Author Topic: Potty Over Crank Wall Engine (Read 227005 times)

sbwhart · « **Reply #200 on:** May 12, 2011, 11:18:37 AM »

I was planning on getting more done today than I actually achieved, due to a little unexpected excitement, when backing the car out, to go on the weekly shop, there was an unexpected jolt and the front of the car dropped, the cast iron drain cover had broken and the wheel dropped into the hole, luckily the car came out without any damage, but the cover was so much scrap iron, so the best part of the day was spent finding and collecting a replacement cover of the right size. Not cast iron but a mild steal pressing with a pollypropolean base, looks real flimsy but rated at 5 tonne

.

Any casters out their want some cast iron.

This is what I got done, found a better bit of black mild steel plate than the gray stuff I showed nearer to size and not as thick, cut it roughly to size and squared it up then, with it sitting on some washers to raise it off the table, set too and milled some radiuses, on the RT.

Bit more work on the mill then by rack of eye and with a selection of files got it to this nice shape.

And on the engine it's a bit long but I can soon cut it down to size when I've got the bearing housing fixed to it.

Stew

AdeV · « **Reply #201 on:** May 12, 2011, 12:21:28 PM »

Did you manage to fish all the bits of cast iron out Stew? I imagine it's nicely aged, and those old drain covers were thick as thieves. Should be good for a few pistons at the very least...?

sbwhart · « **Reply #202 on:** May 12, 2011, 12:36:36 PM »

Quote

Did you manage to fish all the bits of cast iron out Stew? I imagine it's nicely aged, and those old drain covers were thick as thieves. Should be good for a few pistons at the very least...?

No Ade

That was the first thing I did after I checked the car out, sized it up for useful bits its far too thin to get anything useful out of

:-

It must be over 50 years old, thats how old the house is, so as you say well weathered I think thats why it broke it developed a crack after the cold weather we had last winter, should have changed it as soon as I spotted the crack, but you know how it is.

Stew

klank · « **Reply #203 on:** May 12, 2011, 02:21:51 PM »

Stew
Thats is real metal artistry - impressive.

Best wishes and respects

Peter

saw · « **Reply #204 on:** May 12, 2011, 02:42:47 PM »

Lokking good

Stilldrillin · « **Reply #205 on:** May 12, 2011, 03:54:06 PM »

That's a cracker Stew!

David D

Dean W · « **Reply #206 on:** May 12, 2011, 06:35:46 PM »

You just keep throwing on the cool tricks, Stew. Everyone can learn something from this thread. It's great!

Dean

raynerd · « **Reply #207 on:** May 13, 2011, 09:28:40 AM »

Stew, sorry, I haven`t been on this thread in a few days and I`m interested in the butterfly valve. I can see how you have glued the oval into position but due to the heat in my IC engine, I`d have to silver solder. How would you solder the valve in position without heating the lot up and causing the solder in the "case" to melt and come out of line?

Am I right in thinking that it would need to be silver soldered in situ?

Excellent build Stew, amazing photos and good explanations. As always

Chris

dbvandy · « **Reply #208 on:** May 13, 2011, 09:36:19 AM »

Quote from: craynerd on May 13, 2011, 09:28:40 AM

Stew, sorry, I haven`t been on this thread in a few days and I`m interested in the butterfly valve. I can see how you have glued the oval into position but due to the heat in my IC engine, I`d have to silver solder. How would you solder the valve in position without heating the lot up and causing the solder in the "case" to melt and come out of line?

Am I right in thinking that it would need to be silver soldered in situ?

Excellent build Stew, amazing photos and good explanations. As always

Chris

It would be easier to pin it for an IC engine than to try to solder down in a small hole, you would just end up soldering it all shut unless you have the hands of a surgeon....

sbwhart · « **Reply #209 on:** May 13, 2011, 10:25:02 AM »

Quote from: dbvandy on May 13, 2011, 09:36:19 AM

Quote from: craynerd on May 13, 2011, 09:28:40 AM
Stew, sorry, I haven`t been on this thread in a few days and I`m interested in the butterfly valve. I can see how you have glued the oval into position but due to the heat in my IC engine, I`d have to silver solder. How would you solder the valve in position without heating the lot up and causing the solder in the "case" to melt and come out of line?

Am I right in thinking that it would need to be silver soldered in situ?

Excellent build Stew, amazing photos and good explanations. As always

Chris

It would be easier to pin it for an IC engine than to try to solder down in a small hole, you would just end up soldering it all shut unless you have the hands of a surgeon....

That what you'd have to do is pin it, but you'd have to drill the butterfly through first before you assemble, so it would be the devils own job to get thing aligned when you come to assemble it in the body.

You could try soft solder, what you have to do is blacken the bore in the body with sooty smoke from a candle to stop the solder sticking to it and only use a tiny amount of solder paste. Never tried the sooty smoke trick I read it someware.

Stew

raynerd · « **Reply #210 on:** May 13, 2011, 10:47:17 AM »

lol, I can see it all ending up a sitcky mess of solder with a permenantly closed valve

!

Anyway, thanks both of you for the reply. Keep up the good work with the engine.

Chris

NickG · « **Reply #211 on:** May 15, 2011, 08:49:03 AM »

Chris,

Not sure whether it'd be easy at this scale - but on my clio the spindle had a slot in it that the butterfly went through - if you did that you can sort of get it to self align by opening and shutting it with the butterfly in the slot then you could drill through to get the right location, take to bits and tap for a screw. Bit fiddly though.

Stew, why is the butterfly an oval shape? I must have missed something obvious!

Nick

Divided he ad · « **Reply #212 on:** May 15, 2011, 09:13:22 AM »

Nick, does the one in the clio not have a slight oval shape to it? Many of the ones I've seen have a slight oval shape, allowing return springs to pull the valve shut tightly when the throttle is released. if it were round it would just open in the other direction when the spring pulled it.

Just mu 2 p's

Sorry we didn't get to talk more at the show too... Well, not at all really

I turned around to see if you were still there and you'd gone. So had loads of the others!
Could have talked RS's

Ralph.

sbwhart · « **Reply #213 on:** May 15, 2011, 09:25:56 AM »

Quote from: NickG on May 15, 2011, 08:49:03 AM

Stew, why is the butterfly an oval shape? I must have missed something obvious!

Nick

It doesn't sit square across the bore it sits at a 30 deg angle so that it shuts tight.

Stew

sbwhart · « **Reply #214 on:** May 15, 2011, 09:45:58 AM »

Completed the bracket for the governor.

Turned up a length of bar and stuck a roughing drill down it to reduce the mass, then mill a couple of slots to take the bracket.

Then silver soldered the two bit together then set up in the mill found the centre with the coaxial indicator, and drilled it out 9.5 mm followed by a 10mm reamer.

Then cut away the unwanted bit in the middle and fixed the ball bearings in place with loctite bearing retainer, made a couple of brass spacers to take up the clearance in the bore.

Drilled and pegged the flyball fixed end to the shaft so you get this.

This is how it looks on the engine.

I think it would be better closer to the fly wheel but there is too much gubbins around the front of the cylinder to mount it.

Stew

saw · « **Reply #215 on:** May 15, 2011, 10:35:40 AM »

This is fantasic well builld.

NickG · « **Reply #216 on:** May 16, 2011, 06:24:34 AM »

Thanks for that chaps, totally makes sense - just didn't think of it! It must just be a very slight oval on the car ones though but it must be there otherwise it would tend to jam up too.

Yeah sorry I had to rush off, I was a bit peeved in the end as I only had about an hour and a half to rush around the show / tools, happens every year

I'll be there next year though and if we do the meet after there will be plenty of time to chat. Talking RSs is good but I'd get upset as mine is not on the road!

Stew, great method of keeping the bearings aligned. Love the governor and can't wait to see it working

Divided he ad · « **Reply #217 on:** May 24, 2011, 04:03:47 AM »

Nice fabrication Stew

One of these days I'll have to try this solder then cut out method.

Sorry Stew... Well

but, yes Nick, will have to get a bit better organised for next year

I know someone selling a black Escort turbo in very good cond' for 3k.....

Ralph.

sbwhart · « **Reply #218 on:** May 26, 2011, 12:31:57 PM »

Thanks Nick/Ralph

Bin away on a short holiday to the isle of Islay off the West coast of Scotland its famous for whisky and ship wrecks, the ferry we were on nearly become one when it developed engine problems on the crossing and had to return to port, it all adds up to make life interesting

Made the little lever thing that connect the fly ball governor to the butterfly valve, it's a right tricky little beats, I had no idea how to make it so decided to just start cutting it out of a chunk of metal I had a rough idea what it was to look like.

Rouged it out with the end mills.

Then it was a matter of taking files to it and nibbling bits off and adjusting until it fitted and started to do what was required.

This is it fitted to the cylinder.

I'd removed the cylinder from the engine so that I could drill the hole for the bracket so couldn't try it running, but I did connect a power drill to the shaft and gave it a spin and its works nicely operating the valve nice and smooth. I'll post a video over the weekend when I get chance, but I've a few family thing to deal with first.

Stew

AdeV · « **Reply #219 on:** May 26, 2011, 12:38:41 PM »

Stew, that's a piece of engineering art, that is. The whole governer just looks so right. Really nice work, sir!

Stilldrillin · « **Reply #220 on:** May 26, 2011, 12:44:15 PM »

Having seen one of those tiny linkages.....

I know, that is a piece of jewellery!

Blummin well done Stew.....

David D

DaveH · « **Reply #221 on:** May 26, 2011, 01:22:26 PM »

My! that does look good

DaveH

arnoldb · « **Reply #222 on:** May 26, 2011, 01:48:02 PM »

Great Job Stew

Hmmmm.... Isle of Islay; I've heard a lot about that one

as I do like a good whiskey myself; that's on my own itinerary when I get to the UK - and current plans looks a go for next year around Harrogate show time; I really want to see that as well. I just hope the exchange rates will hold up!

, Arnold

Rob.Wilson · « **Reply #223 on:** May 26, 2011, 03:41:22 PM »

Very well done Stew

Rob

sbwhart · « **Reply #224 on:** May 26, 2011, 03:43:45 PM »

Thanks DaveD, DaveH and Arnold

Arnold this week is the Islay whiskey festival, the diferent distilery's each have an open days throught the week, if you want to go you have to book your accomodation in advance or bring a tent.

http://www.scotlandwhisky.com/whisky-festivals/Islay-malt-and-Music-festival/

Stew

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Author Topic: Potty Over Crank Wall Engine (Read 227005 times)

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