Three Cylinder Radial Engine

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Darren:
Very nice Stew, wish I had the confidence to tackle a project like this :clap:

Divided he ad:

--- Quote ---Not much head space:
--- End quote ---
:lol: I noticed that when I came round for the little visit!! That shop was built for one man.... And he's making little wonders in it! :ddb:

I really like the DRO's that you guys have, makes things much easier to do..... I think I'll have to wait a while for that though.... Either that of figure out how to make my shop pay :scratch:

Very good looking job so far Stew, nice to see it all taking shape :thumbup:

Ralph.

sbwhart:

--- Quote from: Darren on December 05, 2009, 07:57:30 AM ---Very nice Stew, wish I had the confidence to tackle a project like this :clap:

--- End quote ---

Darren with the great job your doing on your machinery you'll soon be knocking out some superb work.

This is the first real test I've given the DRO one of the reason I wanted to make a Radial is that they have lots a features to test the DRO on, you don't need a DRO to do all of this work but what it does is take the pain of dealing with back lash out of your machine so it makes thing a lot simpler.

Any way got a little bit more done:-

With the job parted off I set it up in the chuck to face it off to length, when disaster struck, the @£$%%^&* thing flipped out of the chuck putting a few dings in it, luckily they are in places that won't be seen when its all assembled together, so set it up in the mill vice to fly cut it off to length.

Now for the port face:-

A little bit more setting up required for this.

First as it will be easy to put features in the wrong orientation, I marked the job up where things were to go checking and double checking I'd got it correct, it wasn't accurately marked just enough to keep me on the straight and narrow.

Next get the job on the RT centre line, to do this you rotate the RT, as I was using a three jaw self centre chuck I had to keep channing the position of the job in the chuck and tightening up on different jaws to find the best place I got it to 0.1mm run out well fit for function.

Next I had to get the hexagon in the correct orientation by clocking up a face level with the RT on zero.

Then get the job on the centre line of the quill (spindle) to do this you hold the DTI in the spindle and rotate the spindle.

Then use the DRO drill the holes in this case one set of 6 and one set of 3.

At this point domestic duties were beginning to call so called it a day.

Cheers

Stew

NickG:
Nice work Stew, we're all getting DRO envy here. Lucky escape with the little mishap, it's a relief when that happens!

Nick

sbwhart:
Ok last bit of work on the crank case:- cut the steam galleries, the drawing calls for the angle from edge to edge to be 60 deg, but for machining the critical feature is centre to centre of the cutter I'm using a 2mm slot drill so drew it up in cad and checked the cutter centre to centre angle 44 deg.

The mill was still set on the centre of the job, move the radius distance to where the ports will be, and rotated the RT 30 deg then off set 1mm to allow 1/2 cutter dia. lower the cutter 1 mm into work and rotate RT 44 deg. To make things simple I worked out the movement of the RT in advance and wrote out a crib sheet.

Like this

Ports cut

Last job tap all the holes:- I used my home made tapping stand, so that they were all tapped nice and square.

And there we are Crank case done.

Made a start on the cylinders I'm going to make these from ally with cast iron liners.

2" diameter length of ally being turned down.

I was hopping to get four cylinders out of this ally (one spare) but I forgot about the width of the parting tool so only got three, I'll have to be real carful

When making multiples its important to get certain key feature as near as posable all the same size, in this case its the width and the bore dia.

So by putting the job hard up against the back of the chuck and zeroing up the cross slide they were all faced off the same length.

Because of how I'm going to machine things down line I'm not particularly worried about getting the bore concentric with the OD. So sticking the blanks back in the chuck all the bores were centre drilled and drilled out with bigger and bigger drills.

They were all then rough out to within 1/2 mm of finish size with a boring bar.

Then finished off to size with the boring bar:- one after the other at the same setting, running the final cut through a couple of times to take the spring out of the bar.

For length they were all within 0.05mm and for dia 0.02 mm thats well fit for purpose.

Here they all are.

Next job the cast iron sleeves.

Have fun

Stew

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