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| NormanV:
I am in two minds whether or not to post this project, I don't have a huge amount of confidence that I will complete it successfully. This engine is based on a design by Edgar Westbury as a 10cc side valve water cooled engine which he named the Whippet. The cylinder and crankcase are cast in one piece and at the size he designed it I have no chance of casting it accurately enough. I decided to double up on the size, this will give me an engine that stands approximately 240mm high and have a capacity of 80cc. Here is the pattern for the main casting. |
| NormanV:
For the hollow crankcase I decided to make the core in two pieces. The mould for the crankcase core was made as a negative mould and packed with sand wetted with sodium silicate (thanks Andrew) and placed in a large plastic bag that was inflated with CO2 from a fire extinguisher. That was quite exciting as the first attempt tore the bag to shreds due to the pressure of the gas. The second attempt with a more delicate touch of the trigger did the trick. Here is the mould: I made it to separate into 5 pieces to allow removal of the core. |
| vtsteam:
That's quite a project Norman! And mahogany patterns, too.... :thumbup: |
| NormanV:
The cylinder core was more complicated. I first made a split wooden male pattern from which I cast a two piece cement mould. This was again filled with sand wetted with sodium silicate and placed in a bag of CO2 as before. The patterns were made with Sapele which is has similar working properties to mahogany, and was free! |
| NormanV:
Here are the two cores, there was a little part of the sand that broke away but it won't cause too much of a problem. |
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