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NickG:
Thanks David, Tim, Stew and Dean,

I 've been struck down with Man Flu :lol: I musn't have had a bad cold for about 2 years so forgot how bad it was! Anyway, still made a small amount of progress -

First I put the cylinders back in the 3 jaw with some protective thin aluminium around them and faced to length before using the adjusable reamer, I had adjusted it just about spot on, made it slightly larger than I had measured it and reamed right through at about 45rpm with cutting oil - this has produced a good smooth finish and very parallel and accurately sized bores - they have actually come out at 0.625" as intended, am quite astonished!

I then made a bit of a jig from nylon which had a 5/8" spigot and a smaller 1/4" one to hold the cylinder covers concentric. Gripped that in the milling vice and let the cylinder rest against the top of the vice jaws - probably not the best practice but I marked a cross on the cylinder covers with a centre square and a set square by eye. I then found the centre of my spigot in the milling machine and wound it out to the 0.422" or whatever radius it was then put a dab of loctite on the cyl covers to hold them on whilst spotting through with a centre drill, turning it around and drilling on each of the 4 scribed lines. This has produced a decent and repeatable result, I think the 2 covers will both fit on any of the 4 cylinder ends so I may have got lucky. If not, it wouldn't have mattered, they would have just been matched. I nearly messed up drilling the bolt holes on the other end of the cylinder - they have to be in the same place at both ends which only just occured to me before drilling. This is because there has to be a gap at the bottom for the valve to pass through! I opened the holes up to 8ba tapping size on the normal drill since

I didn't take any pictures of the jig yet but it's still in the milling machine as i still need to tap the holes so will get some pics tonight. I lapped both sides of each cylinder cover too.

I was a little bored of the cylinders by this time so on Fri night I decided to do something else – thought I’d try the oil cups. When I looked at the drawings the small numbers scared me but I thought they have to be done sometime so I’ll try and stick to it.

So chucked some brass hex in the 3 jaw and turned the outer body dia and smaller neck dia that’s threaded to go into the cylinder. This brass was rock hard – much harder to turn than stainless, I should maybe have used that.

I then had to drill a 0.020” hole – no way I was trying that so I used my smallest number drill instead, no. 60 0.040” ! Twice the size but still the smallest hole I’ve drilled and small enough in my opinion! So the hole was drilled at the lathes max speed 720rpm, it coped surprisingly well, I had to drill about ¼” or so deep so just took it steady and didn’t break the drill to my surprise.

I then cut the 8ba thread using one of my xmas pressies:

Sawed it off, turned around in the chuck, drilled out with number 13 or something which broke into the tiny hole, then faced to length.

Quite happy with the result but I then had to repeat the whole process for the other one which is starting to bore me having to do everything twice but I’ve got to remember I’ll have 2 engines then!

Next job is to tap all the holes in the cylinders and do the pistons and yokes before I start on the frames.

Nick

NickG:
PS can't seem to get the camera to focus in on this small things which is quite annoying as it's supposed to be one of the best compact digital types. Maybe it's the light.

kellswaterri:
Hi Nick, I see the reamer worked for you all right, but if I have read your post correctly...''hand reamer, adjustable'' in lathe...decidely dodgy :bugeye: but it did the job and you are coming on well with the build.
All the best for now,
John.

Powder Keg:
Looking pretty nice there Nick!!!

On the camera... There should be a Icon somewhere on it saying tat it is focused. On mine there is a red square in the center that turns green when it is focused. Make sure you have plenty of light and turn off the flash on the camera. I have an extra light mounted over my mill, lathe, and work bench. This helps alot!!! Also, I've found that I try to get too close to my subject. I found that if I back up just a couple inches I have better results.

Thanks,

sorveltaja:

--- Quote from: NickG on February 07, 2010, 05:19:19 AM ---PS can't seem to get the camera to focus in on this small things which is quite annoying as it's supposed to be one of the best compact digital types. Maybe it's the light.

--- End quote ---

Nick, does your camera have a macro-function? it usually helps when taking closer shots. More important is an even ambient lighting, that isn't much of a problem at the summer, but at the winter it would be a good practise to use white background.

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