4705.jpg)

Nice slide fit in the bore.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4707.jpg)

Got all the studs the same lenght by putting a couple of washers under the nut and filing the studs off flush with the nut, remove a washer and you've got them all the same amount of stud sticking out above the nut.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4715.jpg)

Made a start on the bearing housing drop a bit of a clanger when I drew it up for some reason I thought the flat bar I had put aside for this was 10mm * 55
no its 10mm * 50, never mind I see this as an oportunity to make the diference up with a bit of bling.

First job cut the three housings off the bar, blue one of them up mark it out, then stick all three in the vice and drill them all through to take two 3mm dowels to keep them lined up whilst the rest of the machining is done.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4756.jpg)

Rough drill for the bearing and the corner.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4761.jpg)

Clean the faces up to get them nice and square.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4764.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4766.jpg)

Stick a 10mm drill in the bearing hole and use this with an edge finder to get the mill on the bearing centre line.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4768.jpg)

having first marked out the holes for the bearing caps

Then drill M4 tapping

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4771.jpg)

Cut the bearing caps out with a slitting saw

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4774.jpg)

Tidy up the step

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4777.jpg)

This is how far I've got I've stamped the caps so they will go back where they came from.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4780.jpg)

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: saw on February 13, 2011, 01:15:00 PM
Nice  :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: madjackghengis on February 13, 2011, 01:34:31 PM
Hi Stew, the engine is looking good and coming together nicely.  Looking forward to seeing it go together and end up running.  A fine display of craftsmanship. :nrocks: :poke: mad jack
Title: Re: Potty Over Crank Wall Engine
Post by: shoey51 on February 13, 2011, 03:48:33 PM
you make it look to easy Stew lovely work mate :clap:

Graham
Title: Re: Potty Over Crank Wall Engine
Post by: Dean W on February 13, 2011, 04:09:50 PM
Coming along very well, Stew. 
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on February 14, 2011, 01:46:40 AM
Nice progress Stew  :thumbup:

"Got all the studs the same lenght by putting a couple of washers under the nut and filing the studs off flush with the nut, remove a washer and you've got them all the same amount of stud sticking out above the nut."
Thanks for that tip!!! - So simple a solution to a problem that's bugged me in the past.

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 14, 2011, 02:00:22 AM


Thanks for the comments and support Chaps

 :wave:


Nice progress Stew  :thumbup:

"Got all the studs the same lenght by putting a couple of washers under the nut and filing the studs off flush with the nut, remove a washer and you've got them all the same amount of stud sticking out above the nut."
Thanks for that tip!!! - So simple a solution to a problem that's bugged me in the past.

Kind regards, Arnold

Arnold

The stud tip came from John Bogstandard, I'm just passing it around  :D

Thanks again

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 15, 2011, 06:57:28 AM
I was hoping to be further on with this engine but Family commitments keep taking priority, any way got a little more done.

Tapped the housing and the lubricator hole in the bearing cap M4 and opened the clamp holes in the cap out to M4 clearance.
Then assembled the caps to the housing pinching down onto a couple of folds of paper, this is so the caps will tighten down onto the bearing.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4786.jpg)

Then transfered over the mill and found the edges then indexed to the bearing centre and machined out the bearing location using a 15mm end mill fed straight down, it cut over 15mm thats doesn't matter i'll just make the bearings to fit.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4789.jpg)

Flipped the job over and drill the base M4 tapping and whilst I was at it drilled a line of 3mm holes so if I wish I can line the housings up on the base plate with dowels not sure if I'll do this or not but may as well drill the holes whilst I'm at it as they are out of the way.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4792.jpg)

I managed to drop on some jig plate on flebay paid an arm and a leg for it but needs must, so tried the parts out to get some odea of how things are looking.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4794.jpg)

Not to bad unsure how the seven inch fly wheel will look though.

Stew


Title: Re: Potty Over Crank Wall Engine
Post by: shoey51 on February 15, 2011, 02:55:14 PM
 :thumbup: lubly jubbly looking good Stew

Graham
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on February 15, 2011, 03:34:07 PM
REALLY looking great Stew!  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 21, 2011, 09:23:33 AM
Cheers Dave/Graham

Well, I've bin quietly making progress not as fast as I would like but progress nevertheless.

Next part the crank but before I can assemble the crank I need a couple of other parts first:- the eccentric sheaves and the bearings.

I had a bit of a false start with the sheaves it was my intension to have them as plain disc the straps being kept in place by adjoining bits but after I made them I realized there would be too much space between the parts and some of the part wouldn't have a smooth face so they would catch, so decided to make the sheaves edged so that the straps would be retained. I also went about making them a different way to the method I've used in the past I've got more confident with the mill so decided to use the mill to drill the off set hole.

First turn a chunk of bar up to the required diameter and put a small centre drill in it.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4812.jpg)

The retaining the bar in the chuck transfer it over to the mill centre it under the quill.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4813.jpg)

Zero the dials and off set the table and drill the hole right through the bar, I drilled it letter U to allow a final clean up with a 3/8" hand reamer.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4816.jpg)

Then back to the lathe and machine the groove for the straps using a parting tool, then part off to length.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4817.jpg)

Face to length using the back stop in the chuck.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4824.jpg)

Then drill and tap M2 one thing a learnt from the first attempt was that the taps are to short to get through the thicker section of the sheaf as drawn, (broke a tap) so for these I tapped through the thinner section.

Next bit the bearing no pic of this as they are simple enough.

The crank shaft is fabricated

So to make the crank shaft webs.

Again I changes my method to take advantage of the accuracy of my mill.

Cut a chunk of plate and milled it to size enough to make all four webs.

Than onto the mill drill four evenly spaced holes down one side again letter U move the table over to give the correct throw and drill down the other side

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4799.jpg)

Bring to size with hand reamer.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4801.jpg)

Cut off with a slitting saw

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4803.jpg)

Then with a couple of same size bars in the holes, mill thickness to size.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4804.jpg)

Turn up a 3/8" mandrel with a M8 nut and in the lathe radius the ends.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4805.jpg)

Thats them done.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4811.jpg)

Now for the crank shaft journals:- first with the bits roughly assembled check the main journal length cut it off the bar then in the lathe face of centre, and turn and thread both ends.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4826.jpg)

Cut off and face the crank journals to size.

Now to stick the crank shaft together with high strength loctite, its important not to rush this and to do it in stages letting the loctite cure between stages.

Stage one glue the crank journals to the webs using spacers, the main shaft is there just to keep everything lined up.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4827.jpg)

Stage two glue one of the crank journals to the main shaft the correct distance from the end. (no Pic)

Stage Three glue the remaining crank journal to the main shaft 90 deg to the first at the correct distance. Using 1*2*3 block:-not forgetting to assemble the sheaves and the bearings in-between first.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4834.jpg)

Next as I keep my trousers up with a belt and brasses, pin the cranks in place, I just put the pins 1/2 way through that will be enough to stop things slipping, but as an insurance against having to break the crank down to change something one of the pins a drilled all the way through so that I can nock the pin out and take the crank apart to get at the sheaves and bearing.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4835.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4838.jpg)

Cut the bit out of the middle you don't want

And her we have it finished in the housings its turns over nice and free   :D

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4840-1.jpg)

Stew







Title: Re: Potty Over Crank Wall Engine
Post by: saw on February 21, 2011, 09:52:05 AM
Nice, :headbang: you do everything so easely  :(
Title: Re: Potty Over Crank Wall Engine
Post by: cfellows on February 21, 2011, 10:53:14 AM
Nice series, Stew.  The crank assembly turned out real nice.  On the sheaves, there are a couple of different tricks I've used in the past for putting a setscrew in a deep hole.  One trick is to drill the pilot hole all the way through, then, drill a larger hole, the size of your set screw or a little larger part way through.  Then you only have to tap the last little bit for the set screw.  Another trick is to drill the pilot hole all the way through, then thread only the outer portion of the hole.   Put a suitable length of steel or brass pin the diameter of the pilot bit in the hole first, then just tighten the setscrew down against the pin.  These alternate methods are useful if there is no thinner section, as there is in the sheave.

Chuck
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on February 21, 2011, 10:54:52 AM
stunning  Stew  :bow: :bow: :bow: :bow: top job  :thumbup:

Have you decided on the flywheel size ?


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on February 21, 2011, 10:58:29 AM
Saw is right, to me doing the crank is a big job - you made it look easy!

Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on February 21, 2011, 10:59:41 AM
 :clap: :clap: :thumbup: That crank really looks good Stew!

 :beer:, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 21, 2011, 11:40:52 AM
Thanks Guys

Chuck they are great way of getting round the sheaves problem.  :thumbup: I'll file them away fro future use.

Rob:- I think I'm going to go with the 7" fly wheel, I've also decided to use a Hackworth governor they are more compact, and look easyer to make.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on February 21, 2011, 03:58:29 PM
Hi Stew

Witch Hackworth ,,,,,,,,,,,,,,,,, the bloke from up here ?


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 21, 2011, 05:23:36 PM
Don't know whhere I got Hackworth from  :bang:

Got it wrong just checked the book its Hartnell but I bet he's from up north all the best engineers are.

Tried googling his name but kept getting pitures of Doctor Who  :scratch:

Any way this is the sort

http://murdochsite.tripod.com/Hartnell.pdf

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on February 22, 2011, 01:49:55 PM
Hi Stew

You had me thinking there ,as i could not remember MR Hackworth ,, making a governor  :doh:

Rob


Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on February 24, 2011, 03:43:37 PM
Looking good Stew  :thumbup: 

This is going to be a stunner me thinks?    :headbang:

Double inspired today  :beer:




I might not be saying much but I am following along  :)






Ralph.
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 25, 2011, 04:36:46 PM
Cheers Rob/Ralph

These post are coming in big lumps, My Dad is in hospital, his dementia has got worse over the last month, so I've been spending quite a bit of time visiting, and taking R and R in the shop, to keep my mind off things, so the posts have been a bit spread out.

Any way making the con rods, first I spent a bit of time getting a bit of old rusty garage door squared up and milled to size then a stuck the two rods together with two sided type, and doweled them through in a part that will be milled away later, and marked the rod out.

This is one of those jobs where you have to get the sequence correct cutting the wrong bit off at the wrong time and you will make things difficult for yourself, so I spent quite a bit of time machining the rods in my head first before doing it for real.

Making two together save a lot of setting time.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4842.jpg)

Rough drill the bearing holes and holes for what will eventually form the middle of the rods

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4843.jpg)

Then drill through for the clamp holes for the big end bearings caps.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4845.jpg)

Then over to the RT and radius the ends

Big end

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4847.jpg)

Little end

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4851.jpg)


Then with a slitting saw cut off the big end bearing caps.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4854.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4855.jpg)

Drill for a 3mm dowel hole that will stop the bearing shells turning.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4858.jpg)

Tap the bearing caps M4 I'm going to bolt things together from the rod side this way the bolt heads won't fowl the cross head.

Chew away the meat from the middle.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4859.jpg)

As the cap bolts will be on the rod side the bolts won't sit flat due to the rad, I could square this off but that wouldn't look right, the solution is to back face to give the bolts a flat seating.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4866.jpg)

To make the back facing tool.

Using a length of 8mm silver steel (drill rod) mark it out for length for the back facer, turn a 4mm holding spigot, then gash out a single flute, and with a file back the cutting edge off, heat to cherry red hold it at this for a couple of minutes and quench in water, temper to a straw color, and sharpen the cutting edge on an oil stone.

To use pass the tool through the bolt hole grip the end in a chuck, tightened good and tight, and slowly wind it back so that it cuts a flat platform for the bolt.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4871.jpg)

Worked a treat the bolts sit nice and flat now.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4885.jpg)

This is my set up for using the coaxial on my mill and No 3 morse taper collet with a concentric split bush:- I didn't have a collet of the correct size but it runs dead true.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4886.jpg)

This gives me plenty of head room on my X3.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4889.jpg)

Clock the little end up to get thing on centre and zero the dials.

I then worked back from the big end, finding the edge and zeroing up the Y, set the vice stop, removed the rods from the vice, fastened the caps tight onto the rods, returned to the vice hard up gainst the stop, and them with a 15mm end mill finished off the big end bearing seat.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4890.jpg)

Move to little end position, and finished of that bearing seat with a 12mm end mill.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4894.jpg)

Now I have to decide how I'm going to fancy up the rod, when at John,s the other night he showed me a con rod that he had made, it was tapered toward the little end with a radiuses scallop that matched this taper looked real nice, so I was wanting to do something similar.

Tried a lose assembly of the parts to try and get a feel for how things would looked.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4895.jpg)

Decided that I would stay with the square parallel lines but to thin the rod off up to the little ends with nice radiused corners and a scallop down the middle.

Radius the corners both sides first with a ball nosed cutter then with an end mill thin it out by 1.5 mm a side.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4897.jpg)

Then mill the scallops with a ball nosed cutter I just went 0.5mm deep.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4902.jpg)

And last I reduced the width of the little end, If I'd done this earlier it would have made gripping thins difficult.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4903.jpg)

Thats them done a bit of a tickle with a file and a rub with some emery and I reckon they'll do.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4904.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4905.jpg)

Stew




 



 


Title: Re: Potty Over Crank Wall Engine
Post by: dsquire on February 25, 2011, 04:55:01 PM
Stew

Very well done and nice presentation as well. Our thoughts and prayers are with you for you Dad. Just keep plugging away with 1 (or 2) piece at a time and before you know it you will have the last piece in you hands.  :D :D

Cheers  :beer:

Don

Title: Re: Potty Over Crank Wall Engine
Post by: saw on February 25, 2011, 05:00:08 PM
Thanks for the lession very nice indid.  :bow:
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on February 26, 2011, 02:29:01 AM
Stew.
So sorry to hear of your, and Dad's problems. Been there ourselves.......


I'm a little preoccupied, too.

But. Still watching...... Still appreciating all you're doing, and showing.  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 26, 2011, 02:29:51 AM
Thanks for your kind thoughts Don

Thanks Dave Hope things work out OK for you to.

Thanks for you comments:- Kenneth and Saw

 :wave:


I do like to show things step by step, as it's not always appreciated how much thought and planning has to go into making a part, its far more involved than just hacking away at a chunk of steel and hopping it will come out right at the end.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on February 26, 2011, 03:58:45 AM
Stew, amazing stuff and great photos. Two trivial questions compared to the rest of the work and setup you have shown... firstly what blue layout ink do you use? Your parts always look much darker and clearer layout out than my efforts- I`m always squinting to see my markings never mind capture them on camera. Secondly, exactly how did you pin the two piece together? I have a feeling if I tried this mine would separate mid-machinging. You said you used 2 sides tape and a dowel. Just standard 2 sided tape? How was your dowel inserted -  a hole drilled in one side and a matching hole whole on the other with a dowel glued in place?

Excellent work -can`t wait to see it running!
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 26, 2011, 05:45:13 AM
Thanks Chris

The blue I use is just standard engineers marking blue from Chronos, I put it on with a brush and let it dry for 1/2 hr, the lines show up better if you applied it to a shiney serface.

The dowels I use are 3mm silver steel but I drill No 32 or No 33 which is just under 3mm so that the dowels are a light drive fit. Try and dowel the parts together before you square the stock up that way it will be like working with one solid lump of steel and the parts will be identical when parted, the two sided tape comes in handy just to keep the bits together whilst you drill for the dowels, the tape is just cheep stuff I got from the local market works OK for me.

Doweling parts together is used a lot in jig and tool manufacture:- the tool room I served my apprentiship in made a lot of press tool with parts doweled together, to maintain alignment.

Hope this helps

Stew



Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on February 26, 2011, 06:01:43 AM
Bin thinking about the marking blue, I guess on a dull or black hot rolled surface marking white would show up the lines better, I think I've seen castings marked up this way I wonder what was used, any ideas.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: andyf on February 26, 2011, 06:43:45 AM
Maybe you could use paint - white primer or undercoat would do.

Andy
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on February 26, 2011, 06:59:04 AM
Bin thinking about the marking blue, I guess on a dull or black hot rolled surface marking white would show up the lines better, I think I've seen castings marked up this way I wonder what was used, any ideas.

Stew

Stew.
When I wor a lad......  ::)

Every morning I had to crush a lump of chalk, big as me fist, and mix it with water for the marking out department men.

They painted on. Then blew dry with the airline, when in a hurry.  :thumbup:

Used on iron valve castings. Daren't leave any lumps in.......  :doh:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: scrapman on February 26, 2011, 12:47:40 PM
Hi stew  :wave: the build is looking great, sorry about your dad i know what your going through my mother had vascular dementia,


Ray.
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on February 27, 2011, 04:57:00 AM
What about those white paint markers? Don't know what they'd be like but worth a try.
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on February 27, 2011, 03:39:42 PM
Hi Stew


Cracking job you have made of the rods  :bow: :bow: :bow: :bow:   ,,,,,,,,,,,,, Will this be your next engine publication  in model engineer  :poke: :poke:  :)


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 05, 2011, 04:57:17 AM
Hi Stew

Will this be your next engine publication  in model engineer  :poke: :poke:  :)

Rob

Hmmmmm depends on how it comes out Rob, little bit concerned about the size it looking as though it will be a bit bigger than I had in my minds eye, its scaled at 1/3 of the full sized engine I think I would have been better if I had based it on a 4" fly wheel which would have bin about 1/6 th but that would have led to other complications.

Any way on with the build :-the split big end bearings, I was concerned that to make split bearing is waist-full on material, then John suggested to make them from two bit of oblong bar milled of square and held in a four jaw. I had already got some brass plate put aside to make the eccentric straps, when I measured it up I realized that I could get the split bearings out of it as well.

So soldered the two half's together as John showed in his resent post

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4906.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4909.jpg)

Square it up in the mill and with a slitting saw cut the bits out:-The square bit will make the Straps and the the long bit at the top the bearings.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4913.jpg)

For the bearings square the bar up making sure to get the join on centre, then grip it in the self centering four jaw, turn up dia then drill and ream the bore and part off to length.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4914.jpg)

Apply a little heat to separate

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4915.jpg)

To finish off fit a small dowel in the hole I drilled in the con rods and mill a small flat in one bearing half, the dowel will stop the bearing spinning in the housing, like a key.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4919.jpg)

Thats them done

Eccentric straps

Taking the same amount of both sides so the join stays central thin the blank out a bit

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4922.jpg)

Then drill a 10mm hole in the middle, turn a mandrell up and use this to mount the blank on the RT line the RT up using the centre in the mandrel.

Scratch a centre line using a centre drill held in the chuck.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4929.jpg)

I used CAD to work out the angles to generate the strap.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4931.jpg)

Then first drill the corners 3mm

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4932.jpg)

Then with a 3mm slot drill mill out the shape.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4935.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4937.jpg)

With the straps still on the mandrell and using the mandrell to find the centre line drill the strap M2.5 tapping and drill a 1/6" hole to help locate the rod.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4938.jpg)

Then line the scratched centre line up using a parallel.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4944.jpg)

And with a 1mm slitting saw split the strap in half.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4945.jpg)

Tap one half M2.5 and open the other up to 2.5 and bolt the two half's together, then in the four jaw, (check the split is on centre) bore out to for a nice running fit on the eccentric sheath.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4948.jpg)

Separate the two straps by heating them up.

To face the straps to thickness you need to ensure you get the bolt holes central so turn up some little bushes 4mm dia and fasten the two half of the strap together with these bushes.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4954.jpg)

Turn up a mandrel same size as the sheaths, I used the bit of bar the sheaths were made from, clamp the strap to this and with a sharp tool, small cuts and time, face the strap off until you just kissing the bush, turn it over repeat the other side and the hole will come out in the middle.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4956.jpg)

Done

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4959.jpg)

This is what it's looking like

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4962.jpg)

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: ozzie46 on March 05, 2011, 05:29:10 AM



   Great work Stew. Your really coming along nicely.

 Ron
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on March 05, 2011, 05:30:04 AM
That is really looking well now Stew. Those parts have turned out perfect.

You've done a great job scaling it down, and personally, I think you have got the size right, any smaller and the parts would start to get a little fragile, plus you wouldn't have as much 'fiddle factor' to play with, a big consideration when doing a one off like this.


John
Title: Re: Potty Over Crank Wall Engine
Post by: saw on March 05, 2011, 09:00:33 AM
Nice work.  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on March 05, 2011, 03:52:36 PM
 :D Looks great Stew  :thumbup: :clap: :clap: Lovely Job  :bow:

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 12, 2011, 03:20:47 AM
Thanks John/Keneth/Ron/Saw/Arnold

Well things slowed down a little on this project over the last week I wanted to get all the connecting rod things done before moving on to other parts, but the material for the return connecting rod has bin a long time in coming I bought it nearly three weeks ago off flebay, chased them up a couple of times and was on the point of putting it in dispute and claiming my money back from paypal, when I got notification this morning that it was in shipping, we will have to see if it arrives next week. In the mean time I did that little break rod job, with that complete I decided to get on with the fly wheel and pulleys for this engine.

For the pulley I thought I would try a method thats bin cooking away in my head for some time:-fabricate sticking all the bits together with high strength loctite, not sure if this will work but we'll give it a go.

This is the material I'll be working with:-a dog end of some thick wall pipe, a bit of hex bar and some 3/8" round mild steel bar.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4982.jpg)

First job drill across the hex bar and tap M5 for each six sides, turn up some 3/8" spokes and thread M5 then stick them in the hex with the loctite.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4983.jpg)

Then clean up the rim, and bore out leaving a step 1/2 dia of the spokes + the thickness of the rim deep.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4985.jpg)

Then after giving the loctite 24 hrs to cure and with light cut skim the spokes down to a close fit in the rim.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4988.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4994.jpg)

Then assemble the two together with the loctite.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4996.jpg)

 My employer was a big user of loctite and the rep always said that the strength of the bond was a function of the contact area so I'm hoping that the thick spokes will give enough contact area for a strong bond that will do the job, if it doesn't the fall back will be to drill through the rim into the spokes and pin them together.

I'll leave it to cure before I do anything else to it, them we will see what we will see.

Stew


Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on March 12, 2011, 03:43:32 AM
If you wanted material Stew, you should have given me a call, if it is here, you can have it.

That pulley is looking nice. I too am putting a lot more faith in retaining compounds, as long as there is no heat about the area.


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 12, 2011, 04:04:43 AM
John the material I'm waiting for is 3mm * 30mm * 1000mm mild steel, if I'm let down I'll come round and see if you can help.

Thanks

Kenneth

Those are good pointers for use of adhesive:- I didn't use cutting oil so I new all the bits were nice and clean, just a bit of cutting dust wiped off with a clean rag, Adhesive can have a bit of a bad press but I think its all a matter of understanding the right conditions and aplications to get the best out of it. I've had that little bottle for over three years now and used it quite a lot I'm begining to think its a endless supply, I certainly got my moneys worth out of it.

Thanks for your interest.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: NickG on March 13, 2011, 03:57:28 AM
Looking great that Stew. I like the pulley. I think I may try making a flywheel with that method. Is the pulley going to drive anything? I recon it'd have to be a heck of a load to break the bonds so very
Much doubt it'd happen. If you had to pin it, you probably wouldn't see the pins anyway unless you made them from a different material as a feature!
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 13, 2011, 06:48:12 AM
Thanks Nick

I had though of the posibilites of different material using this method, it would result in an interesting fly wheel.

This little experiment was a limited sucess. Mounted this wheel up in the lathe this moring I had thought of rigging something up that would drive it on the spokes to trim the hub up, taking the load off the bond, but in the end thought no, may as well give it a good test, cleaned the hubs up no problem the adhesive bond held, with just taking light cuts, drilled and reamed out the bore this went fine, ho ho I thought wer're onto a winner, but when I tried the pully on the crank and gave it a spin it was running out, on closer inspection the bond had failed, the failure was axially not radialy, when I drilled out and reamed, I had the wheel chucked so that axiall loading wasn,t being supported by the step I had turned in the rim, allowing the hib and spokes to move back slightly.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_4998.jpg)


This is what it looks like on a lose assembly.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5000.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5002.jpg)

Not to bad

But as one of the critical features of any wheel on a small engine is that it be woble free.
So to fix it I turned up a mandrel, pushed the hub back so that the area of bond was exposed reaplied more loctite, got it back into position and nudged the rim back concentric with a crude nugger, just a bit of brass bar in the tool post, worked a treat wheel is running dead true again, I'll give it plenty of time to cure before having a think about pinning it.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5004.jpg)

On the face of it I would think that this is a feasable method for fabricating a fly wheel, but you have to take care on any post fixing machining.

Stew

 
Title: Re: Potty Over Crank Wall Engine
Post by: saw on March 13, 2011, 07:22:46 AM
Looking very good.  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on March 13, 2011, 09:22:19 AM
That's a crackin' way to fabricate a flywheel Stew!  :clap:  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 13, 2011, 08:07:10 PM
Cheers Saw/Dave

I'm still not sure about that pulley though, I've a mind to pull it apart and start again, salvaging what parts I can.

In the mean time made a start on the fly wheel, I'm using a 7" dia cast iron fly bought from RDG. Gave it a good going over with files cleaning off all the lumps and bumps and getting to grips to its shape.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5008.jpg)

Set it up in my big four jaw chuck and cleaned the face off and the inside of the rim and part of the OD, found that its got some blow holes in it that wont clean up, looks like I'll have to fill them with something have you guys got any suggestion, at Crewe Loco works they used a concoction they called buggerum, made up from putty red lead and iron filing, but I thought of body filler.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5010.jpg)

Cast iron is real filthy stuff to work with, looks like I can join John's black hand gang.   :D

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5009.jpg)


Stew
Title: Re: Potty Over Crank Wall Engine
Post by: madjackghengis on March 13, 2011, 09:45:36 PM
Hi Stew, it's looking very good so far, I'm really interested in seeing her running :bugeye:  I think I'd use some JB weld and maybe some of the casting dust if necessary, it's epoxy with iron in it already, and it holds well, assuming it's available that side of the pond.  It even looks okay on cast iron if it's not painted or covered, particularly if you've got some iron dust from turning. :beer:  cheers, Jack
Title: Re: Potty Over Crank Wall Engine
Post by: John Hill on March 14, 2011, 12:25:07 AM
Quote
Set it up in my big four jaw chuck and cleaned the face off and the inside of the rim and part of the OD, found that its got some blow holes in it that wont clean up, looks like I'll have to fill them with something have you guys got any suggestion, at Crewe Loco works they used a concoction they called buggerum, made up from putty red lead and iron filing, but I thought of body filler.

Google "Beaumont's Egg" or sweep up around your grinder and mix with cement.

Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on March 14, 2011, 03:02:56 AM
I think I have some JB weld knocking around here Stuart, from when I did the Bantam engine. Very good stuff.


John
Title: Re: Potty Over Crank Wall Engine
Post by: lordedmond on March 14, 2011, 04:37:55 AM
Stew

they used the same stuff at the Iron works sand casting dept , not sure of the name used but then they left the casting to age in the wind and rain , it was then buried in the ground and forgot about ( I am talking about sand cast water pipes 36 inches did and a 4 inch wall thickness ) never did see a sand cast pipe tested

build looking good and as usual well documented


Stuart
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 14, 2011, 05:36:00 AM
Thanks for your suggestion guys, just faced the other side of the casting up and its perfect, I guess the bad side was on top so that's where all the **** collected. I think it will fill in OK and I'm going to paint it so its not a desaster.

I'll nip round some time this week John for a natter and to scrounge some of that JB weld if that OK, I'll bring that small pully round as well still not sure what to do with it  :scratch: .


Cheers

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on March 14, 2011, 09:02:48 AM
Give a call first Stew, I do have a couple of meds this week, one this afternoon with Mal.

I need to talk with you about some matters anyway.


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 14, 2011, 01:04:12 PM
Will do John

I was going to finish off the fly wheel using a face plate, but have you ever noticed with them that what ever the job the holes just not in the right position, so decided to use the four jaw gripping on the cleaned up inside rim, there was only a small area to grip on but I decided there would be enough particularly if I supported it with the running centre when doing the OD.

Clocked the turned register up true, and centre drilled.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5013.jpg)

Then turned up the OD, face the inside rim and the hub.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5015.jpg)

Then open out the centre with an 8mm drill followed by a 12mm, and bored it out with a 10 deg taper so the big dia was 14mm ish.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5017.jpg)

Keeping the compound at the same setting turned up the tapered collet, split the collet with a saw, this is how the collet fits in the wheel, the locking bolt squeezes the collet onto the shaft.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5021.jpg)

Another how it looks shot.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5018.jpg)

I think the crank is a touch too long, but I can easily put that right as its still got its centers in.

Just in time delivery as I finished the fly wheel the postie called with the material for the return connecting rods

Stew


Title: Re: Potty Over Crank Wall Engine
Post by: Dean W on March 14, 2011, 07:03:06 PM
It sure is coming out a beauty, Stew.  Going to be a great looking engine.
Title: Re: Potty Over Crank Wall Engine
Post by: saw on March 15, 2011, 05:21:20 AM
Looking very good  :thumbup: :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on March 15, 2011, 08:17:27 AM
Impressive stuff Stew  - really getting a feel for the size of it now!   :jaw: :thumbup:

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: cfellows on March 16, 2011, 10:06:21 AM
Lot of nice work going into this engine, Stew.  I'm just following along and watching.

Chuck
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 21, 2011, 12:38:21 PM
Thanks for your support and kind comments chaps.

Things slowed down a bit over the last week, but did get a bit more done.

What I call the return con rod, this is made from some 3mm thick * 30mm wide mild steel plate, first off drill and dowel the holes so that I can chew them out all together.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5023.jpg)

Then drill and with the boring head cut out the corners

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5025.jpg)

Then with a slot drill join them up (sorry no pic)

Then onto the RT and radius the end just set this up with MK1 eye ball

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5027.jpg)

Then mill the slide bar to size, giving a little extra support with a toolmaker clamp

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5030.jpg)

Then counter sink the holes, and that them done

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5034.jpg)

Turn and tap the spacers M3, I'll bling them up later.

This is how they assemble up.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5045.jpg)

And a few hows it looking shots.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5042.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5044.jpg)





Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on March 21, 2011, 01:30:06 PM
That is starting to look very business like Stew. :thumbup:

If it runs as well as it looks, you are onto a winner.


John
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on March 21, 2011, 02:39:48 PM
It is looking great Stew!

Chris
Title: Re: Potty Over Crank Wall Engine
Post by: saw on March 21, 2011, 03:13:11 PM
Very nice good work  :clap: :clap: :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: spuddevans on March 21, 2011, 04:48:54 PM
Not long to go now, looking really good  :thumbup: :thumbup:

Tim
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 25, 2011, 08:34:52 AM
Thanks Chaps, must admit I'm getting quite excited at the prospect of trying to get it to run.

Bit more progress this time with the base:- cut the jig plate to size and squared up the edges.

Then drilled the fixing holes and dowel holes for the bearing housings, and clearance for the crank throw

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5050.jpg)

Assembled the bits to the base this gave me the first chance to see if it turned over OK so put a couple of nuts on the crank and wound it over with a spammer,  :D (if only) and it turned over fine.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5056.jpg)

Next up I need to fit the bearing strips for the slide bars.

I guess another couple of weeks and we will see if it will run.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on March 25, 2011, 09:18:02 AM
It's looking brilliant that Stew. It's going to develop quite a lot of power!
Title: Re: Potty Over Crank Wall Engine
Post by: saw on March 25, 2011, 09:34:18 AM
You are doing very well, I am very glad that you are showing us this wundefull engine.  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: shoey51 on March 25, 2011, 11:43:03 PM
wat to go Stew lovely engine :thumbup:
cheers Graham
Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on March 26, 2011, 05:49:05 AM
That's going to be a hell of a wall clock driver   :jaw:    :lol: 

I bet you can't wait to see this ticking over Stew?


I could not see the detail properly in you photo's cause they are small.... Maybe mine are just too large again?  Anywho, I don't know if any of you out there know this but....

(on vista at least)
If you hold CTRL down and then press the + button it magnifies the whole screen text and pic's included. Then CTRL and the - button and it goes back.  I just count the number of +'s I  hit and return back to the normal screen with the same amount of -'s .  Just a thought?   :borg:


Clad to see you got rid of than bodge in the re-sizer too  :headbang:



Very nice work Stew  :thumbup:






Ralph.
Title: Re: Potty Over Crank Wall Engine
Post by: BiggerHammer on March 26, 2011, 09:18:17 AM
That is looking very nice. Can't wait to see it go.
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on March 26, 2011, 10:40:31 AM
It looks great all assembled like that Stew  :clap:
Can't wait to see it finished  :thumbup:

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on March 28, 2011, 12:10:50 PM
 :bugeye:  WOW Stew

you have really made  great progress with the engine since i last looked ,,, she is looking great  :clap: :clap: :clap: :clap: :clap:


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on March 31, 2011, 07:23:21 AM
Thanks for your support and interest Guys.

It's starting to assemble up nicely.

Next up the slide bar bearings.

This is what I'm making them from

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5057.jpg)

Spent a bit of time measuring up the assembly to check the size to make them to. The inner bearings are different to the outer, when I was drawing the engine up I couldn't see how to line up and fix the inner bearings, so left the ? hanging now that i've got a few bits around me the solution is quite simple just screw them to the bearing housing with a counter sunk cap screw, I can get alignment by ensuring I drill the hole for the cap screw central, and drilling the housing on the same centre line as the bearing, the outer bearing will be tapped with four M2.5 threads and will be bolted to the outer housing

Milled the bearings up in pairs.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5058.jpg)

Drill and counter sink the inner bearings

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5059.jpg)

Next up the slide valve attachment made from a bit of square mild steel bar, faced off and tapped and parted off in the lathe, then milled and drilled using my little vice.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5060.jpg)

This is where they go.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5061.jpg)

Then with them fitted measured up the eccentric straps for the forks.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5063.jpg)

The fork were made from some round brass bar with flats milled and the fork cut with a 3 mm slot drill.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5066.jpg)

Next using the method John showed us but solder the fork to the strap.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5067.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5070.jpg)

This is how they fit.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5077.jpg)

And how the assembly is looking.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5071.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5075.jpg)

I've got to strip it all down now and drill the bearing housing for the slide bar bearings and I need to modify the crank a little so that the fly wheel fits.

I'll be more or less ready them to try it out:- fingers crossed.

Cheers

Stew



Title: Re: Potty Over Crank Wall Engine
Post by: saw on March 31, 2011, 10:08:25 AM
Amazing it's so fine engine you are making :bugeye: :bugeye: :bugeye:
Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on March 31, 2011, 07:38:16 PM
That really is a good looking machine your building Stew  :bow: 

I'm really going to have to try to remember many of these techniques!  :scratch: 







Very nice.




Ralph.
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on April 04, 2011, 07:03:19 AM
Well its a runner a video is on its way,

Grinning Stew
Title: Re: Potty Over Crank Wall Engine
Post by: spuddevans on April 04, 2011, 07:34:37 AM
Well done that man :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap:, cant wait for the video :mmr:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on April 04, 2011, 07:50:52 AM
Here we go



Stew
Title: Re: Potty Over Crank Wall Engine
Post by: saw on April 04, 2011, 07:56:06 AM
This was something, so cool and I love the sound.  :bugeye: :bugeye: :bugeye: :bugeye: :clap: :clap: :thumbup: :thumbup: :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: Bernd on April 04, 2011, 08:50:17 AM
Stew,

WOW :jaw: :bugeye: :jaw: :bugeye:

Sounds just like "I think I can, I think I can"

Bernd

Oh, forgot to add a few of  :ddb:  :ddb:  :ddb:  :ddb:  :ddb:  :ddb:  :ddb:
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on April 04, 2011, 08:57:19 AM
That really is great Stew, I can't wait to see it in person.

I bet the chaps at the museum would be well pleased to see it as well.


Wonderful work.


John
Title: Re: Potty Over Crank Wall Engine
Post by: spuddevans on April 04, 2011, 09:11:28 AM
That has a beautiful movement  :clap: :clap: :clap:

A lovely slow runner too.


Have a few nana's

 :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb: :ddb:

Tim
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on April 04, 2011, 09:30:31 AM
 :bow: :bow: :bow: :bow: :bow: :bow: :bow: :bow: CRACKING Stew ,,,,,,,,,Crackin  :clap: :clap: :clap: :clap: :clap: :)


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: Gerhard Olivier on April 04, 2011, 10:13:13 AM
That is a GREAT engin Stew


Fantastic love the sound in slow-go

Gerhard
Title: Re: Potty Over Crank Wall Engine
Post by: BiggerHammer on April 04, 2011, 10:31:11 AM
VERY NICE! Love that sound when it is at the lower rpms.
Title: Re: Potty Over Crank Wall Engine
Post by: Bluechip on April 04, 2011, 10:48:07 AM
Hi Stew

NICE ENGINE     :clap:  :clap:

Unusual layout, very interesting to watch..

It's much bigger than I thought, you going to run it on steam?

How fast is it intended to run?

Dave BC


Title: Re: Potty Over Crank Wall Engine
Post by: HS93 on April 04, 2011, 11:24:19 AM
very nice  :bow:
   

                      :ddb:  :ddb: Peter  :ddb:  :ddb: 

                                                                                                :nrocks:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on April 04, 2011, 12:04:51 PM
Thanks for all your kind comments Guys.

I was that pleased at getting it running I forgot to show how I cut back the crank

Set it up in the lathe using the fixed steady

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5086.jpg)

Clocked it up.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5087.jpg)

Cut the shoulder back and faced the length back, taking small cuts with a sharp tool worked a treat.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5085.jpg)

To get the guide bar bearings on centre measured the centre line of the crank and checked piston rod was on the same centre line.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5089.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5090.jpg)

Then as I'd milled the bars concentric drill the fixing holes in the bearing housing so that the guide bar bearing come onto the centre line, this sounds as clear as mud, but I'm sure you can work it out.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5091.jpg)

Worked out well

Now that I've got the engine running I want to spend a little time doing a few other jobs before I pic it up again and make the fly ball governor and tart it up for painting fit oiler and make a proper base thinking of mounting it vertical are the original.

Thanks again

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: cfellows on April 04, 2011, 12:15:22 PM
Very nice!  I love the sound at slow speed.  It's one of the few, 2 cylinder, double acting model steam engines I've seen where you can hear all 4 individual strokes.  Simply lovely.

Chuck
Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on April 04, 2011, 12:41:41 PM
Stew...  :thumbup: 


Love it! Sounds great and wasn't expecting the thunder at the end  :bugeye: Had the speakers up!!  :headbang: 








Ralph.
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on April 04, 2011, 12:50:02 PM
 :D Great runner Stew  :clap: and a top job  :thumbup:

Just love the sound !

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on April 04, 2011, 12:53:03 PM
Wow, that's really impressive Stew - it is interesting motion to watch too. Well done, a great feat to see something you like in a museum and turn it into a scale model.  :bow:

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: Dean W on April 05, 2011, 03:19:16 AM
Oh, it turned out so well, Stew (naturally!).  What a fine job, and the sound is pure symphony.  It is definitely one
of those "watch-it-run-for-hours" engines, and I watched the vid more than once...  A lot more than once!
Thanks for a great build thread!
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on April 05, 2011, 04:24:53 AM
That's pure, "Poetry in Motion", Stew!  :D

Blummin well done!  :clap: :clap: :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on April 05, 2011, 05:27:51 AM
Thank you all again Chaps

So far its bin an interesting project, some of you Guys have commented on its size, it did come out bigger than I had in my minds eye, but in its original state it's not a very big engine, it would comfortably fit in a suite case, the model loco guys like to build narrow gauge Locos as they come out as large engines I thinks its something to do with scaling. The original engine has a fly wheel of about 24" dia I used a 7" fly wheel about 1/3 full size, and scaled everything from that, I think if I had used a 4" fly wheel some of the parts would have come out too small to comfortably make.

I don't intend running it on steam I don't think its performance on steam would be very good as I made the steam galleries on the small size.

I went away from the drawing I posted quite a bit:-as the build progressed I saw better or alternative ways of doing things, so at some point I will update them.

When I come to finish the engine off I want to round the sharp corners off and fill internal corners with something so that it looks more like a casting, can any of you guys suggest a filler.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on April 05, 2011, 05:41:21 AM
Stew,

You can use car body filler, but I found it very messy and hurtful on the fingers getting it to the right shape after it has set. You don't really have the time to get things perfect before it goes off.

When modifying parts on the figures I used to do when making model boats, I used Milliput.

Mix the two parts of the putty together, push it into where you want to change the shape, then while still soft, mould and carve to shape, just like modelling clay. Once to roughly the right shape, using wet fingers, blend everything in position so that it looks like part of the original. Leave to set overnight and paint straight over the top, you would never be able to tell it wasn't part of the original. You can even texture it if needed, before it goes fully hard after a couple of hours.


John
Title: Re: Potty Over Crank Wall Engine
Post by: andyf on April 05, 2011, 05:45:53 AM
.... When I come to finish the engine off I want to round the sharp corners off and fill internal corners with something so that it looks more like a casting, can any of you guys suggest a filler.

Stew

Superb job. Like others, I was surprised by its size in the video, or conversely how tiny your hands are  :)

I've used "Milliput" for filling (Google it). If you haven't met it before, it is an epoxy resin based filler which comes as two sticks. Cut off an equal length from each and mush then together between your fingers. It has a putty-like consistency and will stay put once in place, rather than being runny like Araldite. It smooths over quite well with a wet finger.

Andy
Title: Re: Potty Over Crank Wall Engine
Post by: doubletop on April 05, 2011, 06:53:23 AM
Stew

I'll post it here as well as John will know what this stuff was

"Hemetal" (or some such) came to mind, it was a metal based filler the riggers used in the RAF for bunging up things (can't think what). I believe it was in the Hematite gasket people product range. Had a dig around and Hematite is now Loctite and nothing about Hemetal

I did find this though that looks similar

http://www.eal.com.au/hypoxy.php?PHPSESSID=cc353e31e70189b5218aca111a6e97ec (http://www.eal.com.au/hypoxy.php?PHPSESSID=cc353e31e70189b5218aca111a6e97ec)

Pete
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on April 05, 2011, 10:43:59 AM
Pete,

Hermetal or Doublebond, the stuff we used came in two flat round tins

Milliput is almost exactly the same.


John
Title: Re: Potty Over Crank Wall Engine
Post by: Jasonb on April 05, 2011, 11:21:46 AM
And if your fingers are too fat to give the desired radius just glue a suitable ball bearing to a bit of rod or tube, dip in water and use that to form the fillet, you can buy modeling tools which do the same thing. Duro and Magic Sculpt work in teh same way but in the UK Miliput will be the easiest to find.

J

PS The white superfine is the best of the colours
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on April 08, 2011, 02:39:50 AM
I forgot to mention, Stew brought the engine round for me to have a look at the other afternoon.

Even in it's unfinished state, it has a great 'wow' factor, and how Stew managed to build it from a few photos and rough measurement defies belief, especially in such a short build time.

It is one of those engines that, when finished, needs to be stripped down, and a full set of good quality drawings made up of it, then share it with the world.


Great achievment Stew.


John
Title: Re: Potty Over Crank Wall Engine
Post by: JimM on April 08, 2011, 03:34:35 AM
That's a cracking engine Stew, it looks and sounds great especially on the slow tickover - I'd be well chuffed if I could make something half as good one day

Would JB Weld be any good for filling the corners ?  It's a bit sticky/messy to work with but dries rock hard and is the right colour (sort of)

Cheers

Jim
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on April 08, 2011, 04:05:11 AM
Thanks John

I've gone away from my origonal drawing quite a bit when I was doing the build all the main features are their but as the build progress I saw or learn't better way of doing things, so at some point I will ammend the drawings and post them up her.

I took the engine to our club open night where members showed off their work and gave a little talk on the project and it got lots of interest and thats from a club that is very much locomotive based and a number of members asked for compies of my drawing even with the warts.

Thanks very much Jim I've just ordered some milliput from fleabay so when I get to do the fillets I'll let you all know how I got on with it.


Stew
Title: Re: Potty Over Crank Wall Engine
Post by: ksor on April 13, 2011, 03:00:49 AM
Cast iron is real filthy stuff to work with, looks like I can join John's black hand gang.   :D

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/100_5009.jpg)


Stew


Hi Stew !

I think it's a "little" dangerous working with a wedding ring - I remember seeing some horrific images where the meat was pulled from the bones of a finger because of such a ring.

But oh, what nice peace of work you do  !

Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on April 13, 2011, 07:05:46 AM
Hi Ksor

Thanks for the reminder I've seen pics of fingers pulled off due to rings also :-not nice.

And thanks for your kind comment on my work.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 04, 2011, 10:30:44 AM
Well, time to pic this back up again by making a start on the governor in fact I've been agonizing over it for a couple of weeks for some reason I've been full of self doubt and uncertainty, I've drawn and redrawn the governor up 1/2 a dozen times changing my mind as to type and size, eventually I gave myself a good talking too:-just get on with it and stop p******g around.

So her we are first bit the little spinning things that hold the arms, making small parts can be a bit of a pain if you don't get the machine sequence right, you can end up with nothing to hold onto.

So started off on the lathe and machined out the outer shape and reamed the bore out 3mm, I'm making the two out of the same bit of bar one at each end.

Her they are one at each end

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0155.jpg)

Then over onto the mill gripped in the four jaw self centering chuck, centre the chuck on the centre line of the quill, zero the dials, then with a 2mm slot drill, mill the slot across the end, then with a bigger end mill, mill flats either side, flip it round and repeat on the other end.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0157.jpg)

Then over to the vice first set the quill on to the centre of the bar, with a ruler or straight edge in the slot grip it level in the vice, index to position and drill through 0.8mm for the pivot pin.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0158.jpg)

Back onto the lathe and part them off, doing them this way you had the bar to grip onto.

Her they are on a length of 3mm stainless that will be the spindle with a bit of 0.8 piano wire through pivot hole.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0167.jpg)

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: saw on May 04, 2011, 01:18:20 PM
Nice work  :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on May 04, 2011, 03:44:27 PM
 :thumbup:    good start Stew  :dremel:  ,,,,,,,,,,,,,,,,,,,, looks fiddly  :)



Rob 
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 04, 2011, 04:13:07 PM
:thumbup:    good start Stew  :dremel:  ,,,,,,,,,,,,,,,,,,,, looks fiddly  :)


Rob 

You can say that again

Quote
   :thumbup:  good start Stew  :dremel:   ,,,,,,,,,,,,,,,,,,,, looks fiddly   :)

 :D

I can see me losing some of these bits on the floor.

 That will turn the air blue

 :bang: :bang: :bang: :bang:

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on May 05, 2011, 02:25:21 AM
Stew.
I looked at your last pic. My first thought was.... They're tiny, I would have to make a few spares!  ::)

Looking great. Well done!  :clap: :thumbup:

David D

Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 06, 2011, 08:14:45 AM
Thanks Dave.

Yes, the parts are small and fiddly, but one of thing I was agonizing about was getting the scale of the governor correct, to often you see engines dominated with over scale governors, small governors don't work as well but after all they are not working engines as long as they look right and work something like is the important thing.

Any way on with the link arms first the arms that will hold the balls.

Turn and thread a small length of 4 mm dia bar M2 I took care to get the length the same on both bars I don't want the balls hanging odd

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0184.jpg)

Then carefully mill the 4mm dia into 2mm square.

Then drill 0.8mm for the links.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0185.jpg)

Her they are fitted.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0186.jpg)

That was the easy bit now for the more complex yolk link.

First mill up the shape in a chunk of mild steel more than enough to make two links.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0188.jpg)

Zero the mill on the x, Y edges of the bar, and drill 0.8mm holes in correct position as deep as the slender drill would go, fast speed, drop of cutting fluid and peck the drill in and out to clear the swarf.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0198.jpg)

Now for milling the slot, the arms will only be 1mm thick and as the slitting saw will tend to spring the arms open the slots were cit in the bar well away from the edge to give a thicker section I'll mill them to size later.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0199.jpg)


With thin sections its important to use good sharp tools if they are blunt the part will be bent, so with a new end mill skim off arms until 1mm thick, then mill step, to form the yolk.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0202.jpg)

With another bigger dia slitting saw cut the link from the bar leaving plenty of meat around the arms for finishing later.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0204.jpg)

The second arm was just a repeat of the first, this is it being split off, I was a little lean on material, but their was just enough.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0205.jpg)

The links were flipped over and the other side end milled to size sorry no pics.

The hook was filed to shape.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0208.jpg)

I left them over long to give something to grip on only cutting them of to length as a last op.

Here's one finished with its mate.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0210.jpg)

And the finished bits assembled, they still need a bit of a clean up but not looking too bad. It will be fitted with some 3/8" phosphor bronze balls, when I work out a way to drill and tap them.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0211.jpg)

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: saw on May 06, 2011, 08:45:15 AM
Good work looking fantastic  :bugeye: :bugeye:
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on May 06, 2011, 08:53:46 AM
It is looking really great Stew !  :bow:
Title: Re: Potty Over Crank Wall Engine
Post by: andyf on May 06, 2011, 09:41:17 AM
That looks great, guv'nor!

Andy
Title: Re: Potty Over Crank Wall Engine
Post by: lordedmond on May 06, 2011, 11:18:19 AM
Stew


just bung em in the three jaw on the lathe drill and tap there

grip them lightly and they will not dimple , but they will get hot ,very hot . they are a pain to drill , don't ask how I know  :(



Stuart
Title: Re: Potty Over Crank Wall Engine
Post by: mklotz on May 06, 2011, 11:33:58 AM
This article...

http://www.homemodelenginemachinist.com/index.php?topic=6852.0

describes how I held some (spit) wooden balls to drill them.  However, I have successfully used the same technique to hold and drill steel and brass balls.
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on May 06, 2011, 01:08:21 PM
 :clap: :clap: :clap: :clap: very nicely done Stew ,,,,,,,,,,,,,,,,,  :thumbup:



Rob
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 07, 2011, 05:32:12 AM
Thanks for your support Guys, and thanks Stuart and Marv for your ball drilling suggestions they will both work  :thumbup:, as I'm using phosphor bronze balls the likely hood of damaging them in the chuck is very high I opted for the method suggested by Marv.

Had a rummage through my bits and pieces box and came up with this I've used this for all sorts of odd fixtures, and it will be just the ticket for the ball job.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0213.jpg)

So gripped it in the vice and fly cut the face up nice and flat, then drilled a bit of ally bar for a top clamp, fixed it to the base, locked the x and y axis of the mill. And drilled a 3 mm hole in the clamp into the base.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0215.jpg)

Then with a big centre drill drilled a big cone into the base for the ball to sit in.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0217.jpg)

Clamp the ball in the fixture centre drill followed by an M2 tapping drill and tap, I used the chuck to guide the tap to keep it square.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0219.jpg)

Cleaned things up and fixed the pins and balls with a tiny bit of supper glue.

Looking good

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0225.jpg)

Scale looks about right  :thumbup:

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0227.jpg)

Pleased how that turned out.
 
:D


I was kind of working from drawings and from gut feel for the job, I'll bring the drawings into line with what I ended up with and post them her along with the other governor designs I came up with some of you guys may be able to put them to use.

Stew


Title: Re: Potty Over Crank Wall Engine
Post by: saw on May 07, 2011, 05:53:02 AM
 :clap: :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: klank on May 07, 2011, 06:14:35 AM
Stew,
I was waiting for this latest chapter before posting.
Thanks for such a clear write up of the governor - I have one to do for the Side Rod Engine - but the plans for it are a bit difficult to follow.
Seeing you do it gives me the impetus to have a shot now.
As regards drilling the balls - I was told of a set up for this, where a scrap piece of steel or brass rod of greater diameter than the ball(s) is set up in the lathe chuck and then drilled from the tailstock to a hole diameter and depth of slightly less than the ball.
The ball is pushed into the "cup" recess and can then be drilled/tapped from the tailstock without moving it.

What a lovely engine you are making.

Best wishes

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on May 07, 2011, 06:29:27 AM
Stew, looks great - scale looks spot on!
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on May 07, 2011, 07:11:19 AM
For anyone with a 5c or er collet chuck that fits the lathe nose, drilling balls, or as I do softened ball bearings, is a very easy job.

Just pop them into the collet, tighten up, and drill and tap away at leisure.


Bogs
Title: Re: Potty Over Crank Wall Engine
Post by: cfellows on May 07, 2011, 08:58:41 AM
Nice work on the governor.  I like the process for making the curved bits.

Chuck
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 07, 2011, 11:16:07 AM
For anyone with a 5c or er collet chuck that fits the lathe nose, drilling balls, or as I do softened ball bearings, is a very easy job.

Just pop them into the collet, tighten up, and drill and tap away at leisure.

Bogs

 :bang:

Never tought of a collet.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: AdeV on May 07, 2011, 01:01:37 PM
Stew, that's one gorgeous engine - I love the noise it makes on tickover. I agree you should mount it vertically like the original. It will look fabulous  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on May 07, 2011, 01:17:09 PM
Lovely work on the governor Stew  :bow: - I can see why you're smiling!

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on May 07, 2011, 01:38:00 PM
I was going to say use a collet - but knew Stew would already know that  :doh: !
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 07, 2011, 01:49:44 PM
Thanks Chaps

Bin sitting twidling the governor when I realised that if I mount it horizontal I'll need to spring load it, to do the job that gravity does when its verticle, had a rummage through my spring box and came up with a spring from a ball point pen, may be a bit strong, but still works with it, I'll try and pick up a lighter spring next Saturday at the Harogate show.

Thanks again

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: cfellows on May 07, 2011, 05:10:32 PM
Nice work on the governor, Stew.  Really an interesting process you used.

Chuck
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on May 07, 2011, 05:17:16 PM
Now that looks just right Stew  :clap: :clap: :clap:

I bet the bracket will be a work of art to  :med:


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 08, 2011, 09:34:23 AM
Cheers Chuck/Rob

The butterfly valve is based on a tubal Cain design in his book "Building the Beam Engine Mary" that I've adapted and metricated for this engine.

 First part the main body just a simple turning job.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0232.jpg)

Mount it in the mill vice find its centre in the X and Y and mill a 10mm dia flat with a 2mm hole 4mm deep in the middle.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0233.jpg)

Turn up a little nugget of brass with a 2mm nipple to locate in the body.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0242.jpg)

Silver solder the two together mount back in the vice with the nugget horizontal, and skim it off flat the drill 3mm through into the hole and a little way through the other side, and drill and tap 1/4"*40 ME.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0248.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0270.jpg)

Mount the other way round sitting on a parallel and in the vice gripping on the flat face, find the centre of the hole using the coaxial indicator, and drill the four bolting down holes using the DRO, make sure you get them oriented the correct way.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0271.jpg)

The boss floated off line when I soldered it, but I think it gives it that just cast look, what do you say ROB.  :D

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0272.jpg)



The butterfly sits at a 30 angle across the air way which means its has an oval shape, this is the way Tubal Cain made the butterfly which I think is real neat. Mill a 30 deg angle across a bit of brass bar.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0246.jpg)

Soft solder the brass shim that will form the butterfly on the end.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0247.jpg)

Turn the bar down to 6mm.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0249.jpg)

Heat the bar up again so that the butterfly drops off, clean it up and you've got an oval.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0260.jpg)

Now wasn't that neat  :D

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: DaveH on May 08, 2011, 10:44:23 AM
Stew,

Neat!! - bloody clever :clap: :clap: :clap:


DaveH
Title: Re: Potty Over Crank Wall Engine
Post by: saw on May 08, 2011, 10:53:27 AM
Nice  :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: klank on May 08, 2011, 01:43:08 PM
Very very good to see - thanks for showing.

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on May 08, 2011, 04:40:20 PM
Yes, Stew!

That was neat!  :clap: :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: CallMeAl on May 08, 2011, 04:43:11 PM
Interesting solution to a tricky problem.  I continue to impressed with the tricks people come with to solve difficult problems.  Great work on this engine and this lesson in oblique thinking.

Al
Title: Re: Potty Over Crank Wall Engine
Post by: dsquire on May 10, 2011, 01:48:09 PM
Stew

Nice way to do that last bit. This whole project is coming out very nice. Will be watching for the final outcome.  :)

Cheers  :beer:

Don

Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 11, 2011, 12:00:58 PM
Cheers Guys

I'm following Tubal Cain's (Tom Wiltshaw) methods her he certainly had some neat tricks  :headbang:

The valve shaft is a bit of 3mm stainless, put a 0.5mm slot down the end with a slitting saw.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0273.jpg)

Then cross drill 0.8mm I.m not sure if this is required.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0276.jpg)

So you've got this.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0277.jpg)

Now Tubal called for the stem to be brass and to soft solder the butterfly to it whilst assembled to the body, but he was writing before cyinoacalate came along and as i won't be steaming the engine that's what I'm going to use.

So this is the assembly kit.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0278.jpg)

It was my intentions to cross drill the butterfly using the little drill but when I came to it I couldn't get in, I think the idea is to give another route for the solder/supper glue, but it seems to have fixed well enough without the cross drill. You have to probe about a bit to get the butterfly sitting square then apply a drop of glue on the end of the stick, don't over do it as you'll stick the lot together  :hammer:

Her we are with it in the open position.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0281.jpg)

And closed

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0284.jpg)

I then turned up the gland nut, assembled it with a few turns of graphite yarn to seal thing up.

The finished Job

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0291.jpg)

Next up the mounting frame.

Marked it out on a bit of steel plate.

(http://i431.photobucket.com/albums/qq32/sbwhart/131_0300.jpg)

I'll cut it out tomorrow.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: klank on May 11, 2011, 01:16:40 PM
Its making sense now Stew - thankyou for the pics.

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: saw on May 11, 2011, 01:47:41 PM
Wow, this is exstrimly nice work, and so small  :bugeye:
Very nice work, good workmanchip  :clap: :clap: :clap: :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on May 11, 2011, 01:53:20 PM
Good going Stew  :bow: - That's a neat way of making the valve!

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 12, 2011, 11:18:37 AM
I was planning on getting more done today than I actually achieved, due to a little unexpected excitement, when backing the car out, to go on the weekly shop, there was an unexpected jolt and the front of the car dropped, the cast iron drain cover had broken and the wheel dropped into the hole, luckily the car came out without any damage, but the cover was so much scrap iron, so the best part of the day was spent finding and collecting a replacement cover of the right size. Not cast iron but a mild steal pressing with a pollypropolean base, looks real flimsy but rated at 5 tonne  :scratch:.

Any casters out their want some cast iron.

This is what I got done, found a better bit of black mild steel plate than the gray stuff I showed nearer to size and not as thick, cut it roughly to size and squared it up then, with it sitting on some washers to raise it off the table, set too and milled some radiuses, on the RT.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0302.jpg)

Bit more work on the mill then by rack of eye and with a selection of files got it to this nice shape.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0303.jpg)

And on the engine it's a bit long but I can soon cut it down to size when I've got the bearing housing fixed to it.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0305.jpg)

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: AdeV on May 12, 2011, 12:21:28 PM
Did you manage to fish all the bits of cast iron out Stew? I imagine it's nicely aged, and those old drain covers were thick as thieves. Should be good for a few pistons at the very least...?
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 12, 2011, 12:36:36 PM
Quote
Did you manage to fish all the bits of cast iron out Stew? I imagine it's nicely aged, and those old drain covers were thick as thieves. Should be good for a few pistons at the very least...?


No Ade

That was the first thing I did after I checked the car out, sized it up for useful bits its far too thin to get anything useful out of  :( :-

It must be over 50 years old, thats how old the house is, so as you say well weathered I think thats why it broke it developed a crack after the cold weather we had last winter, should have changed it as soon as I spotted the crack, but you know how it is.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: klank on May 12, 2011, 02:21:51 PM
Stew
Thats is real metal artistry - impressive.

Best wishes and respects

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: saw on May 12, 2011, 02:42:47 PM
Lokking good  :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on May 12, 2011, 03:54:06 PM
That's a cracker Stew!  :clap: :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: Dean W on May 12, 2011, 06:35:46 PM
You just keep throwing on the cool tricks, Stew.  Everyone can learn something from this thread.  It's great!

Dean
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on May 13, 2011, 09:28:40 AM
Stew, sorry, I haven`t been on this thread in a few days and I`m interested in the butterfly valve. I can see how you have glued the oval into position but due to the heat in my IC engine, I`d have to silver solder. How would you solder the valve in position without heating the lot up and causing the solder in the "case" to melt and come out of line?
 
Am I right in thinking that it would need to be silver soldered in situ?

Excellent build Stew, amazing photos and good explanations. As always  :bow: :bow:

Chris
Title: Re: Potty Over Crank Wall Engine
Post by: dbvandy on May 13, 2011, 09:36:19 AM
Stew, sorry, I haven`t been on this thread in a few days and I`m interested in the butterfly valve. I can see how you have glued the oval into position but due to the heat in my IC engine, I`d have to silver solder. How would you solder the valve in position without heating the lot up and causing the solder in the "case" to melt and come out of line?
 
Am I right in thinking that it would need to be silver soldered in situ?

Excellent build Stew, amazing photos and good explanations. As always  :bow: :bow:

Chris

It would be easier to pin it for an IC engine than to try to solder down in a small hole, you would just end up soldering it all shut unless you have the hands of a surgeon....
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 13, 2011, 10:25:02 AM
Stew, sorry, I haven`t been on this thread in a few days and I`m interested in the butterfly valve. I can see how you have glued the oval into position but due to the heat in my IC engine, I`d have to silver solder. How would you solder the valve in position without heating the lot up and causing the solder in the "case" to melt and come out of line?
 
Am I right in thinking that it would need to be silver soldered in situ?

Excellent build Stew, amazing photos and good explanations. As always  :bow: :bow:

Chris


It would be easier to pin it for an IC engine than to try to solder down in a small hole, you would just end up soldering it all shut unless you have the hands of a surgeon....


That what you'd have to do is pin it, but you'd have to drill the butterfly through first before you assemble, so it would be the devils own job to get thing aligned when you come to assemble it in the body.

You could try soft solder, what you have to do is blacken the bore in the body with sooty smoke from a candle to stop the solder sticking to it and only use a tiny amount of solder paste. Never tried the sooty smoke trick I read it someware.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on May 13, 2011, 10:47:17 AM
lol, I can see it all ending up a sitcky mess of solder with a permenantly closed valve  :lol:!

Anyway, thanks both of you for the reply. Keep up the good work with the engine.

Chris
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on May 15, 2011, 08:49:03 AM
Chris,

Not sure whether it'd be easy at this scale - but on my clio the spindle had a slot in it that the butterfly went through - if you did that you can sort of get it to self align by opening and shutting it with the butterfly in the slot then you could drill through to get the right location, take to bits and tap for a screw. Bit fiddly though.

Stew, why is the butterfly an oval shape? I must have missed something obvious!

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on May 15, 2011, 09:13:22 AM
Nick, does the one in the clio not have a slight oval shape to it?   Many of the ones I've seen have a slight oval shape, allowing return springs to pull the valve shut tightly when the throttle is released. if it were round it would just open in the other direction when the spring pulled it.

Just mu 2 p's


Sorry we didn't get to talk more at the show too... Well, not at all really  ::)   I turned around to see if you were still there and you'd gone. So had loads of the others!
Could have talked RS's  :)





Ralph.






Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 15, 2011, 09:25:56 AM


Stew, why is the butterfly an oval shape? I must have missed something obvious!

Nick

It doesn't sit square across the bore it sits at a 30 deg angle so that it shuts tight.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 15, 2011, 09:45:58 AM
Completed the bracket for the governor.

Turned up a length of bar and stuck a roughing drill down it to reduce the mass, then mill a couple of slots to take the bracket.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0313.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0316.jpg)

Then silver soldered the two bit together then set up in the mill found the centre with the coaxial indicator, and drilled it out 9.5 mm followed by a 10mm reamer.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0317.jpg)

Then cut away the unwanted bit in the middle and fixed the ball bearings in place with loctite bearing retainer, made a couple of brass spacers to take up the clearance in the bore.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0318.jpg)

Drilled and pegged the flyball fixed end to the shaft so you get this.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0321.jpg)

This is how it looks on the engine.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0319.jpg)

I think it would be better closer to the fly wheel but there is too much gubbins around the front of the cylinder to mount it.


Stew
Title: Re: Potty Over Crank Wall Engine
Post by: saw on May 15, 2011, 10:35:40 AM
This is fantasic well builld.  :clap: :clap: :clap: :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on May 16, 2011, 06:24:34 AM
Thanks for that chaps, totally makes sense - just didn't think of it! It must just be a very slight oval on the car ones though but it must be there otherwise it would tend to jam up too.

Yeah sorry I had to rush off, I was a bit peeved in the end as I only had about an hour and a half to rush around the show / tools, happens every year  :(

I'll be there next year though and if we do the meet after there will be plenty of time to chat. Talking RSs is good but I'd get upset as mine is not on the road!

Stew, great method of keeping the bearings aligned. Love the governor and can't wait to see it working  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: Divided he ad on May 24, 2011, 04:03:47 AM


Nice fabrication Stew  :dremel:  One of these days I'll have to try this solder then cut out method.


Sorry Stew...  Well :offtopic: but, yes Nick, will have to get a bit better organised for next year  :thumbup:

I know someone selling a black Escort turbo in very good cond' for 3k.....  :ddb: 




Ralph.
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 26, 2011, 12:31:57 PM
Thanks Nick/Ralph

Bin away on a short holiday to the isle of Islay off the West coast of Scotland its famous for whisky and ship wrecks, the ferry we were on nearly become one when it developed engine problems on the crossing and had to return to port, it all adds up to make life interesting  :)

Made the little lever thing that connect the fly ball governor to the butterfly valve, it's a right tricky little beats, I had no idea how to make it so decided to just start cutting it out of a chunk of metal I had a rough idea what it was to look like.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0326.jpg)

Rouged it out with the end mills.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0331.jpg)

Then it was a matter of taking files to it and nibbling bits off and adjusting until it fitted and started to do what was required.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0347.jpg)

This is it fitted to the cylinder.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0354.jpg)


I'd removed the cylinder from the engine so that I could drill the hole for the bracket so couldn't try it running, but I did connect a power drill to the shaft and gave it a spin and its works nicely operating the valve nice and smooth. I'll post a video over the weekend when I get chance, but I've a few family thing to deal with first.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: AdeV on May 26, 2011, 12:38:41 PM
 :bow: :bow: :bow: :bow: :bow: :bow: :bow: :bow: :bow: :bow: :bow:

Stew, that's a piece of engineering art, that is. The whole governer just looks so right. Really nice work, sir!
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on May 26, 2011, 12:44:15 PM
Having seen one of those tiny linkages.....  :bugeye:

I know, that is a piece of jewellery!  :thumbup:

Blummin well done Stew.....  :clap:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: DaveH on May 26, 2011, 01:22:26 PM
My! that does look good :thumbup:

 :beer:
DaveH
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on May 26, 2011, 01:48:02 PM
Great Job Stew  :thumbup: :clap:

Hmmmm.... Isle of Islay; I've heard a lot about that one :drool: as I do like a good whiskey myself; that's on my own itinerary when I get to the UK - and current plans looks a go for next year around Harrogate show time; I really want to see that as well.  I just hope the exchange rates will hold up!

 :beer:, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on May 26, 2011, 03:41:22 PM
 :bow: :bow: :bow: :bow: :bow: :bow: :bow: :bow: Very well done Stew  :thumbup:


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 26, 2011, 03:43:45 PM
Thanks DaveD, DaveH and Arnold

Arnold this week is the Islay whiskey festival, the diferent distilery's each have an open days throught the week, if you want to go you have to book your accomodation in advance or bring a tent.

http://www.scotlandwhisky.com/whisky-festivals/Islay-malt-and-Music-festival/

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Bluechip on May 26, 2011, 04:01:12 PM
Thanks DaveD, DaveH and Arnold

Arnold this week is the Islay whiskey festival, the diferent distilery's each have an open days throught the week, if you want to go you have to book your accomodation in advance or bring a tent.

http://www.scotlandwhisky.com/whisky-festivals/Islay-malt-and-Music-festival/

Stew

Stew

Our be-kilted friends will be chucking bricks through you windows ..

WHISKY in Scotland

WHISKEY in Eire ... and some others ...

Dave BC

Title: Re: Potty Over Crank Wall Engine
Post by: lordedmond on May 27, 2011, 03:15:59 AM
Stew 
 A more sober question  :)   your throttle valve the elliptical bit does it tend to close or open,  e.g. does it point towards the gas flow like a car carb. blow shut or is it the other way

one way it will be gas assisted to shut and the other it will be blown open



Stuart
Title: Re: Potty Over Crank Wall Engine
Post by: metalmad on May 27, 2011, 03:57:29 AM
looking great now  :bow: :bow: :wave:
Pete
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on May 27, 2011, 04:24:37 AM
Stew, it looks spot on that ... shame you've made it so the valve closes more the slower it goes ....  :lol:  :doh:  :palm:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 27, 2011, 07:25:55 AM
Thanks DaveD, DaveH and Arnold

Arnold this week is the Islay whiskey festival, the diferent distilery's each have an open days throught the week, if you want to go you have to book your accomodation in advance or bring a tent.

http://www.scotlandwhisky.com/whisky-festivals/Islay-malt-and-Music-festival/

Stew

Our be-kilted friends will be chucking bricks through you windows ..

WHISKY in Scotland

WHISKEY in Eire ... and some others ...

Dave BC


Dave

Didn't know ther was two spellings  :scratch: , but they both give the same result:- drink too much and you fall over  :D

Stew

Thanks Pete/Nick

Stuart

Glad you brought that up, I've bin trying to get my head around that for some time, and keep thinking my way in and out of which way to mount it  :scratch:

I quite like the idea of it working against the flow that way it will self close and I may be able to do without the spring, it will be quite easy to change it round by just simply flipping the valve over, so I'll probably try it both way.


Stew
Title: Re: Potty Over Crank Wall Engine
Post by: lordedmond on May 27, 2011, 11:18:15 AM
I have activated the single brain cell and gave it more thought with it assisted shut by the gas ( steam/air ) it may not reopen or the other way round it would not open


Whisky  try some http://www.glenfarclas.co.uk/en/pages/78,105_Cask_Strength.html


it is very good, dark like rum and undiluted from the cask about 14 degrees proof  :) :) :)


That must be why only one cell is active  :D

Stuart
Title: Re: Potty Over Crank Wall Engine
Post by: srm_92000 on May 27, 2011, 11:45:56 AM
Interesting one this :scratch:
In respect of the butterfly valve-
I would have thought that if pivoted in the middle, air flow would neither open nor close it being the same area on both sides.
But... just playing about I now have come to the conclusion it would always try to close it, at least until it were nearly shut.
It's the same both ways though so turning it round will make no difference :scratch:, again if, as I assumed, it is pivoted in the middle?

If I've got my head round things right the spring is needed to hold it open then the balls flying out against the resistance of the spring close the valve, so, spring strength varies how much it closes at a given speed.

Nice build anyhow  :thumbup:

Steve.
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 27, 2011, 12:11:49 PM
Thanks for your input Steve/Stuart it's a bit of a brain teaser  :scratch:.

Stuart i've never had a liking for whisky or whiskey, I'm a beer and wine man myself  :beer:.

Thought I'd go  :offtopic: and post a few pics of Islay

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3259.jpg)

Stormy sea

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3262.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3266.jpg)

There's lots of Gray seals about the Common seal are not so common  :scratch:

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3263.jpg)

They like to lie on rocks just under the surface and look like huge black Bananas.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3264.jpg)

Back on topic I changed the spring on the governor for something a bit lighter and made a video the shot looking down is a bit out of focus but you can see the butterfly valve working.



Enjoy

Stew :nrocks:
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on May 28, 2011, 04:00:07 AM
Didn't know ther was two spellings  :scratch: , but they both give the same result:- drink too much and you fall over  :D
:lol: I can't stand the stuff.


Quick question Stew relating to my flippant comment before; in your video it sounds like you've got the valve closed by the spring i.e. when the balls are in? If that's the case, the faster the engine goes, the more the balls will swing out and the more the valve will open which will make it go faster. Shouldn't it work the other way around so as you put a load on the engine and it slows down, the balls move inwards due to less speed which opens the valve more to give the extra power necessary to drive the load?

Sorry if it's me getting my knickers in a twist. Can't quite see down the hole whether it's opening or closing./

Cheers

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 28, 2011, 04:34:36 AM
Hi Nick

Sorry I missed your ? before,

I've had the same ? asked on HMEN the valve does close the faster the engine goes, you can't see this very well on the video as your looking down a hole and its not in focus, I'll have to do a bit of experimenting with it regards to pully size, spring loading, and input air pressure via a control valve, and running speed.

This morning I've just completed strippped the engine down for painting and a rebuild, I'll be adding a control valve, oilers, and bling as I build it back up, I have an head ache in the crank to fix as well: I'm also going to build it a brick wall  :bang:

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on May 28, 2011, 04:43:34 AM
Stew,

If you would like to make your 'brick wall' out of some hardwood (you could cut the mortar in with a ball end cutter), I have a load of thick and wide planks of oak here that would do the job admirably.

It wood be dead simple to simulate and do using your dro.


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 28, 2011, 04:46:26 AM
That sounds like a good idea John.

I'll have to be carfull with hardwood as I've developed an alergy too it, but I may be OK with good old English oak.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: HS93 on May 28, 2011, 09:26:47 AM
try

http://www.minaco-uk.com/page4.htm

http://www.wonderlandmodels.com/products/pegasus-hobbies-28mm-large-bricks-red/?utm_source=Froogle&utm_medium=PriceComparison&utm_campaign=GoogleShopping

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on May 28, 2011, 04:40:53 PM
Hi Peter thanks for the scale brick link, unfortunatly I think they will be too small a scale the engine is approx 1/3 full size.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: klank on June 03, 2011, 11:05:49 AM
Hi Stew - just saw your video - are you a master watchmaker or what?

I don't know if this might help - I "bricked and stone floored" a small plant using real brick/stone materials from "Richard Stacey" - http://www.richardstacey.com/
They do stone/brickwork/slate in all kinds of scale sizes.

If its ok to put this photo here? - I used their products to "brickwall" a Stuart H10/Boiler plant :-


(http://i336.photobucket.com/albums/n354/klank_photo/AfterPointing.jpg)

I don't want to go "off topic" - this is just to show what their stuff looks like. I used cyano to glue each brick onto wood, coated in Plasticard plus a thin wash of white glue, let down with water.
Courses were "pointed" with Stacey's own mix.

With all respects

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 03, 2011, 05:32:16 PM
Hi Peter

Thanks for your kind comments and link to the brick supplier, I think they will be too small, the engine is 1/3 full size.

I've stripped the engine down and started to paint it, for the wall I,m planning to use chip board with scale bricks cut into it with a radius cutter I'll then paint the bricks different tones of orange and paint the pointing a dirty grey, I'm hopping that will look OK.

I'll post some pictures in a few days.

Shop time is a little scares at the moments as I've got my 86 year old father seriously ill in hospital.


Thanks again

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 06, 2011, 12:30:42 PM
Slowly making a bit of progress.

Made a start on painting the engine up, got some cans of spray paint and acid etch primer for the none ferrous bits, and made a start masking parts up.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0356.jpg)

I also spent quite a bit of time rounding the sharp edges off, paint hate sharps corners it just pulls away from them, and giving stuff a good clean and a degrease in my ultrasonic cleaner, the bits that were too big to fit in it went in the dishwasher.

I used the milliput to fill the corners of the base in so that it would look like a casting.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0358.jpg)

The non ferrous parts were primed with acid etch using an air brush, this is nasty stuff so be sure to read and understand the instructions.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0359.jpg)

These are the bits sprayed up I'm going to leave them for a few days to harden off before I do anything to them.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0361.jpg)

Made a start on the stop valve' turned the body up and milled a flat to take the input flange with a small hole to line the flange up, turned the flange with a small boss to locate in the hole.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0360.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0368.jpg)

And silver soldered the two together.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0369.jpg)

Mill the flange to width locate on its centre drill the air way and the clamp holes.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0371.jpg)

The holes in the top and bottom have a different orientation, so the flange was used to get the orientation correct.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0373.jpg)


Her we have the body finished.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0374.jpg)

Stew



Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on June 06, 2011, 12:33:18 PM
Sweet!  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 06, 2011, 12:33:51 PM
Forgot to add the PDF drawings for the butterfly valve and the stop valve.


Drawing for the Governor will follow in a couple of days.


Stew
Title: Re: Potty Over Crank Wall Engine
Post by: HS93 on June 06, 2011, 12:53:34 PM
Very nice Stew, I cannot wait to see it finnished, Dont forget you now a sand blasting facilety close to you, they even give you drinks while you use there machine, nice case it is in. have you been there latley?

peter :)
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 06, 2011, 01:20:31 PM
 :doh:

I just missed out at giving that sand blaster a try, Pete, all the bits were masked up and primed when I found out about it.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: HS93 on June 06, 2011, 01:31:14 PM
It's a handy place to go that , the owner is a bit Grumpy but his dog is great. :lol: :lol: :lol:


                                :ddb: :ddb: Peter  :ddb: :ddb:
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on June 06, 2011, 05:50:53 PM
Good choice of colour stew  :med:

sure looks great ,,,,,,impressed at the way the base has turned out  :bow: :bow: :bow: :bow:


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on June 06, 2011, 05:55:47 PM
Yep, really looks the part Stew.  :thumbup: Everybody is nearing completion of projects - this is depressing!  :lol:
Title: Re: Potty Over Crank Wall Engine
Post by: saw on June 06, 2011, 06:00:28 PM
Very nice  :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 09, 2011, 08:29:12 AM
Thanks Guys  not much more to do now before we will be putting it all together.

Had a bit of disaster with the paint the base came out great but the cylinders needed a bit more of a spray, and the re-spray came out all crinkly, I then did what I should have done first and read the instruction on the can, it said :-Respray before 6 hours or after 36 hrs or it will go crinkly  :bang:

Real Men don't read instructions they just live with the consequences.
 
:D


So I've had to rub things down and start again.


Finished off the stop valve.

I made the valve gland and the bridge from the same bit of brass.

First turned up the OD and the step fro the gland.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0384.jpg)

Then over onto the mill using the PCD function drilled the four clamp holes taking them deep enough to get the bridge made.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0383.jpg)

Part the gland off, then turn the bridge and part off

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0385.jpg)

Then milled off two opposite holes to complete the bridge.

The valve stem is made in steps if you chuck grips reasonably concentric you can do it this way as it will tolerate a little eccentricity between the threads, but it is important that the cone is concentric with the main body.

So first turn and thread M2 on the end and transfer it over to the spin indexer and mill a 2.5mm square for a length of 3mm.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0392.jpg)

Then back onto the lathe and with just enough sticking out turn and thread M4.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0393.jpg)

Pull some more stock out and turn the main body 5mm dia, then slew the compound over and turn the cone until it drops off the bar, the cone will be perfectly concentric to the body.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0399.jpg)

The bridge posts are one of those small jobs that you have to machine in the correct sequence or you end up with little to grip on.

So first job mill a hex part way along the bar, I used both ends of the bar, her it is with one end just with the hex and the other with the M2.5 thread and plain bit turned on the other end.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0402.jpg)

Her are the part finished pair, it was a simple job the grip on the plain bit and turn and thread M2.5 taking care to get the length between the threads the same on the pair.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0408.jpg)

Now for the hand wheel, I've shown this a few times so I'll just show a few shots.

Turn up the wheel

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0410.jpg)

Transfer over to the RT still in the chuck, centre the RT under the mill spindle and using a combination of the DRO PCD function and movement from the RT generate the wheel.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0411.jpg)

And her we have the completed valve on the steam chest cover with the butterfly valve.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0414.jpg)

I've had it connected to the air and it shut off nicely with no leaks, it gives some controll reduceing the angle of the cone would have given a bit more but I've enough for my purposes.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: NickG on June 09, 2011, 09:00:01 AM
what a beauty valve!  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: spuddevans on June 09, 2011, 09:15:01 AM
Now that really looks the part  :clap: :clap: :clap: A lovely piece of workmanship.


Tim
Title: Re: Potty Over Crank Wall Engine
Post by: saw on June 09, 2011, 12:16:27 PM
Good work, very nicw  :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 10, 2011, 11:31:55 AM
Cheers Guys

On the home strech now.

To days job the oilers for the crank bearings, as this is a vertical engine, the oilers need to have a 90 deg elbow.

Start by drilling a two lengths of 14mm brass bar bar all the way through 3/8*32 ME tapping and tap each end about 8mm deep.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0419.jpg)

Then drill a 8mm hole across the middle of each bar, then cut them in half.

Drill the next bit part way through 2mm, thread the end for 12mm M4.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0423.jpg)

You end up with this kit of parts for silver soldering together.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0424.jpg)

Turn up some caps.

And you have your oilers.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0426.jpg)

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on June 10, 2011, 12:04:28 PM
Very nice indeed
John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 11, 2011, 01:18:23 AM
Thanks John

Well finaly her are the drawings for the governor.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 11, 2011, 11:46:24 AM
Slowly assembling the engine, could resist a how's it looking shot

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0430.jpg)


Now isn't that tasty.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on June 11, 2011, 12:58:56 PM
 :drool: Tasty  - DEFINITELY  :thumbup: - Some serious eye candy that Stew  :bow: - can't wait to see it all done and running  :D :D

Kind regards, Arnold

Title: Re: Potty Over Crank Wall Engine
Post by: cfellows on June 11, 2011, 01:46:28 PM
Very nice stew.  Hoping for some nice pictures and a video once you have it all back together.

Chuck
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on June 11, 2011, 02:15:53 PM
Gor-jus!   (http://freesmileyface.net/smiley/love/thinking-about-you-007.gif) (http://freesmileyface.net)

David D
Title: Re: Potty Over Crank Wall Engine
Post by: Bernd on June 11, 2011, 02:24:34 PM
Lookin' great Stew.  :drool:

Looks like a museum piece to me.  :thumbup:  :bow:

Bernd
Title: Re: Potty Over Crank Wall Engine
Post by: Brass_Machine on June 11, 2011, 07:44:02 PM
 :jaw: :jaw: :jaw: :jaw: :jaw:
 :bow: :bow: :bow: :bow: :bow:

I haven't looked in on this in awhile... OMG. that looks amazing.

Eric
Title: Re: Potty Over Crank Wall Engine
Post by: KB3RLJ on June 11, 2011, 08:10:58 PM
Omg! First time I've looked at this thread. That's beautiful. Is there a prototype for it or your own design? Are you planning to drive something with it?
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 12, 2011, 01:11:46 AM
Well thank you all for your kind comments.

I can't wait to get the wall built for the finished engine.

KB3RLJ (is that a car reg  :scratch:)  If you look on page one of the thread there is a picture of the prototype, its on display at Quarry Bank Mill Style Cheshire (try googling it for more info) I contacted the museum for information on the engine and all they could tell me was that it was a "steam engine"  :loco:  I drew it up from photographs, the model is about 1/3 full size, if you read back through the thread you will find that I've attached drawings for you to down load. I have no plans to drive anything with it, I only intend to run it on air, the pasageways are too narrow for steam running.

Thanks for your interest.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on June 12, 2011, 01:27:43 AM
Hi Stew, your also an early bird I`ve noticed!

It is looking really great, can`t wait to see it finished. Spot on so far!

Chris
Title: Re: Potty Over Crank Wall Engine
Post by: HS93 on June 12, 2011, 03:11:49 AM
Radio Ham I think Stew.

Peter

G0PAH
Title: Re: Potty Over Crank Wall Engine
Post by: KB3RLJ on June 12, 2011, 05:46:57 PM
Yes, its my ham call sign. I was on my iphone and didn't have time to go back and read the whole thread. I'll do it now. Georgous engine.

Brian

Well thank you all for your kind comments.

I can't wait to get the wall built for the finished engine.

KB3RLJ (is that a car reg  :scratch:)  If you look on page one of the thread there is a picture of the prototype, its on display at Quarry Bank Mill Style Cheshire (try googling it for more info) I contacted the museum for information on the engine and all they could tell me was that it was a "steam engine"  :loco:  I drew it up from photographs, the model is about 1/3 full size, if you read back through the thread you will find that I've attached drawings for you to down load. I have no plans to drive anything with it, I only intend to run it on air, the pasageways are too narrow for steam running.

Thanks for your interest.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on June 12, 2011, 05:52:35 PM
I had the pleasure of watching this engine run at Harrogate (in the back of a car)
I can assure you it runs as well as it looks
That valve is a work of art in its self
John
Title: Re: Potty Over Crank Wall Engine
Post by: John Stevenson on June 12, 2011, 06:33:12 PM
I had the pleasure of watching this engine run at Harrogate (in the back of a car)

John

Voltswagen ??


John S.
Title: Re: Potty Over Crank Wall Engine
Post by: andyf on June 12, 2011, 06:47:12 PM
Voltswagen ??
John S.

Didn't know they made electric ones!

Andy
Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on June 12, 2011, 06:48:34 PM
I think it was
Hatch back anyway
Rob Wilson was there he would remember
Title: Re: Potty Over Crank Wall Engine
Post by: John Stevenson on June 12, 2011, 07:22:37 PM
Engine in the back ? Voltswagen ?

Oh forget it that was wasted.....................
Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on June 12, 2011, 07:29:03 PM
Very good for a monday morning  :D :D :D :D got me anyway  :) :) :) :)
Title: Re: Potty Over Crank Wall Engine
Post by: BiggerHammer on June 12, 2011, 09:30:31 PM
Engine in the back ? Voltswagen ?

Oh forget it that was wasted.....................

LOL! Got me too.
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 13, 2011, 02:11:13 AM
 :doh:

I was wondering what you were on about, then the penny dropped, a good:- "got ya"  John.   :)

It was a Toyota Estate and I ran the engine with one of those little tyre inflater things you plug into your fag lighter:- (thats cigaret lighter for you guys across the pond).

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on June 13, 2011, 03:41:03 AM
And....... Yer 'tiz. A bit, LOUD.........  :thumbup:

http://madmodder.net/index.php?topic=4422.90

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 15, 2011, 01:39:51 PM
 :update:

Well got it all assembled and running again its run like a little sewing machine for at least eight hours.

Finished off the governor and got it hooked up to a drive belt, bin using one of those long springs john gave me but it keeps coming apart in the end I tried a spot of supper glue on the joint how do you guys join them up.

Thought I'd try a nicker elastic drive and asked my boss to donate some, all she said was you'll have to let me take them off first, that caused a sweat I though my birthday had arrived early.  :D

Johns making me a hardwood base, so here's a few shot on the test bed.

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0434.jpg)

The governor is sort of working the shaft from the butterfly valve is catching the frame and sticking so I've to cut that back a bit and try again also I think the return spring is too strong, so a bit of experimenting is required.

And here's a few beauty shots

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0437.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/131_0438.jpg)

I'll post some more pics when I get the posh hardwood base and a video of it running.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on June 15, 2011, 01:50:15 PM
Stew,

For joining the spring belt, you bend out a tiny half loop hook at each end from one of the spirals and just link them together. If it is a standard Mamod type, one end should be tapered down so that it screws into the other larger end.

Due to appointments, your base is due to be machined some time this weekend. But to cut the flywheel slot, you will have to bring the engine round for me to play with first and measure it up.


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 15, 2011, 03:45:20 PM
Quote
tew,

For joining the spring belt, you bend out a tiny half loop hook at each end from one of the spirals and just link them together. If it is a standard Mamod type, one end should be tapered down so that it screws into the other larger end.

Due to appointments, your base is due to be machined some time this weekend. But to cut the flywheel slot, you will have to bring the engine round for me to play with first and measure it up.


No rush John:- I've other things on untill next week, we can sort it out when ever your ready.

Thanks for the spring joining info, I can't remember where it came from, you could have gave it to me  :scratch:

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: HS93 on June 15, 2011, 04:15:33 PM
Hi stew it's looking Great,I bet if you went around to that local Philanthropist he may show you how to do it with his spring material,  :lol: :lol: :lol:


 :ddb: :ddb: Peter  :ddb: :ddb:                                              :nrocks:
Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on June 15, 2011, 04:28:17 PM
Looks great   :clap: :clap: :clap:
Very classy
John
Title: Re: Potty Over Crank Wall Engine
Post by: AdeV on June 15, 2011, 04:40:18 PM
Stew, that's a work of art that engine is. I think it looks better than the prototype.

Are you still thinking of mounting it vertical & having a spot of line shafting for it to drive? I think that would really cap off a fabulous build.


Anyway, have a few of these:  :bow: :bow: :bow: :bow: and some of these:  :clap: :clap: :clap: and plenty of these:  :beer: :beer: :beer:
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on June 15, 2011, 06:14:43 PM
:update:

Thought I'd try a nicker elastic drive and asked my boss to donate some, all she said was you'll have to let me take them off first, that caused a sweat I though my birthday had arrived early.  :D


Too much information  :palm: Engine looks brilliant Stew, so professional, can't wait to see it on the bogsie base and running  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: saw on June 15, 2011, 06:50:09 PM
Very beutifull  :clap: :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 16, 2011, 12:58:02 AM
:update:

Thought I'd try a nicker elastic drive and asked my boss to donate some, all she said was you'll have to let me take them off first, that caused a sweat I though my birthday had arrived early.  :D


Too much information  :palm: Engine looks brilliant Stew, so professional, can't wait to see it on the bogsie base and running  :thumbup:

She ment off the washing line.
 
:lol:

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 16, 2011, 01:26:26 AM
Quote
Are you still thinking of mounting it vertical & having a spot of line shafting for it to drive? I think that would really cap off a fabulous build.

Ade

Thats what I'm thinking about doing, I took the engine round to Johns for a natter and to bounce some ideas off him regarding the base it was my plan to make a brick wall but with the correct 1/3 scale bricks they would be lost behind the engine and it wouldn't look like a wall. John has a very nice piece of red oak that we think would make a base to mount it horizontally and to add some line shafting to it, so eventually that will be the plan, but in the mean time I can display it horizontally on the base.

John very kindly offered to machine the red oak up as I've an allergy to hard wood dust, I come out with a very uncomfortable rash.

Thank you all for comments munch appreciated.

Stew
 
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 22, 2011, 11:45:58 AM
John has very kindly finished the base he's used a beautiful piece of oak, I've added some bun feat to it made from draw knobs.

This is it on its posh base

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3286.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3287.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3288.jpg)

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/IMG_3289.jpg)

I'll post a video of the finished engine running tomorrow.

Stew

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on June 22, 2011, 12:23:01 PM
That is a fine looking engine  :thumbup: :thumbup: :thumbup:
The base sets it off just nice
Credit to you Stew
John
Title: Re: Potty Over Crank Wall Engine
Post by: Bernd on June 22, 2011, 12:48:02 PM
Very nice engine and base, a real show stopper if I may say so.  :thumbup:

Now about that base. Is this the same John that hates brown stuff?  :lol:  :lol:

Bernd
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on June 22, 2011, 12:54:03 PM
Bernd,

Just because I hate working with it doesn't mean I can't.


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 22, 2011, 12:55:26 PM

Quote
Now about that base. Is this the same John that hates brown stuff?

 :doh:

I've just shot myself in the foot.

Seriously though it a lovely bit of oak full of character I think it must have come from an old medieval church.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on June 22, 2011, 01:57:36 PM
 :bow: :bow: :bow: :bow: :bow: :bow:  stunning Stew  :drool:


I thought you would have mounted it  vertical  :med:


Rob  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: Jasonb on June 22, 2011, 02:13:02 PM
Maybe its got a keyhole plate on the back so it can hang on the wall, Oh and thats not like any oak I've ever seen.

Jason
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on June 22, 2011, 03:29:13 PM
Ohhhh...... That's nice!  :clap: :clap: :thumbup:

David D

Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 22, 2011, 03:36:25 PM
Thanks Guys


:bow: :bow: :bow: :bow: :bow: :bow:  stunning Stew  :drool:


I thought you would have mounted it  vertical  :med:


Rob  :thumbup:



Rob:-

 I have the option to mount it vertical, all I have to do is make a foot for it to slot into, I'll probably make that next week, I can also add line shafting at some point in the future.

Thanks again

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on June 22, 2011, 04:29:02 PM
 :bow: :bow: Congratulations Stew - that's a REALLY good looking model - well done indeed! - in fact words fail!

A BIG "THANK YOU"  :beer: for taking us along your trials and tribulations on your build - and even on some off-topic matters  :bow:

Your build log here is a Golden Thread; with much to learn from your shared experience, as well as that from other respected model engineers.

Once again, WELL DONE mate  :bow: :bow:

Sincerely, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: saw on June 22, 2011, 04:47:09 PM
This is an wunderfull engine that you have built. First I was wundering why you should have black color, but now when it's finish it's just fantastic. This engine should goes to hall of fame  :clap: :clap: :clap: :thumbup: :thumbup: :thumbup: :drool:
Title: Re: Potty Over Crank Wall Engine
Post by: Bogstandard on June 22, 2011, 04:48:51 PM
Jason,

Quote
Oh and thats not like any oak I've ever seen

Do a google image search for 'red oak'.

I was given a load of the stuff a while back, and thought it might make good machine display bases. Looks like I was right.


John
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 23, 2011, 04:17:03 AM
Arnold/ Saw:-  thanks for your kind words

Quote
First I was wundering why you should have black color, but now when it's finish it's just fantastic.

Saw its the brass fittings that help to set the black off, it will do the same for any dark colour:- maroon, dark green etc.

Got the video loaded now so enjoy




Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on June 23, 2011, 06:34:58 AM
  :clap:  :clap:  :clap:  :clap:  :bow:  :bow:  :bow:

That is Poetry in Motion, Stew!..... Blummin well done!

Thank you for allowing us to share your adventure.......  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on June 23, 2011, 10:46:04 AM
Beautiful!  :bow:
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on June 23, 2011, 03:49:44 PM
Stew, just watched your video over a few times and the engine is truely amazing. I real cracking build log and super engine. I could sit all night watching it tick over slowly like at the end of the video you posted. :bow:

So I take it your digging out those Colin Thorne plans for your project, well over due!!  :lol:

Chris
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 23, 2011, 06:55:27 PM
Thanks again for all your comments Guys I can't get over the responce this engine has generated



Jason,

Quote
Oh and thats not like any oak I've ever seen

Do a google image search for 'red oak'.

I was given a load of the stuff a while back, and thought it might make good machine display bases. Looks like I was right.

John

Just Done a search on types of oak and found "Bog Oak" so that's explains it.

 :lol: :lol: :lol: :lol: :lol: :lol:

Stew



Title: Re: Potty Over Crank Wall Engine
Post by: Nelson92757 on June 26, 2011, 09:26:16 PM
Stew
That was one of the nicest build I have seen yet.  Poetry in Motion, quoted by David D, doesn't go far enough. I have enjoyed the build from the beginning and words can not say enough. This is what makes this site what it is.
Nelson Collar
:D :) :clap: :D :) :clap: :D :) :clap: :D :) :clap: :D :) :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 27, 2011, 06:50:46 AM
Thank you very much Nelson

Will finaly bashed the drawings into some sort of shape.

I'm not a trained draughtsman I've just done my best with them so don't beet me up over their quility.

I've attached them below

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 27, 2011, 06:51:50 AM
And the rest
Title: Re: Potty Over Crank Wall Engine
Post by: DaveH on June 27, 2011, 10:31:40 AM
Stew,

Beautiful engine, all in all an excellent post, well written with great photo's. :clap: :clap: :clap:
Thank you.

 :beer:
DaveH
Title: Re: Potty Over Crank Wall Engine
Post by: SPiN Racing on June 27, 2011, 10:57:08 AM
Gorgeous Engine Stew.. beautifully done.  :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on June 27, 2011, 11:12:36 AM
Stew, just been showing your model to Jamie, he thinks it's fantastic, and that was before I'd explained what you'd actually done! Unfortunately we can't watch the videos here though. :thumbup:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on June 27, 2011, 12:08:31 PM
Hi Nick

Give my regards to Jamie, he's still doing a bit for the old firm then. :hammer:

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on June 27, 2011, 04:23:51 PM
Will do, haha, yeah still there!

Nick
Title: Re: Potty Over Crank Wall Engine
Post by: klank on June 29, 2011, 01:31:17 PM
Stew - what a lovely lovely engine - the finish of black and polished steel is just so right.

Congratulations - so much to learn from your build.

Best wishes

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: cfellows on July 02, 2011, 11:52:44 AM
Stew, thanks for uploading the pictures and drawings.  And thanks for the exhaustive build thread.  Do you have something else on the drawing board?  I always look forward to your posts and projects.

Chuck
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on July 02, 2011, 12:40:22 PM
Thanks Peter

Chuck thanks for your interest.

I've one or two things bubbling in my head, (V4, IC and a steam powered rolling mill) but in the mean time I've got few little projects for the grand kids and a little shop maintenance work to do and I want to make some progress on my loco build, its taken a back seat for far too long now. So I think it will late on in the year before I undertake another engine, in the mean time I,ll keep my eyes open, you never know I just may see something that will inspires me before then.

Thanks again

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: metalmad on July 03, 2011, 01:36:55 AM
Wonderful build Stew
congratulations on a great runner !! :beer: :clap: :clap:
Pete
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on July 06, 2011, 04:10:48 PM
Thanks Pete

 :update: :update: :update: :update: :update: :update:

Just to bring you guys up to speed.

I posted a few pick on the ME web site, lo and behold I got an email from the editor asking for an article on the engine, so thats what I've been up to the last couple of days, nearly got in finished just need to top and tail it.

Last night was my local model engineering society members night and pie and peas supper, members who had completed engines had them on show and the rest voted for best engine, yep you guessed it:-  the over crank got best engine.

Chuffed to bits

Stew


Title: Re: Potty Over Crank Wall Engine
Post by: DaveH on July 06, 2011, 04:20:32 PM
Stew.

Congratulations

DaveH
Title: Re: Potty Over Crank Wall Engine
Post by: spuddevans on July 06, 2011, 04:28:09 PM
Well done that man!!  :clap: :thumbup: :clap: :thumbup: :clap: :ddb: :nrocks: :ddb: :nrocks: :ddb:

Tim
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on July 06, 2011, 04:48:02 PM
It just gets better and better!  :D

Congratulations Stew. Blummin well done!  :clap: :clap: :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on July 06, 2011, 04:58:06 PM
Congratulations
Stew
 :thumbup: :thumbup: :thumbup: :thumbup:
John
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on July 10, 2011, 02:09:53 PM
 :clap: :clap: :clap: :thumbup: :thumbup: :thumbup:

Well done Stew  :beer: :beer: - Congratulations!

 :beer:, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: Rob.Wilson on July 11, 2011, 02:05:18 PM
 :clap: :clap: :clap: :clap: :clap: nice going Stew  :bow: :bow: :bow: :bow:


Rob
Title: Re: Potty Over Crank Wall Engine
Post by: SPiN Racing on July 11, 2011, 03:49:52 PM
Woo!!! Thats great! Congrats Stew!
Title: Re: Potty Over Crank Wall Engine
Post by: raynerd on July 11, 2011, 04:42:21 PM
Quote
I've one or two things bubbling in my head, (V4, IC and a steam powered rolling mill) but in the mean time I've got few little projects for the grand kids and a little shop maintenance work to do ...........

....ey ey ey... Colin Thorne, John Wilding...need I say more!!  :lol:


Nice work on this engine Stew, just had a look through the plans and they look great as well. I look forward to seeing it in ME.
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 06, 2011, 12:41:11 PM
 :update:

With a bit of luck the over crank engine build will be published in ME in a few weeks time.

I'm keeping my fingers crossed that this will make the front cover

(http://i431.photobucket.com/albums/qq32/sbwhart/Potty%20Over%20Crank%20Wall%20Engine/overcrank1.jpg)

I've not bin idle since I finished this engine I've had a major sort out of the shed and garage, plus I've done a few small projects for my grand kids:- over hauled an old TONKA Truck and made a wheel barrow, plus done a bit of work getting a new vice up to scratch, I'll start a thread showing finished jobs. In the comming weeks we're having the house rewired, plus we'll be moving my old dad into a nursing home so we have to sort his flat out, so their won't be much activity in the shop.

But I have done a fair bit of research into a new stationary engine for later in the new year when I've got some work done on my loco:- at the moment its a toss up between a Grasshopper haulage engine and a very interesting Tripple expansion mill engine, we will see which one takes shape.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: saw on August 06, 2011, 12:53:11 PM
It's just beutifull very nice work.  :clap: :clap: :clap:
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on August 06, 2011, 01:42:49 PM
Just fabulous Stew  :thumbup:

I'll have to try and get an issue of that ME  :D

 :beer:, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: Jasonb on August 06, 2011, 03:10:58 PM
Yes the current issue says the new build series will start in Issue 4411, shoul dbe in the shops in about 3 weeks. Looking forward to it second time around.

J
Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on August 06, 2011, 05:23:26 PM
That masterpiece certainly deserves to be on the front cover Stew!  :clap: :clap: :thumbup:

Good luck, with your out of shop activities......

David D
Title: Re: Potty Over Crank Wall Engine
Post by: doubleboost on August 06, 2011, 05:47:15 PM
This has got to make the front cover  :bow: :bow: :bow: :drool: :drool: :drool: :drool:
Apart from looking fantastic it runs rather well
John
Title: Re: Potty Over Crank Wall Engine
Post by: CallMeAl on August 06, 2011, 06:39:36 PM
Masterful work and great skill on display with this engine.  I will be going through this build again and again to pick up tips on how to do many things. :thumbup:  Thanks.

 :bow: Stew

Al
Title: Re: Potty Over Crank Wall Engine
Post by: HS93 on August 06, 2011, 08:48:37 PM
Magic job , look forward to the artical I will even buy the mag

Peter
Title: Re: Potty Over Crank Wall Engine
Post by: NickG on August 08, 2011, 05:03:45 AM
It should definitely be on the cover Stew  :bow:
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 08, 2011, 01:05:02 PM
Cheers  chaps,

Just had the latest issue of ME and to my suprise in the next issue they are not only serializing the over crank but they are doing the elbow engine as well I sent them the article over a year ago and thought it had been spiked.

Real cuffed.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: Brass_Machine on August 08, 2011, 04:15:26 PM
A little late on this one....

Deserving Stew. Very deserving.

You do outstanding work sir!

Eric
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 09, 2011, 03:18:58 PM
Thanks Eric

And thank you for running a great forum.

 :thumbup:

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 25, 2011, 02:30:30 AM
 :update:

It did make the front cover.

I'm real chuffed.

 :D :D :D :D :D :D

 :ddb: :ddb: :ddb: :ddb: :ddb: :ddb:


Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Jasonb on August 25, 2011, 02:46:26 AM
Yes it looks good, will you be getting your copy framed :D

And I'll let you off the two spelling mistakes in the text as well :)

Jason
Title: Re: Potty Over Crank Wall Engine
Post by: kvom on August 25, 2011, 08:33:34 AM
Seems it should be mounted vertically as a wall engine.   That would make ikt really stand out from all the horizontals.   :thumbup:

Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 25, 2011, 03:41:45 PM
Quote
Yes it looks good, will you be getting your copy framed

Done    :)

Quote
And I'll let you off the two spelling mistakes in the text as well

Only two thats darn good for me.

 :D :D :D :D

Actually they cocked up with the views they call the plan view side and the side view plan  :scratch:.

With the elbow they call fig 2 the cylinder drawing when it's really the base drawing.

But I suppose thats the way it goes with these things I know from my time in industry we spent ages checking through specs checking and rechecking but we still had some blatantly obvious mistakes creep through, when you live with something you just get blind spots.

Quote
Seems it should be mounted vertically as a wall engine.   That would make ikt really stand out from all the horizontals.

The base was made so that I could fit a foot on it to display it vertical, and took some pics of it, but some how it just didn't look as good, in reality I think they would have mounted it to suite how they were using it.

Its easier to display horizontaly as well, vertically its not as stable.

Thanks for your interest guys

Stew



Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on August 27, 2011, 10:24:52 AM
Cheers  chaps,

Just had the latest issue of ME and to my suprise in the next issue they are not only serializing the over crank but they are doing the elbow engine as well I sent them the article over a year ago and thought it had been spiked.

Real cuffed.

Stew

Superb timing Stew!  :clap: :clap:

We've got a meet next weekend, and earlier, I had promised the elbow will be running, via my loud compressor.......  :D

(http://i110.photobucket.com/albums/n95/Dayjo/P1010375.jpg)


Well done Mate!  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 27, 2011, 12:42:33 PM
Cheers Dave

I've been getting a bit of ribbing and teasing from my family, they want to know when I'm having a book signing  :D.

Then I got a phone call out of the blue from our club talk organiser asking if I do a talk on the engine at the club and the North Staffs model engineering club as well.

So now they are ribbing me about that, asking when I'm going on my lecture tour.

 :D :D :D :D :D

It all helps to keep the old mind active, and add to the fun of life.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on August 27, 2011, 01:08:21 PM
Stew.
Soon, you'll be so famous, we'll have to pay to talk to you........  :D

David D
Title: Re: Potty Over Crank Wall Engine
Post by: Jasonb on August 27, 2011, 01:40:09 PM
As long as you don't go the way of your avitar and end up with a big head, thats the main thing :lol:


What issue will the popcorn engine be starting in  :thumbup:   BTW did you see "American Pickers" in teh week they found a Cretors engine & boiler.

J
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 27, 2011, 02:25:21 PM
Quote
As long as you don't go the way of your avitar and end up with a big head, thats the main thing

I don't think that will happen Jason, my family keep my feet on the ground, I'm just so pleasantly suprized at the interest this little engine has generated.

My main motivation is in some small way to get people interested in engineering and manufacturing.

Quote
What issue will the popcorn engine be starting in     BTW did you see "American Pickers" in teh week they found a Cretors engine & boiler.

I'm not sure about the popcorn, if it comes to that it will be some time off I want to start and make some progress on my loco build first.

I'd be interested in the American Pickers I'll try googling it, I guess thats the best way to find it.

Thanks again for you interest.

Stew

PS just found out that American Pickers is a TV program I think  :scratch:, I guess they show it in the UK, I'll look out for the repeat.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Jasonb on August 27, 2011, 03:56:08 PM
Its on Satalite, History chanel Sky 529 I think

http://www.history.co.uk/shows/american-pickers/about.html
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 27, 2011, 04:39:02 PM
Thanks for the link Jason,

Unfortunatly we havn't got sky, I guess you can't get it on freeview.

Stew
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on August 28, 2011, 04:07:02 PM
 :beer: :beer: Really good going Stew, and well deserved  :bow: :bow:

I know for a fact your Elbow plans are top notch  :thumbup: , and the Over Crank is definitely on my to-do list as well.

Kind regards, Arnold
Title: Re: Potty Over Crank Wall Engine
Post by: sbwhart on August 29, 2011, 01:41:58 AM
Thanks for your support and encouragement Arnold.

My articles and others have come in for a little critacism over on the ME site, I'm afraid people forget that if it wasn't for people like you and I who are prepared to share our adventures there would be no Magazine and no great forums like this.

Stew

Title: Re: Potty Over Crank Wall Engine
Post by: Stilldrillin on August 29, 2011, 02:10:49 AM
Thanks for your support and encouragement Arnold.

My articles and others have come in for a little critacism over on the ME site, I'm afraid people forget that if it wasn't for people like you and I who are prepared to share our adventures there would be no Magazine and no great forums like this.

Stew

Stew.
The ME magazine, isn't my cup of tea.... And I don't think I've been on any ME forum.......  ::)

BUT...... However does any right thinking hobbyist, find fault with others prepared to share their experiences?  :scratch:

There are some strange people out there......   :loco:

Chin up Mate!  :thumbup:

David D
Title: Re: Potty Over Crank Wall Engine
Post by: arnoldb on August 29, 2011, 04:44:51 AM
Thanks Stew

We all open ourselves to criticism when we post publicly (or have articles published like you do) and share our experiences, and there will always be criticism in one form or another. 

Don't worry about it - sometimes it's good to get criticism if it is positive/constructive.  I try to use that to improve a bit.  With negative criticism, I just tend to ignore it and not let it get at me.  At least we try, and I'm sure we all try our best! 

I don't know about you, but what makes sharing my work for me worthwhile is not necessarily the public feedback I get in the forums (though that does help), but rather the once-in-a-while golden private feedback from persons I've never even met that shares a quick but heartfelt thank-you for inspiring them.  To me, that's what sharing our experiences is all about; I've been inspired by you and many other members on the forums, and by posting my escapades I'm trying to keep that spirit up and doing my little bit to keep our hobby alive in a world that's all gone plastic and depends on instant gratification.

Many members feel disinclined to post their experiences - some feel that they don't have a way with words, others feel that their work is not worthy of posting, and for some it's simply too much time taken out from having fun in the shop.  I fully respect all these and the other reasons - there is nothing wrong with that.  In fact, looking back at the last two and a bit years since I've started posting, I'm surprised at the fact that I posted as much as I did; normally I'm a very shy and bashful person; I can't even stand up and make a speech at a function, but somehow I find it easy and rewarding to share my shop escapades.

So like David said - Chin up mate and carry on the good work  :thumbup: - it is worth it!

Kind regards, Arnold