Gallery, Projects and General > Project Logs
a nine cylinder radial engine, plans by "ageless engines"
madjackghengis:
With the master rod blank in the four jaw, starting to machine it down to size
both sides will be machined down leaving the "big end" thick, for the slave rods, and bringing the master rod down to 5/16ths thickness
after leaving a shoulder for the bushing, and an inch and a half big end, the rod is flipped in the four jaw, re-centered, and the second side begun
With both sides faced off, the master rod is ready for cutting out the rod for the #1 cylinder, and machining off the excess around the big end
With a 5/16ths button in for the wrist pin hole, lines for the sides of the rod are scribed with a 3/8ths hole reamed on either side to locate the bottom of the taper of the rod sides.
after scribing the lines, it is set up on the rotary table and centered for machining off the excess
light cuts and careful operation are the key to not letting a cutter grab the part and take a bigger bite than you intend, when it is almost done, I removed it, cut the rough lines of the "rod", reinstalled it on the rotary table to finish the radius on each side of the "rod", as it connects with the big end, the sides are also milled out straight with the slight taper in the rod.
this shows the main operation of reducing the big end to round, lots of swarf flying
the master rod, ready for the sides to be milled and the recess in the big end, milled to allow the slave rods to fit to the master. The rod is set up on the rotary table, an arbor has been made to hold a 3/16ths cutter which will be used to mill the recess around the big end of the rod. This is how I left it last night, and today will see how the milling goes. With a bit of luck, I will be working on slave rods next. mad jack
Stilldrillin:
Blummin good work well shown, Jack! :clap:
I`m just following, and appreciating what you`re doing, quietly..... :thumbup:
David D
sbwhart:
--- Quote from: Stilldrillin on May 16, 2010, 12:15:51 PM ---Blummin good work well shown, Jack! :clap:
I`m just following, and appreciating what you`re doing, quietly..... :thumbup:
David D
--- End quote ---
Me too
Great job
Stew
shoey51:
--- Quote from: sbwhart on May 16, 2010, 12:27:56 PM ---
--- Quote from: Stilldrillin on May 16, 2010, 12:15:51 PM ---Blummin good work well shown, Jack! :clap:
I`m just following, and appreciating what you`re doing, quietly..... :thumbup:
David D
--- End quote ---
Me too
Great job
Stew
--- End quote ---
Me three
great work :thumbup:
madjackghengis:
You'all better watch all those complements, might make my head swell, and I might not make it through the door! Thanks for looking and the comments, it feels like a club or pretty close. In finishing out the master rod, I started out centering the rod on the rotary table, preparing to cut the slot around the big end, the space for the slave rods to fit in and get pinned in place. I started with a 3/16ths side cutting slitting saw, centered on the width of the rod, taking .100 in passes, and stopping just short of touching the "rod shaft" on either direction
lots of swarf, not much cutting pressure or torque on the rod by the cutter
another cut, more swarf
one of the last cuts with the initial cutter, good depth, width is .010 on both top and bottom as well as depth
first cuts with the 5/16ths keyway cutter, stoned the face and the clearance angle on the cutter to give a clean finish cut, before starting the cutting
one of the final cuts, I took out the .010 on top and bottom in three cuts, two of .150 depth, the last cut being .055 taking out the last of the width, and taking out the final .010 depth. This clears the back side of the recess for the slave rods to swivel side to side, and required touch up with a 5/16ths end mill to ensure clearance for #2 rod and #9, as they are where the final cuts meet with the straight lines of the rod meeting the "big end", and ensuring clearance using the key cutter would eat into the shank of the rod too much. Final clearance for these two slave rods was made carving out the radius left by the end mill, with a pocket knife, leaving a flat face top and bottom for the slave rods.
with a piece of scrap in the vise, I drilled it and reamed it for the 3/16ths pin the wrist pin size, and using a pin in the hole, and the rod end over the pin, and the side of an end mill, I radiused the small end of the rod
the last step is drilling an oil hole in the small end, to oil the wrist pin when it is in place, this was done with a #1 center drill, leaving a conical center to hold oil.
the finished master rod, lying next to the crank shaft it will have to fit on. The plans call for a bushing for the master rod to run on, I didn't have one long enough, but I did have six that were new and too short. Since the crank pin is supposed to have a groove around it to allow lots of oil to this bushing, I chose to press in two bushings from the opposite sides, with their inside bevel end both meeting in the middle, and essentially forming an internal groove in the bushings, then reamed the bushings, and turned the ends off to final length to fit between the cheeks of the crank. Next move is to finally drill the oil passages in the crank now that I have a master rod to test them in situ. I don't like the design of the slave rods, so I will be modifying it a bit, to give them some character, and have them look more natural. I have a dozen or so slave rods from a full sized Jacobson radial engine for examples. While the master rod came out as expected, and appears to be in spec and should work, it looks like a model, and less like an original than I think it should. If it doesn't work and fit right the first time, I will redo it, only with some different aspects so it looks more like an original has more radii where planes of it intersect for strength and greater ease in machining. We shall see how things fit together before anything like that takes place. I chose to machine lightening grooves in the sides of the rod, rather than in the faces, following the original rods. :headbang: mad jack
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