PeterE Tries to Build a Trojan ...

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PeterE:
While waiting for delivery of both some tooling (taps etc) and material I decided that I would only be dis-satified if I "fixed" the goofed parts. I would only see the errors and not the rest, so I made some new bits from some brass bar stock I have. First a new top cap ...

Compared with the original it is only the colour differing.

Then the bottom cap is in the 4-jaw...

... and it will stay there until I have all things ready like piston rod bore (4 mm) and the gland socket (1/4"x40) as the underside is the datum side. When the gland bore and thread is done I will narrow down the "spigot" somewhat and then I can simply fit the whole thing in my ER-32 collet holder to make sure that the other side becomes correct and true.

I also read ahead in the documentation I found, and it seems like Mr Bertinat liked to make the different bits to measure as one chain and then make the holes and threads as a second round, hence nothing mentioned at this stage on how to machine and thread the bits as one go.

So, being a beginner with this, I find it suitable to follow the build description before doing it my way :)

BR

/Peter

saw:
Good work Peter :thumbup: :thumbup:

PeterE:
Finally got delivery of a set of Imperial ME taps and dies which will make it easier to make the sensitive bits. Thereby I could also finalize the drilling and threading for the gland nut in the lathe. Now it is perfectly in line with the piston bore! :D

Next step was to turn to thickness and make the little seat positioning (centering) the cover in the cylinder bore. I used the spigot to set it up in the collet to guarantee that it was centered and true and it worked beautifully.

The flange is still far too big but I will wait to saw/file it to shape until the necessary holes are in place. Then I can easily copy the original piece.

So, this means that I am back on track again!

BR

/Peter

saw:
Nice done PeteE and it was a good deside that you bought the Imperial, I think that you will be more pleased with that when you are threading. :headbang:
Nice to see youre progress :clap: :clap:

PeterE:
:update:
Hi all,

Finally I did get some shop time which resulted in one new item - the trunk guide - the material for which I waited for quite some time.

Made from one single piece of BMS. Turned out quite nicely, and I am pleased with it. Waiting to mark out and drill the holes until all bits are made.

Furthermore I took the plunge and set up to mill the port face holes, and they turned out well too :bugeye: :ddb: :ddb: :ddb:
Also the steam outlet hole landed in the correct place. :D

Here we can see both the port face and the steam outlet.

After reading up I saw a useful tip on how to get the angle of the steam inlets from the port face to the ends of the cylinder at the right angle and in the correct place. the text said to mark out on the side using a pencil which will help determining the angle. Good idea, now it is time to see if I manage to do it right as well. The channel between the ports and the cylinder end shall be two 2mm dia holes. In the cylinder end there shall be a land of the same width as the ports (9/32 or 7,2 mm) and just over the 2 mm in breadth.

Will be back with pics on both my setup, the milling, and the result.

BR

/Peter

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