Elmer's horizontal mill engine.

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modeldozer:
Hi Steve,

As I do not have a band saw to make the cuts acuratly the orriginal idea was to slice it with the slitting saw, unfortuanatly my saw blades are all to small to make the cut, so came up with this method witch worked out well.

Cheers
Abraham

vtsteam:
Abraham, marking wood with a square and then saw scoring all around before cutting through with a hand saw is the traditional Japanese joiner saw way of cutting a timber square without a miter box.

This is the same thing, with the added convenience of the slitting saw being held square and at the same height by the mill spindle while scoring all around.

modeldozer:
Hi all,

Had a few household chores to do so did not get a lot done this week.
Amongst chores, took all my shavings and off cuts to the scrappy and managed to get a bit of funds for tools.

Finished the cylinder bore, leaving it a tad (precision engineering term) undersize to allow for honing. The steam passages on both ends were milled to the correct depth.

Turned a plug to go in the tailstock end to support the cylinder.

Turned down the outboard end.

Then flipped around and turned the inboard end.

After checking that the bore is running dead on centre, a small recess was cut to allow the head to fit.

Back to the mill to cut out the middle sections, again a very slow process.

Cheers
Abraham

modeldozer:
Hi all,

Between a broken down compressor :bang:, visitors from South Africa and an extreme heat wave in Spain time in the shed was short and far between.

The middle sections were finally done.

The cylinder was set up at 45 degrees to mill the comer off.

It was moved to the rotab to round over the corner.

As I do not have any slot drills or centre cutting end mills, had to do lengthwise cuts in facets every one-degree.

While on the rotab the edge on the round ends was cleaned up.

The rotab was repositioned and the mounting holes were drilled in the heads.

The heads were then used as templates to drill and tap the cylinder ends.

All done.

Had to re bore the cylinder as for some reason it was oval. Took the bare minimum out to get it round.
Then used a brake cylinder hone to finnish it.

The piston ended up with a bit more clearance than I would have liked, but decided to test it first before making a new one,.
Made the studs for the heads from threaded bar.

And the studs for the steam chest from bar.

The engine was assembled and I found a small error with the eccentric travel :bang:, somehow I machined it for only half of what is needed. Had no choice but to make a new one making double sure I had the travel correct.

And we have a runner, no gland packing or gaskets but it runs. :ddb: :ddb: :D :D :) :)
Not the best video but here she is.

Need to make some accessories and tiding up a bit.

More to follow.

Cheers
Abraham

awemawson:
Very nice work Abraham :bow:

I would imagine that the cylinder became oval as the material relieved internal stresses as you machined the various outer features.

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