Author Topic: Enlarged rocking engine build (Read 19029 times)

Ross · « **on:** August 24, 2012, 06:48:45 PM »

Hi everyone,

I started a new project on my lathe today. I'm building a enlarged version of the rocking engine, designed by member NickG on here. His oiginial build:

http://madmodder.net/index.php/topic,1718.0.html

I will be making a few artistic changes to the original plans it won't be a fast build though! Sadly I don't have much time to get to The shed at the moment do bear with me!

I didnt get much done today, I had to make a Gear knob for my dads new car it took longer than expected due to my tail stock failing. I need to strip it tomorrow as the part that extends when you turn the wheel has come loose and is slipping. The link for the knob is below for those that are interested!

http://madmodder.net/index.php/topic,7540.0.html

Anyway, I faced all of my stock and turned the cylinder to length.

I also started on the cylinder cover, I turned it to the correct diameter. It needs to be marked out for the 6 equispaced holes next.

Tommorow I think drill and bore the cylinder and Lap it to size, but I shouldn't get ahead of my self!

Ross

Stilldrillin · « **Reply #1 on:** August 25, 2012, 02:27:26 AM »

Hi Ross.
Nice to see you've made a start, already!

Good luck with the build....

David D

NickG · « **Reply #2 on:** August 25, 2012, 03:30:31 AM »

Hi Ross,

Yeah good luck - will be great to see somebody building one of my engines! If you have any more questions don't hesitate to ask - the others on here may have better advice than I do, I will only be able to tell you how I did / would do it.

Cheers,

Nick

Ross · « **Reply #3 on:** August 25, 2012, 12:03:58 PM »

Hi,

Today I marked out the holes on the cylinder cover and drilled them.

It was very hard to do on my pilar drill and it took some lining up. I think I moved in a bit to far in while marking the PCD I will have to make the bore of the cylinder smaller by 2mm.

Next, I cut the stock and faced to the required thickness and drilled and tapped M5:

I finish turned the cylinder cover, and adjusted it slightly to Make it easier to drill the holes in the cylinder. The only thing I didn't do was put a recess for a seal as I'm not sure of the size of the one I'll use.

Next I turned the outer diameter of the cylinder, turned the majority first.

And then turned it in the chuck and finished all the way.

Next I drilled the bore to 13mm

And then bolted The cylinder plate and cylinder together ready for drilling and tapping.

NickG · « **Reply #4 on:** August 26, 2012, 09:17:47 AM »

That's def the best way to do it, you can use the cover to drill both ends then use it on the frame as well, sure fire way to get them to line up.

Think I just used a paper gasket on mine.

Nick

krv3000 · « **Reply #5 on:** August 27, 2012, 07:28:25 AM »

thats shaping up nice

Ross · « **Reply #6 on:** August 27, 2012, 01:22:44 PM »

Hi guys,

I drilled and tapped the holes in the cylinder, I messed up the centre punches on the first try hence the extra set.

I drilled the bore to the final diameter and lapped.

That's all I got done today due to my lathe having a blip! I made a little start on the piston I'll finish that this weekend hopefuly.

Stilldrillin · « **Reply #7 on:** August 28, 2012, 01:50:59 AM »

Nicely done Ross!

Don't worry about the marking-out glitch. We won't tell.....

Don't mention lathe blips!! I've had enough of 'em, now!

David D

Ross · « **Reply #8 on:** August 31, 2012, 12:56:55 PM »

Hi Guys

Not munch done today, just got myself into a bit of a pickle on the piston.

While roughing out I thought to myself , why the hell did I face it to length? It would have been 10x easier to make then.

Im finding it hard clamp it to turn it to size, so I think I may scrap this and order a new bit of stock and redo it.

The diameters on the far left and right are .0010" off finish size, but I'm left with noting to clamp onto for the middle!

Live and learn!

Stilldrillin · « **Reply #9 on:** August 31, 2012, 03:34:47 PM »

Hi Ross.

Centre drill the small dia end.
Then, hold on piston with revolving centre in conrod end. Finish conrod to size.
Hold on conrod, to finish the piston.

David D

Ross · « **Reply #10 on:** August 31, 2012, 06:35:53 PM »

Not to worry David, I remembered I had another piece of brass long enough so I've just made another!

I made the piston a little bigger on this one so it gives me lots of room to play with for the radius on it.

Brass_Machine · « **Reply #11 on:** August 31, 2012, 06:48:17 PM »

Nice start Ross!

Eric

NickG · « **Reply #12 on:** September 01, 2012, 04:22:12 AM »

Nice one Ross - I told you what happened on mine didn't I ... I got carried away when filing the radius so get to form taking as little off as poss then go very gently trying the cylinder over it all the time.

After my first attempt I cut the piston off the end and threaded the end of the rod / made a disc with a threaded hole for piston so I could have multiple attempts!

You've done a good job doing it out of a solid piece now though.

Ross · « **Reply #13 on:** September 01, 2012, 07:17:45 PM »

Hi everyone.

Today I put the radius onto the piston and made it fit the bore.

It was VERY easy to go undersize, the piston fits and turns in the bore nicely its not as snug as it probably could be but I think it should be good enough I can always adjust when it is all together.

NickG · « **Reply #14 on:** September 02, 2012, 03:16:46 AM »

Good job there, you've done the hardest bits of the project now! However you do the frame etc just remember to have the offset beween crank hole and cylinder bolt ring - otherwise the engine will do one stroke and never exhaust!

Nick

Ross · « **Reply #15 on:** September 23, 2012, 11:22:00 AM »

Hi everyone,

Today I made two crank wheels. They just need the off set hole drilled through the for the crank pin.

I also shortened the bolts for the cylinder plate.

NickG · « **Reply #16 on:** September 23, 2012, 02:59:41 PM »

hang on - 2 cranks? is there something you're not telling us??!!

Ross · « **Reply #17 on:** September 23, 2012, 04:40:14 PM »

Quote from: NickG on September 23, 2012, 02:59:41 PM

hang on - 2 cranks? is there something you're not telling us??!!

It all goes downhill from now on Nick!

Stilldrillin · « **Reply #18 on:** September 24, 2012, 07:54:12 AM »

Quote from: NickG on September 23, 2012, 02:59:41 PM

hang on - 2 cranks? is there something you're not telling us??!!

He's building a twin, Nick!

David D

Ross · « **Reply #19 on:** September 26, 2012, 05:35:57 PM »

Quote from: Stilldrillin on September 24, 2012, 07:54:12 AM

Quote from: NickG on September 23, 2012, 02:59:41 PM
hang on - 2 cranks? is there something you're not telling us??!!

He's building a twin, Nick!

David D

I wish! I don't think it would be done before the end of next year if I did that! I'm just modifying the crank end of the engine slightly.

Ross · « **Reply #20 on:** October 20, 2012, 03:13:19 PM »

Hi everyone,

Finally got back onto this today.

First I made a mandrel for clamping the crank wheels while drilling the offset holes.

I drilled the first hole with no problems. But on the second I over tightened the nut and stripped the thread, I had to put the 3 jaw back on and skim the face.

Clocked and drilled.

Then I drilled the holes for the grubsrews to fix onto the crank. And. Threaded M3.

Ross · « **Reply #21 on:** November 01, 2012, 04:19:30 PM »

Hi everyone,

I ordered some aluminium for the engine frame a while ago, and it arrived today

I had a go at filing the edges of the engine frame square. And being probably the worst filer in the world even using a square and taking off the high spots, I was tearing my hair out! I don't think I can get any straighter than what I've ended up with!

The only problem being is that the rectangles are now 2x1.5 inches they need to be 2x1.25 I don't particularly fancy trying to file the longer edge square but I'm worried that the extra .250" height will dwarf everything else! Ideas?

Ross

Stilldrillin · « **Reply #22 on:** November 01, 2012, 06:47:50 PM »

Ross.
If you're worried about sawing/ filing 1/4" off, accurately.

Do you know anyone with a mill?

David D

Ross · « **Reply #23 on:** November 01, 2012, 08:16:40 PM »

Quote from: Stilldrillin on November 01, 2012, 06:47:50 PM

Ross.
If you're worried about sawing/ filing 1/4" off, accurately.

Do you know anyone with a mill?

David D

Not anyone nearby I don't think, it dosent have to be too accurate but I will need use of a mill to do the part that attacthes to the cylinder so it holds everything sqaure.

NickG · « **Reply #24 on:** November 02, 2012, 07:01:50 AM »

You could leave it as it is Ross, not bother with the turned legs and sink the flywheel into the base? You should be able to get the ends square if you have a vice and just using the top of the jaws as a guide or clamping a known square bit of metal next to it in the vice and using that as a guide?

kayz1 · « **Reply #25 on:** November 02, 2012, 11:19:05 AM »

I was going to say come and use my mill if you want,,,,then i looked at your profile ***
Lincoln bit of a treck that..
Lyn. PS: kep up the good work, i am learning a lot here for when i TRY to do some thing like this.

Ross · « **Reply #26 on:** November 04, 2012, 12:09:30 PM »

Hi everyone,

I got quite a bit done today, I took the aluminium plate down to size using the four jaw on my lathe.

Then I marked out the holes on the plate.

And then drilled.

And then I marked out and drilled the holes in the bottom ad tapped M4

And then I rubbed the faces and sides down with sandpaper to remove the marks etc..

And loctitited the bearings in the holes flat.

And while that was drying I turned and finished the crank shaft diameter.

NickG · « **Reply #27 on:** November 05, 2012, 01:47:28 PM »

Wow, you're flying now mate - can't believe I didn't think of using the 4 jaw!

Ross · « **Reply #28 on:** November 23, 2012, 01:45:43 PM »

Hi everyone,

I've taken another few weeks off on this but I've been busy doing a couple of bits and pieces to my lathe, I've fitted a new guard and a lamp which I made, the light makes a world of difference.

To test it out I had to turn some sleeves for the I/D crank wheels due to me stupidly ordering 5mm bore bearings and drilling the crank wheels to 6mm

I turned he O/D to suit the bore of the wheels and then drilled the bore 5mm and parted off two parts. there isn't much material in it and I thought it was going to all end in tears, but I'm pleased with the result. Just a couple of holes to drill for the grub screws to slot through.

Ross · « **Reply #29 on:** December 01, 2012, 10:00:18 AM »

Hi everyone,

Today I started roughing out the support posts that will go between the engine frame and the base.

I have to make 5 of these so I changed the design to keep it simple and so there less margin for error.

Here is a rough drawing, I left the diameters off as I didn't have the measurements on hand. I'm trying to use imperial measurements more and more, but all the threads are still in metric!

Firstly I parted each post off and roughed out the thread length at the top. This varied slightly per part so I could keep the length of the body the same.

I left the main body of the posts .300" long for ease of clamping.

I drilled the 4.2 mm holes in the bottom of each post for the M5 Thread.

And then I started to turn the O/d of the thread length I marked out previously to 4mm and threaded.
From here, it all goes downhill.

I decided to face the first off to length - .500" and it was all going well as it should. I turned the top half O/D of the part down to 6.25mm.

I went in for the finishing cut of this O/D and was just winding out at the back face when I accidentally knocked the feed on. The part partly sheared out of the jaws and the cutting tip of the tool snapped off. Sadly this mangled the part and the tool beyond repair.

I continued on with the next part and did the above, I was using a new tool and I was having major problems with the clearances as it was rubbing while I was facing it to length. It works fine when cutting the O/D's though. The tool I'd broke worked I'd never had a problem with the grinding clearances but I really can't get the hang of grinding these bigger tools.

I've left it for now as I didn't want to go scrapping all the rest off because of badly ground tools. Maybe a interchangeable tip tool would be a good Christmas present?! But I'll see what you guys think.

Ross

Ross · « **Reply #30 on:** January 30, 2013, 06:00:39 PM »

Hi everyone,

After an extended Christmas break due to passing my driving test I'm back to hopefully finish this one off before I forget how to use a lathe!

I nipped down to the shed after work and got 2 of the 4 engine posts finished as I managed to get some more stock. And the other two just have to be faced to length.

Ready to be parted off:

2 finished.

2 still to face to length!

Stilldrillin · « **Reply #31 on:** January 31, 2013, 03:37:56 AM »

Congratulations on passing your Driving Test, Ross!

I guess, the call of the open road, was much stronger than a cold workshop......

Those two posts look good to me. Have you sorted your tool grinding issues now?

David D

Ross · « **Reply #32 on:** January 31, 2013, 12:58:58 PM »

Quote from: Stilldrillin on January 31, 2013, 03:37:56 AM

Congratulations on passing your Driving Test, Ross!

I guess, the call of the open road, was much stronger than a cold workshop......

Those two posts look good to me. Have you sorted your tool grinding issues now?

David D

Thanks David, though the novelty has now worn off!

The grinding is sorted, thanks some bloke In Derbyshire! The tools cut
Though like butter now thanks David.

Ross

NickG · « **Reply #33 on:** January 31, 2013, 01:15:10 PM »

Well done on driving test Ross, glad to see you back on the project too. I really need to get my act together, started the year full of good intentions but didn't get much further yet.

Ross · « **Reply #34 on:** February 02, 2013, 11:46:00 AM »

Hi everyone,

Got a lot done today.

I cut out a sqaure of aluminium, 1.25" x 1.25"

Squared the sides up using the old reverse milling technique.

Marked out the hole for the bore of the cylinder. 0.625 in each way.

Clocked it in

I drilled the hole to 5mm and bolted the cylinder cover plate to the square so I could use it as a guide for drilling the holes.

I then drilled the holes using my pillar drill.

Then I clamped the cylinder cover to one end of the the cylinder and the square to the front so I could drill and tap the holes on the cylinder.

Ready to drill:

Job done:

After, I marked out and drilled and tapped the holes in the sides of the square so it bolts onto the two other engine frames I made earlier.

And then it was back onto the lathe to drill the bore to match up with the bore of the cylinder.

Job done!

Just need to order some more bolts so I can assemble it all!

Ross · « **Reply #35 on:** June 08, 2013, 11:15:59 AM »

Hi Guys,

Little bit quiet on this one to say the least. I've been doing bits and pieces along the way and I've nearly finished this engine (finally)

This is the mockup in its final stages:

As you can see I'm nearly there Just the crankpin and some flywheels to make.

I made a couple of flywheels but I wasn't happy as I felt they were too small.

And I'm currently in the process of making an air adapter to screw in the back.

I hope everyone is well.

Stilldrillin · « **Reply #36 on:** June 08, 2013, 02:16:32 PM »

Hi Ross.
Was wondering what had become of you.

Nice to see you're still with us!

The engine's looking good. Needs BIG diameter flywheels. If only for the looks........

David D

NickG · « **Reply #37 on:** June 08, 2013, 04:58:34 PM »

Nice work Ross, should work with those flywheels but agree it might look better with bigger ones. Looks good, I like your mods with the 2 bearings.
Proper crank and 2 flywheels.

Ross · « **Reply #38 on:** June 22, 2013, 09:55:46 PM »

Morning all

Just the finishing touches now, machined the air adapter and crankpin!

More metal for the flywheels is on its way!

Ross

NickG · « **Reply #39 on:** June 23, 2013, 03:25:35 AM »

Looking good Ross, nearly there.

Ross · « **Reply #40 on:** June 28, 2013, 11:51:05 AM »

The metal arrived for the flywheels, so I set about making a couple!

Roughed out.

Then onto the mandrel to skim the o/d

I went to drill the holes for the grubs crews, and I managed to snap the crap vice I was using on the pillar drill!

Here is the final mock up! the crankshafts need to be faced slightly shorter. Not sure weather to leave the flywheels plain, I quite like them as they are now.

Ive already test ran the engine! too much air pressure is getting through as I cant control it very well with the attachment I'm I need to find something where I can have full control over the air going into the engine.

NickG · « **Reply #41 on:** June 28, 2013, 04:08:06 PM »

Nice 1 Ross, I quite liked the look of the
Plain flywheel on this engine too so I left it. Would definitely look better with a recess on the outside though. I like the look of the crank poking through too. The poppin flame licker was designed like that. Did it run then or was there too much air. If there's too much sometimes they stop as there's still forward force on the piston when it's trying to exhaust.

Stilldrillin · « **Reply #42 on:** June 28, 2013, 05:28:17 PM »

Hi Ross.
That looks "compact". Well done on getting a runner!

For valves etc, have a look on ebay, for aquarium air line supplies.

David D

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Author Topic: Enlarged rocking engine build (Read 19029 times)