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NickG:
Thanks guys,

I got a bit more done last night and today but the last few bits are taking a lot longer than I expected so slightly behind schedule. Going to cinema tonight so won't be making any further progress tonight!

I started work on the piston with the graphite kindly donated by Ade.

I sawed a chunk off and just gripped it in the 3 jaw - would have been better in the 4 jaw but as long as it held, the cutting forces are very low so I was able to turn myself a new datum to work from.

Faced the end:

Then turned a length any old diameter to grip on:

Flipped it around, faced:

Then started turning down to size:

Now taking the tiniest finishing cuts, something like 1/4 of a thou but easy to do with this material:

Across into the milling machine to mill the slot for the con-rod. When I was turning the datum, it dawned on me to stop short and it would give me something to rest on and keep square in the milling vice. I just cut to the full depth using a 1/8" end mill. I widened the slot slightly though by a few thou as I'm using 1/8" silver steel for the con rod.

Flipped on its side to drill hole for gudgeon pin. I've drilled it for a push fit in there so it stays in place and the con rod will have the clearance hole. I wasn't sure whether the graphite would wear, probably not but anyway, that's what I've done.

Back into the lathe to part off:

Because it's quite brittle it snapped with about a 3/16" pip so I had to put it back into the chuck to face off with some aluminium to protect it:

There's the finished piston with the gudgeon pin:

Next was the conrod big end. This is made up from a couple of bits of brass fastened together then drilled so it can split and be fastened to the crank. The problem was, I didn't have any 3/16" square brass, so I would have to turn some 3/8" down (smallest my 4 jaw can cope with) and then mill the square down to 3/16". This is what took much longer than it should have given the right material.

Facing the 3/8" brass:

Drilling for the 1/8" rod:

Turning down to size:

Over to the mill to whittle down to 3/16"

And the other side:

Centre drilling for pin:

and drilling through:

Sawing off the parent stock:

facing to length:

It was supposed to have a 1/16" rivet in it but as I said before, I didn't have a rivet snap so I just filed it off flush, made a bit of a mess but it's ok I guess:

The other part of the big end has a slot milled into it and fits snugly over the last bit like a clasp (think that's the word!) So this is 3/16" wide to fit between the crank webs and 5/15" deep.

Squaring up the brass:

Milling down to 5/16":

and 3/16" in the other plane:

Squaring the other end so I can stand upright to mill the slot:

Marked up and ready to mill and drill:

Drilling for the pinch bolt - notice my mistake here, I'd already centre drilled it.

Milling the slot - I nearly made a booboo here, I used the graduations on the handwheel to get the width - which didn't work but luckily I had a small cut on and I noticed soon enough. So I just went to my markings my eye then measured each side and the bit it slots over and took appropriate amounts off.

This is what I probably should have done before, don't know why I didn't drill it in one sitting. I had to re-position and pick up the original hole:

Opening up the top prong for 8ba clearance:

and tapping the bottom prong:

At this point I thought I'd finished, but I still need to drill the holes for the crank journal and gudgeon pin and cut the rod to length - just minor points!! I was worried before about getting those two holes parallel but of course because I haven't done either it will be easy, just do it at the same setting.

After that, the engine is technically complete, I just need a base and a burner - which begs the question, do I try it by lashing it together before I have made those, hold the camera with my teeth, burner in one hand and other hand to flip the flywheel! :lol:

Nick

winklmj:
Looks great. Can't wait to see it running.

saw:
Yes I like.. :ddb:

Stilldrillin:

--- Quote from: NickG on January 18, 2011, 03:03:02 PM ---
After that, the engine is technically complete, I just need a base and a burner - which begs the question, do I try it by lashing it together before I have made those, hold the camera with my teeth, burner in one hand and other hand to flip the flywheel! :lol:

Nick

--- End quote ---

What a daft question Nick! :bugeye: Of course you do! ::)

A small tripod might help, by steadying the camera....... :thumbup:

:lol: :lol: :lol: :lol:

:clap: :clap: :thumbup:

David D

Bogstandard:
This is looking really well now Nick, and I am sure you will have it running in no time.

Do what I did when I made my vid for the swing up threading tool, stick the camera onto a mag base, it only took a few minutes to make up a plate to get the two married together.

http://madmodder.net/index.php?topic=2323.msg25332#msg25332

John

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