Enlarged rocking engine build

[kayz1]

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]

 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]

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

[Ross]

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]

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]

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]

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]

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]

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]

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]

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]

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]

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]

Morning all

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







More metal for the flywheels is on its way!

Ross

[NickG]

Looking good Ross, nearly there.

[Ross]

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]

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]

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