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| Poppin Engine build. |
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| ian_in_the_midlands:
Progress today: Hubs threaded, and two nuts made. Picture added of parts assembled. I also made a guide that will hopefully allow me to drill holes that match in the cylinder head and the standard. My method of determining the placement of the 4 holes was to used a punch mounted in the tool holder, making a mark horizontal with the centre then and rotating the piece 90degrees. The correct rotation was determined using a square. This was repeated 3 times. When the holes were drilled they aligned with holes already drilled in the top of the cylinder head, so my strange method must work. Any suggestions for a better method I could have used? |
| ian_in_the_midlands:
What bearings should I be using? As the shafts are 4mm, I was looking for 4x8x4, but can't find any. I could use the bearings in the picture? They are slightly larger diameter at 4x9x4, but I can increase the size of the standard to cater for this. Would these be good enough quality? Would I have to remove the shields to lubricate them? Will they work with the shields removed or would they simply collapse? |
| Stilldrillin:
Ian. I would use the 4x9x4, with the steel shield in place. Occasional lubing with light oil, will penetrate. No problem! This is what I use, for this kind of purpose..... http://www.ebay.co.uk/itm/50ml-Ballistol-Universal-Lubricating-Maintenance-Oil-for-Shooting-Fishing-DIY-/380659885378?pt=UK_SportingGoods_Hunting_ShootingSports_ET&hash=item58a118e542 David D |
| ian_in_the_midlands:
I moved onto making the cam today. I started off with a mild steel bar of 28mm diameter. The end was faced off, then I cut off 1.5mm. This was turned around in the chuck and an 8mm hole was drilled and reamed in the centre. An 8mm mandrel was turned and my new "washer" was threadlocked onto it. This allowed me to face to width and turn it to 1" diameter. I then made a guide of 0.6" diameter into which I could screw the cam. Using a grinder/file/diamond stone, a flat was made that just met the guide. I had no way of measuring angles directly, so I measured a chord of 20.81mm from the end of the first flat, and ground/filed/stoned a second flat up to that mark. This gave me the angle I needed (if my maths is correct). The waste was then removed all the way around up to the guide. I then finished off with some emery paper. I don't think the results look too bad. |
| ian_in_the_midlands:
Today I made a start on the flywheels. I turned some 2 1/2" brass down to 2 1/4" - leaving it 1/4" oversize. Two disks were cut off and faced to width. The centre recesses were bored, but left a little under diameter. A centre hole was then drilled and reamed to 8mm in both wheels. I made a mandrel out of aluminium. The plan is to keep the mandrel in the chuck to ensure concentricity, and use this to hold the flywheels, take them to the to final dimensions. I used aluminium in the hope that it will mark the brass less than steel would, but I have some concerns that it may not be strong enough. I will make up my mind if I use it or not tomorrow. |
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