Poppin Engine build.

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Manxmodder:
Progressing nicely,you're doing a grand job Ian :clap:......OZ

ian_in_the_midlands:
The weather has warmed up a little, so back in the garage to continue with the standard.
Holes were drilled/bored/reamed.
The drilling guide was used to drill the 4 holes through which the bolts will pass that hold the cylinder on.
I am unable to check alignment of these yet, but fingers crossed the holes are in the right place.
I also made the base.

I now have a problem: How to remove the material to complete the standard.
To keep things simple I will keep with square edges rather than the radiuses on the plan

My options are:
1. Drill/saw out the waste and file. Good practice with a file, but is this really practical? Am I more likely to end up wrecking my work?
2. Buy a milling machine. I can not find the room in the garage without selling my woodturning lathe. I need to think hard about this option in the future.
3. Buy a milling attachment for my mini lathe. So far the majority of advice seems to be to avoid this. I am still looking out for one at a sensible price.
4. Find someone with a milling machine willing to help me. I will try a post in the "Request for work" section.

In the meantime, there are of other parts for me to be getting on with.

vtsteam:
I'd just file it -- it doesn't look like that much work. Rough the convex parts first with a nice big rough cross cut flat bastard file, then finish with a finer file. The hollow can be done with a coarse rat tail and a finer round file, the same way

You could cut out a profile of each end from thin sheet steel using tin snips and a file to smoothe it, and attach it to both ends of the block. These will serve as guides, if you're worried about spoiling your work. File close with the rough file, and then file to the guides with the fine file.

Filing is fun.....if you treat it that way, and you aren't working for someone else! :beer:

ian_in_the_midlands:
It is not the amount of work in the filing that concerns me, but my level of skill. Anyway, with your bit of encouragement vtsteam, I thought I would have a go.
After marking out, the holes were drilled at the corners of the waste. The main lump to go was then removed with a drill/jewellers saw/hack saw as close to the line as I dared.
Some filing was done to get close to the lines, bit I need to order some smaller files before I can get into the gap and complete this.

I could now test the cylinder fit against the stand.
It was bolted in place. I am very slightly off to one side (very slightly isn't really an Engineering term is it?). I must have bored the large hole slightly off. It is so small an error that this will probably not show once the standard has been polished.

The good news is the cylinder is upright :thumbup:.

Thought I would put the flywheels on for effect :D.

NormanV:
In engineering there is precision and there is "what you can get away with". I am often surprised with how much I can get away with. Just keep trying.

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