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| a new flame eater, just to be different |
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| madjackghengis:
Hi all, after seeing the success of so many "poppins", and playing around with ideas, I thought I'd build another to try out some new intersections of different engines. This is basically a "poppin", but scaled up a bit, with a three quarter inch bore, an inch and a quarter stroke, cast iron piston in a cast iron cylinder, with a cast iron head. I started with a stick of cast iron, about an inch and a quarter diameter, turning the cooling fins first so I could use the tailstock for support. starting the cooling fins fins completed, time to drill before boring. After step drilling and then boring just undersized, I reamed it out with a .750 reamer I want this to have good compression, so I'm going to lap it using a piece of delrin plastic to hold the compound, and have cut it to just barely fit in the bore as reamed. after smearing the lap with some fine valve grinding compound, it is rolled on a steel table with a piece of steel to embed the compound in the plastic, and this spreads the compound evenly as well the lap is put in the lathe, the cylinder held in hand, and it is lapped until the feel of the whole of the cylinder is the same, and there are no tight spots. a piston has to be turned up, so I put a pipe cap on a piece of pipe, and turned the o.d. to just barely fit the bore. I wrapped the piston with a piece of notebook paper to protect its finish, and bored out the threads, bored to get about a forty thousandths wall, and to get a flat surface parallel to the front face, on the inside once the piston is ready, I used some polishing compound as a carrier, and will be using jewler's rouge to lap the piston to the cylinder with the piston screwed to the end of an old throttle shaft of brass out of a carburetor, I've rubbed in the rouge and clamped the shaft in a vise to hold the piston steady the cylinder is carefully rotated and moved back and forth as it eases into the bore, the compound opening it up just a bit as it goes a look at the piston with compound blackened by the lapping, ready for fresh compound. the final lapping is done with both piston and cylinder in hand, for the feel and to be certain any tight spots are found and worked out with the lapping completed, the cylinder is set up in the milling vise for mounting holes to be center drilled after which the bolt holes are drilled and tapped here I'm squaring up the top side of the frame of the engine flipping it over, getting ready to flycut the bottom side and flycutting it, using soluable oil for coolant at this point, it is time to square up the face where the cylinder will mount flycutting the front face the final cut, finishing the end touching off with the end mill, using a cigarette paper to get a dead zero milling the slot which will set up the thickness of the front face where the cylinder mounts touching off the back side, again with a cigarette paper for zero clearance on the cutter touching off the front side, getting ready to mill the slot for the crank assembly starting the slot, lots of chips and fluid lots more chips, removing a couple cubic inches of volume finishing up the slot for the crankshaft, taking light cuts the full depth, and getting the two pillars even in thickness this about does it for today, more to come soon. Mad Jack |
| saw:
This will be very intressting to follow :thumbup: :thumbup: |
| madjackghengis:
Thanks Saw, well, to start on the crank, I put a piece of free machining inch and three quarters in the lathe, center drilled it, drilled and reamed out a three sixteenths hole, about an inch deep, as the mainshaft holes. I will be parting off two crank cheeks, after I put the stock in the milling vise and drill and ream the crank pin hole, this ensures the two cheeks will hold the shafts and pin parallel to each other. with the center hole drilled and reamed, the stock is set up square in the milling vise, and the crank pin hole drilled and reamed the finished hole will give an inch and an eighth stroke now it needs to be cut off, and the two crank cheeks faced off parallel to each other ready to go back in the lathe two slices a bit over a quarter in thick, enough to face off clean facing the other side off setting up the cheeks for balancing holes to be drilled center drilling, and drilling a pilot hole for each balance hole opening up the holes to a size which looks good cleaning up the crank cheeks for locktite to hold the shafts and pin in place pressing in the crankpin, using a roller bearing in the main shaft holes for alignment using a piece of tube, a bar, setting up to press in the mainshafts pressing a shaft home the assembled crank laying in the slots of the frame another view of the crank laying in place, that's it for now, more to come soon, Mad Jack |
| cfellows:
Nice looking engine. Will be interesting to see how she runs! Chuck |
| saw:
madjackghengis I have to ask you some questions about the flycut (I'll got min this morning but I have never run it). How fast shell the drill run during flycuting? How deep can it take? I suppose it deppend on the mill, I'll got an china-mill, a small one.. ::) Your progress on youre engine is fantastic. :bow: |
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