The Craftmans Shop > Model Engineering
Side Valve i.c. engine from Bar stock
philf:
Brian,
A superb project.
Thank you so much for sharing it with us.
How about fibre gears to mesh with the steel crankshaft gear. They should run much quieter and are no more difficult to make.
Cheers
Phil
Brian Rupnow:
Philf--If I can avoid remaking parts, I will be much happier. I will try this solution first. -Fabrication of the timing gear enclosure went very quickly with no problems. I did have to split it to get it on, as I had indicated on the drawing. The only problem I ran into is that I don't have any bolts long enough to bolt things together. I had to order a minimum quantity of one hundred #5-40 socket head cap screws x 1 1/4" long to get the 6 I need. That will probably last me for the rest of my natural life!!!
Brian Rupnow:
When Ringo sang the song "It don't come easy" I'm sure he must have been thinking about something like this fan shroud!!! The only tube/pipe I could find slightly larger than my 3" diameter fan was a piece of schedule #40 3" nominal diameter steel pipe. It has a 3 1/16" inside diameter. I don't like working with pipe in the lathe.--It's nasty stuff to hold if you don't have a bull nose live center for the tailstock (I don't) and it has a propensity for jumping out of a 3 jaw chuck and rocketing around the room. This forced me to take .002" deep very light cuts until I had things close to the outside diameter that I wanted to end up with. The wall is still a little thicker than I would have liked, but it was just getting too scary. I have had a slight change of plan----I was going to silver solder it to the fan support bracket but that would have given me no adjustability at all. I have come up with a rather novel solution for bolting it to the fan bracket instead, giving me a bit of wiggle room if it ends up interfering with the tips of the fan blade anywhere.
Brian Rupnow:
Going boldly where no man has gone be----Well, you get the idea.--Fan shroud is coming together nicely. At the last minute I decided to make the small pieces silver soldered to the steel hoop from brass. My reasoning--If I have to slot the holes with an end mill to move things around for fan clearance, the brass cuts easier. As you can see in the picture, the soldering job called for a couple of strange little "fixtures" to ensure that everything ended up where I wanted it to be. Now to ensure that the steel hoop will be concentric and clear the tips of the fan blades, I wrapped the fan with masking tape until I had .030" thickness of masking tape. Slid the hoop over that (snug fit) and will mark thru the brass ferrules welded to the hoop with a transfer punch to locate the holes I will tap in the fan stand.
Brian Rupnow:
So, there we are!! Painted up pretty and done like dinner!! Nothing rubs nor scrubs, nor interferes, but a business card won't fit into the gap between the flywheel and the bottom of the fan shroud.--But it does clear. And that, my friends, was the very last part I had to build for this engine. I have to wait a couple of days for my long bolts to come in that hold the timing gear covers in place, but that's it. I will post one more video before I'm done, showing the engine running at its slowest and fastest speeds because someone has requested it, but other than that, I'm finished. This has been a long thread, as I knew it would become when I started it in July, but it's been fun and interesting. I encourage anyone out there who has at least a couple of i.c. engines "under their belt" to build this engine. ---Brian
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