MadModder
Gallery, Projects and General => Project Logs => Topic started by: Bernd on July 24, 2009, 07:26:34 PM
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All this talk about the Rocker Engine, the fine examples shown here, and Bogs fancy flywheel got me motivated to try a Rocker engine also, as if I have the time for another project.
So I started out with the flywheel first. I did a bit of head scratching to see if I could come up with something different in flywheel design. I literally slept on it. The next day I had a design worked out. Nothing fancy mind you, just 10 parts to make up the flywheel.
So here's the first pic of what it looks like.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw10.jpg)
And now how I got to this point. First a piece of 1.5" dia. brass faced.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw1.jpg)
Then turned around, faced, center drilled and drilled to a .188" depth.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw2.jpg)
I then used an end mill to get a flat bottom.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw3.jpg)
Next the boring bar was used to bore the ID of the flywheel.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw4.jpg)
Here it is at 1.000" dia and .188" deep.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw5.jpg)
Next all the little parts that were turned earlier, of which I didn't get any pics of, were tweaked to proper size on a mandrel so they would fit inside the 1.000" dia and sit flat on the bottom.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw6.jpg)
They were then silver soldered together to form one piece.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw7.jpg)
Back to the lathe and faced off.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw8.jpg)
Next I used a chamfering tool to line up the smaller parts. I used a bigger drill to enlarge the holes of all the smaller parts. The hole 180 degrees from the tool is already done.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw9.jpg)
Then it was back into the lathe to have the back side faced off until all the holes showed through.
Here's a couple more pics of the finished flywheel.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw10a.jpg)
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/fw10b.jpg)
Well now, I suppose I need to make the other parts to finish the Rocker. Guess I need to sleep on it to see if I cam come up with something different for the rest of the engine.
Regards,
Bernd
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Bernd
I think you have caught more than Rocker-itus. I believe you have caught a severe case of Acute Impresive Rocker-itus. :ddb: :ddb:
Sure beats laying bricks. :offtopic:
Don ducking and running for cover :wave:
cheers :beer:
Don
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Nice. You never mentioned this on your visit. Done after you left?
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Man Oh Man. Now that is sweet. I love to see new flywheel ideas. And this is a very impressive one I had never thought of. :thumbup:
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Well Bernd,
From a man who don't really do bling much, you're certainly doing a stand up job :clap:
I too love a good flywheel :ddb:
I like this game..... Waiting to see what you can come up with? :nrocks:
Ralph.
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Coor blimey Bernd
Thats one great looking flywheel very impressed.
:nrocks: :clap: :nrocks: :clap:
Have fun
Stew
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:bow: :bow: :bow: :bow: :nrocks:
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Bernd,
At last, people are staring to think outside of the box when it comes to these little engines.
All it takes is a little imagination, and you are away.
Very nicely done indeed. :clap: :ddb:
But be very aware, your flywheel will be very soft and fragile for the next few weeks, until it age hardens a bit, as I have just found out with my build. :(
Bogs
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Glad I'm fairly done with mine or I'd be :bang: the wall trying a version of yours :)
Parts were small enough as it was
Robert
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WOW!!!!! :bow: :bow:
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Sure beats laying bricks. :offtopic:
Don ducking and running for cover :wave:
cheers :beer:
Don
I'm running and ducking with you because she's throwing bricks. :lol:
Thanks Don. It's been raining off and on here quite a bit so bricklaying isn't moveing very fast. I've been trying to keep up with the grass mowing, though.
Bernd
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Nice. You never mentioned this on your visit. Done after you left?
I wasn't sure if I was going that route or not or if it would even work. I was ready to write a "How not to make a flywheeel" if it hadn't. Figgured I surprise you by posting. :)
Bernd
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Bernd,
But be very aware, your flywheel will be very soft and fragile for the next few weeks, until it age hardens a bit, as I have just found out with my build. :(
Bogs
I noticed that when I drilled the holes bigger. I noticed how easy the drill went through the material. I was afraid that it would grab the part and lift it out of the vise, but it didn't. Flywheel has been set aside for now. Need to think of how I'm going to do the rest now. Perhaps a few more nights sleeping on it might help. :)
Bernd
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Thanks for all the nice comments from the rest of you. Just rying to get the creative jucies flowing here.
:proj:
Regards,
Bernd
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I missed this one as well... My mind is slipping.
I love the design Bernd. Care to share the details on how you designed it? I may want to have a hand at trying it.
Eric
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I missed this one as well... My mind is slipping.
I love the design Bernd. Care to share the details on how you designed it? I may want to have a hand at trying it.
Eric
The wheel dia. is 1.250" so I made the inside of the flywheel 1.000". The hub I made .375". I drew this up in Autosketch. I then played with the circle drawing part until I had a round ring that would fit 4 times in the dia. between the .375" hub and the inside 1.000" dia. of the flywheel. The four smaller circles were added the same way.
I used a piece of brass rod about .250" thick and bored it to a .188" depth or there abouts. This allowed me to align the parts flat. Koso Hiraoka does something similar in his building of the three logging locos he's built. Much easier to assemble parts this way. Hope I was able to explain it good enough for you to understand.
Here's the Autosketch Drawing
(http://www.kingstonemodeleng.com/Madmodder/Flywheel2.jpg)
Bernd
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Much easier to assemble parts this way.
Bernd
Easier? I'd go blind or nuts looking for them. Sure at least 2 would find their way to the floor
Robert
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Easier? I'd go blind or nuts looking for them. Sure at least 2 would find their way to the floor
Robert
Robert
There is a simple cure for that. Make em outa steel. When ya drop em just send that big a??ed magnet after em. That will get them every time as long as they haven't pulled an Elvis and left the building. You might be suprised at what else you might find! :bugeye:
If you don't like steel finish then just paint or plate what ever yout heart desires. :lol: :lol:
Cheers :beer:
Don
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Well I was going to work on the cylinder tonight. Notice I said "was".
Well I got the stock cut. I did a quick look at the print and saw the .890" length. Ah, 1.000" aught to do just about right. Cut two pieces.
Set up the Sherline in mill mode and clamped two parts in the vise. Figure if I mess one up I'll have another.
When I finished milling one of the blocks square I figured I'd better check the over all length. So out came the print. A much longer look and I discovered that the over all length is not .890" but 1.020". :bang: :bang: :bang: :bang:
So now I have two pieces to use for two wobblers perhaps or maybe a ................
Next time I better check the print a bit closer. :doh:
So that's it for tonight. Gonna' surf the net for a while.
Bernd
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Bernd,
Love that flywheel! You've made a mistake there though as now the rest of your engine has to live up to it! :doh: :)
Nick
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:doh: :bang: :bang: :bang: :bang: :doh:
:lol: :lol:
Bernd :coffee:
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Here's a couple of pics of the engine as far as I've gotten so far.
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/rocker1.jpg)
(http://www.kingstonemodeleng.com/Madmodder/Flywheel/rocker1a.jpg)
So to complete the engine I need to drill the piston rod, make the crank wheel, the stand and finish the part in the 3" chuck and solder it to the cylinder for the air connection.
What's holding me up right now is figuring out what kind of base I want to make for it.
Oh, I still need to do a bit of polishing between the spokes to get rid of that copper look.
Who knows I might get it done in the next..............years. :lol:
Bernd
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Fudge, now I'm getting the urge to make "ANOTHER"
Robert
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I`m just wondering when mine might be finished......... ::)
It does run though! :D
Just too darned busy with "important" work....... :bang:
David D
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David D - finishing your engine is important work :poke: :lol:!
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David D - finishing your engine is important work :poke: :lol:!
Not to Mrs. D, it aint....... ::)
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Well I got the engine to a state of putting air to it and see if it would run.
It ran a couple of times then gave up. I fiddled with it some and got it running again. It slowly came to a stop. Found out the shaft that the flywheel is on was a bit tight. So a bit of polishing loosened it and it ran again and then came to a slow stop. Flywheel was still free but the engine just wouldn't run again. I fiddled with it for about 2 hours and still no go.
So I either have to build another or tinker some more with it. I decided I'd shelf it for now and build some tooling. Glad I didn't get around to makeing that fancy base I had planned.
Bernd
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Bernd,
I had exactly the same problems, getting my set of parts to run! :scratch:
I had purposely made just sufficient bits to make a runner.
Never having made an engine before I wanted an early boost, to actually finish the build. ::)
Remembering Stew`s early struggles, I turned it all ways around, on the end of the airline.
A shot of WD40, & it chuffed slowly into life as it hung upside down....... :D
This is it, after some 10mins running.......
(http://i110.photobucket.com/albums/n95/Dayjo/th_MPEG0001-3.jpg) (http://s110.photobucket.com/albums/n95/Dayjo/?action=view¤t=MPEG0001-3.flv)
Hang in there!
David D
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Nicly done chaps.
:clap: :clap:
I've lost count just how many of these little beasts have been made now.
Can we ask, has the virus now peaked? :- or are there still a few more out there waiting to be revealed. :proj:
:mmr:
Have fun out there
Stew
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Stew,
Must admit I am feeling a bit wobbly, or am I just of my rocker?! :dremel: :scratch: :nrocks:
Nick
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I've had a sniff for a while, but it might go away by itself as the hospital has been shut...
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Bernd, you saw how mine didn't want to start when the air pressure was up too high? Start it at less than 5 PSI, and then crank it up to about 20. Once it's going, you can make it scream, but starting on high doesn't seem to work.
It likes to be loose, and will have problems if anything is too tight. So, spray it with your favorite lube, and run it at high speed for a few minutes, then clean it all off, and it will tick over slowly. Mine would barely run at first. Now, after running for an hour or so, I can get it to go on lung power.
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Roger,
The engine is pretty loose. I can spin it by hand and it will revolve about 5 times. I think your right about to much air pressure. Unfortunely the compressor dosen't have a regulator on it. I'll have to try it out on the big compressor in the garage. That one I have a regulator on it.
I'll get to it some time. Right now I need to mow that dam big lawn. I think I could make hay it's grown so much. :doh:
Bernd
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Well got the grass mowed. Then it rained. Lucky. ::)
After a bit of lunch I went to the Metal Source and got some aluminum plate and a round 2.5" bar for a total of $93 USD. $2.25 a pound. 41.5 pounds worth of aluminum. :bugeye:
After I carted the stash into the basememnt I decided to give the Rocker Engine one more chance. Seemed like threatening it to make an ajustment with a 16 pound sledge and then drowning it in WD-40 worked. :hammer:
It sprang to live and has been running good now. So it'll be on to making that fancy base for it now. :thumbup:
Thanks Roger, that WD-40 made all the differernce. The thing I don't get is that I used a very light weight oil on it before and it didn't seem to make any difference. I did notice that it's very finicky to air pressure though.
Bernd
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Cool beans!
After you run it for a while, disassemble it and wipe off all the black oily stuff from the wear & WD-40. For some reason, this one doesn't like oil. I oiled mine (watchmaker's oil, from my dad), and it stopped it cold. Cleaned it all off, and it runs like a champ.
So, tell us what all the aluminum is for.
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Hi Bernd
Glad to see that you got it running. I think that "threatening it to make an ajustment with a 16 pound sledge" may have had something to do with it. :lol:
:offtopic: Glad that the rain waited till you finished the lawn but now its got a head start for next week. Thats the beauty of a nice place in the country. There is always lots to do to keep it up. I guess its the price we pay for a 2000 sq ft work shop.
I know that you are planning on posting a vid when you get the base finished so I'll be watching for it because :worthless:
cheers :beer:
Don
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Way to go Bernd :thumbup:
I found mine a bit on the temperamental side when it comes to air pressure and lube
Now all we want is the base :poke:
Have fun
Stew
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Sounds like you're having fun Bernd :ddb:
Now all you need to do is make that massive aluminium base...... $93 seems a bit excessive for such a small engine!
But I suppose if you want it to look different then a 41.5lb base would certainly do it!!! :lol:
As Don pointed out............. :worthless: :poke: :)
Ralph.
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Ok, first of the ali plate is for some jig plates. I need to finish my indexing tool I started which will use the 1.2" thick olate. The other plates, 1/4" and 5/16" will be used for tooling plates for the X-2 mill and Sherline mill.
The 2.25" round bar, of which I'll only need about a 2" long piece is going to be a part for a car a guy wants made.
And I'll be posting with pics when I get "(http://www.kingstonemodeleng.com/HMEMPics/rti1.jpg)"
:lol:
Bernd
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Well this whole project started back in July. I'd have to say I'm working for the "Longest time it takes to build a Rocker Engine Award."
I had trouble getting the darn thing to run. Then rleete suggested I squirt with some WD-40. I'll be d@%&*, it worked like magic. I ran the engine and it got a good breaking in and to prove it I made a vid of how easy the thing runs now.
As you get to the end of the vid you'll here something like a piece of steel dropping on the table. That's the piston popping out as I try to start it again.
This is only my second attempt at making a movie with Windows Movie Maker so the quality and content isn't that great. So here's the movie. I'm hosting it on my own web site. Why? Because I have political issues with the video hosting companies. And lets leave it at that.
Rocker 1 (http://www.kingstonemodeleng.com/Madmodder/Rocker1.wmv)
Next will be a base to set it on. Hope it doesn't take as long as it took to get here. :lol:
The clicking noise you hear is the autofocus of the camera. Kind of anoying. I know I can turn the auto focus off but then you'll get a more blurred picture.
Bernd
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I made another video of the same set up. Looks a bit better than the first one I made.
Rocker 1 (http://www.kingstonemodeleng.com/Madmodder/RockerEngine2.wmv)
Bernd
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Looking good.
Now, take it apart, clean it in alcohol, and reassemble it dry. You ought to be able to power it on lungs. A little break-in is all it takes.
Oh, and get the base done!
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Bernd
Looks great Bernd. :clap: :clap: Maybe you can get a light weight aluminum air tank and fit this in your boat. That would be an interesting project. :smart:
I know that you really don't need anymore new projects but just in case you get bored. :lol: :lol:
Have a drink on me :beer:
Don
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Bernd,
I can`t get your vids to play! :scratch:
Is it me? ::)
David D
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David,
Worked fine for me, just clicked it and it booted media player up.
Nick
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Bernd,
I can`t get your vids to play! :scratch:
Is it me? ::)
David D
Guess it was me! :scratch: ::)
Tried again 1hr or so later...... Worked perfectly! :bang:
Very crisp, clear vid Bernd. The engine`s a cracker too! Well done! :clap: :clap:
David D
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Thanks guys.
I was hoping that it would play for a majority of you guys. I can also upload the mids in in .MOV format. It might take a bit longer to download and the picture is smaller but alot clearer.
BTW, I took a bit more time to video the second vid. I made sure that the lighting was better and shut off the auto-focus feature so it won't click like it did with the first vid.
Now to get busy on the base. Mmmmmmmmmmm...........light aluminum air tank. I don't know Don. :scratch:
Regards,
Bernd
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Bernd
When I mentioned about the boat and air tank I was thinking about something that Bogs said.
:med:"Whether it be a bent nail in a bit of wood" :med:
And since you like boats, why not, it would be something different.
How about light aluminum air tank as the hull with outriggers for balance. That should serve as a base! :smart:
The vids worked fine for me.
Cheers :beer:
Don
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Don,
Ya got me thinking. :smart: :med:
Bernd