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cfellows:
Today I completed work on the cylinder support rods. The first task was to cut the grooves in the end of each rod. The grooves allow passage of the air regardless of how the rod rotates. I used a 1/8" cutoff tool and cut the grooves .050" deep. I realized later that they really only needed to be about .030" deep but, what's done is done.

Next, I drilled the center holes, 1/8" diameter and 2.875" deep from each end. I was a little nervous about drilling that small a hole that deep, but it was uneventful. I backed the bit out about every 1/16" to clear the chips. I used a standard length bit to drill as far as I could, but had to use a longer bit to drill the last 1/2" or so. Yup, that's a 12" long x 1/8" drill bit I'm using there. I bought it at Home Depot and I did have to sharpen it before I could use it! Guess I'll have to break down and buy a set of extra long aircraft bits one of these days.

Here's a picture of both rods with all 4 center holes drilled.

Finally, I drilled the radial port holes in both ends and one on either side of the piston in the middle.

Before the engine is completed, I'll have to plug the ends of the center holes, probably with something resembling a rivet. I'm planning to just use Loctite.

Chuck

cfellows:
After lots of noodling, Thanksgiving, and seemingly endless honey-do items, I got back out in the shop today and made some chips. In fairness to SWMBO, I was kind of stuck on a couple of design issues so probably wouldn't have made much progress anyway! :-\

I decided to change the cylinder material from the thin walled aluminum to thicker walled brass. I was originally going to put screws through the side of the cylinder into the heads, but decided the convention method of screwing through the head into the end of the cylinder made more sense. So, I turned the brass cylinders from 1.125" brass rod. The heads are also turned from 1.125" brass rod. I will probably do some further shaping to the cylinder and perhaps the head at a later time.

I also made an aluminum crosshead guide that will fasten flat to the base. The crosshead will be comprised of either blocks or round rollers attached to the cylinder that fit into the slots in the guide.

Here are some pictures of the parts and partially assembled.

Chuck

NickG:
very cool Chuck, can't not watch this one! :clap:

cfellows:
Work has been slow on this engine, mostly because I've been working on design issues. I'm trying to come up with an engine that will look good with nice proportions and not look like a bunch of parts just bolted together. Consequently, it has been kind of tough.

I did build and fit the pistons, added the cross head bearings and the connecting rod bosses to the cylinders, and made a steel base to hold both the cylinder assembly and the flywheel assembly. I plan to weld milled angle iron around the steel bed-plate to form the base. The other hurdle before me is to design the flywheel support and bearing assemblies.

I'm also playing around with different flywheel designs.

Chuck

sbwhart:
Comming to gether real well chuck :thumbup: like the flywheel :thumbup:

--- Quote ---I'm trying to come up with an engine that will look good with nice proportions and not look like a bunch of parts just bolted together. Consequently, it has been kind of tough.

--- End quote ---

That's a tactic that will pay off in the long run, Chuck:- try cruising around the steam museum sites for inspiration some of those old engine had beautiful architectural detailing.

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