Well, I thought I would get my finger out and get on with this build
![:lol:](https://madmodder.net/Smileys/default/kranke_200-1.gif)
Having finished with another time-sensitive project I got back on track with this, I made a start on the two outer frames that fit either side of the main frame.
After hacksawing, squaring, and then flycutting to thickness, some 6mm ali plate down to just over 5.5mm thick, then I marked out for drilling for the crankshaft and 4 mounting posts.
![](http://velvet-art.smugmug.com/photos/i-PVT8t9K/0/M/i-PVT8t9K-M.jpg)
After drilling the holes I then put all 3 frames together, held in alignment by as couple of 3mm drillbits, and clamped them in the vice in order to drill and tap holes M2.5 for attaching the frames to a base.
![](http://velvet-art.smugmug.com/photos/i-43C3zzn/0/M/i-43C3zzn-M.jpg)
After drilling for the M2.5 holes I flycut across the bottom as they were very slight diferences between them and while they were aligned with the drillbits I thought it would be an ideal time to skim a tiny cut to level them.
![](http://velvet-art.smugmug.com/photos/i-qRXcXbB/0/M/i-qRXcXbB-M.jpg)
Then I moved them over to my tapping stand and tapped them.
![](http://velvet-art.smugmug.com/photos/i-MZ4kTc3/0/L/i-MZ4kTc3-L.jpg)
Then I moved on to shaping the outsides of the frames, 1st up was the outer frames. I have to confess, I did have full intentions of machining them manually using a base-plate jig and the rotary table, but as I had managed to get most of the bugs ironed out of my CNC system I decided to use that method instead.
That being said, it wouldn't take much to set up on a rotary table, and I still had to make a little jig plate to attach the frames to so that they can be held securely for machining, which is what I did next. Using a scrap piece of 6mm ali plate, I quickly squared it up and then drilled matching holes for the 4 3mm holes that are also in all the frames, then I tapped them M3.
![](http://velvet-art.smugmug.com/photos/i-cc683h5/0/M/i-cc683h5-M.jpg)
Then I mounted one of the outer frames onto it and was pleasantly surprised to find that the M3 cap screws aligned quite tightly even before tightening them up, then to make sure everything was held square I ran a dti held in the chuck along one edge of the frame, and again was surprised that it was spot on ( well it was 0.05mm out over the length of the base, close enough for me )
Then I unleashed the CNC and let it do it's thing, just watched and brushed the chips away and squirted a bit of cutting fluid on from time to time until I ended up with this,
![](http://velvet-art.smugmug.com/photos/i-9B3mD7C/0/M/i-9B3mD7C-M.jpg)
After doing the other one and a bit of cleaning up I ended up with this,
![](http://velvet-art.smugmug.com/photos/i-dJFM3nW/0/L/i-dJFM3nW-L.jpg)
I know that the upper circular part is not centered on the crankshaft hole, I may redo that, but will probably use a couple of filing buttons and just hand file it to the right shape.
Then I set up the main frame in the jig and, because there is so much more work involved in the main frame, and some very critical distances involved with the long drilled internal steam passages, I double checked that the frame was still held perfectly square.
![](http://velvet-art.smugmug.com/photos/i-KMt9gnT/0/M/i-KMt9gnT-M.jpg)
That's all I got done, so next will be the sphincter-tightening stage of cutting out the shape on the main frame, either you will hear from me with joy as it has gone well, or you will not hear from me for some time as I have to remake it
![:bang:](https://madmodder.net/Smileys/default/BangHead.gif)
Tim