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Gallery, Projects and General => Project Logs => Topic started by: NickG on September 03, 2009, 07:50:11 PM

Title: Modified Rocking Engine
Post by: NickG on September 03, 2009, 07:50:11 PM: Hi all,

Tonight I started machining the components for my Rocking Engine so am going to do a bit of a project log here.

Incase people haven't seen the design thread I did, basically, I was messing around with the Alibre CAD software I bought for $99, which incidentally was a bargain, and it spawned this:

(http://img.photobucket.com/albums/v287/NickG24/Temp/Rocking%20Engine/Assembly1.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Temp/Rocking%20Engine/Assembly4.jpg)

Anyway, I wasn't sure whether I'd make it as the design is a bit OTT for what it is, was only messing around with the CAD really, but a few of the guys on here convinced me to give it a go. So I completed the drawings over the weekend and also got my garage / workshop sorted out. Just moved house a couple of months ago so it was in a state of turmoil!

Not a great deal to show you after the first night's work I'm afraid! Before I started, I remembered something Stew had said, that while you've got everything set up, and your head around making a component, it's often as easy to make two! That makes sense and it'd be nice to have 2 completed engines.

I started on the pedestals, there are 3 of those so I was going to make 6! Because of this, I thought I'd be clever and set up some calipers and depth gauges etc to make it a speedier process.

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0321-48-56_0001.jpg)

I found some 1/2" stainless steel bar which was machining nicely, but then I realised I'd already made a boo boo! I'd gone in with a sharp tool not allowing for the radius. So I tried to grind a tool with a rad on it, just by eye. All I would have to do was machine a bit further along the bar to sort it out, but the rad tool gave a shocking surface finish, so I ended up putting the larger rad in with a needle file! I managed to grind a tool which gave a decent finish for the smaller rad on the centre section. It's not perfect but it's that small you can hardly tell to be honest. The only other thing I did was made the bottom thread for fixing to the base 2 BA instead of 3/16" x 40 TPI. I think I probably have some 2 BA nuts kicking around, I don't know why I went for the ME thread in the first place really, it's not necessary.

After 2 hours work this is all I have to show:

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0323-40-05_0002.jpg)

After all that tool swapping and cutting threads it tells me that I could really do with a QCTP and a tailstock die holder.

I've abandoned the doing 2 of everything now, if this took me 2 hours it's going to be circa 26 hours for the complete engine, so I think doing 2 of everything is just going to annoy me, although I still think it’s a good idea in principle!

That’s all for now anyway, feeling slightly disheartened due to slow progress but hopefully it’ll pick up!

Nick
Title: Re: Modified Rocking Engine
Post by: chuck foster on September 03, 2009, 09:47:34 PM: looking good nick :thumbup:

keep us posted. :beer:

chuck :wave:
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 04, 2009, 01:34:13 AM: Hi Nick

Nice start :thumbup:, it only pays doing multiples if you got the tools to take advantage of it :- QCTP, Tap and die tail stock holder, back stop, collets, vice stop:- etc etc.

Just a few more jobs to add to the list :lol:

Have fun

Stew
Title: Re: Modified Rocking Engine
Post by: raynerd on September 04, 2009, 02:46:51 AM: Hi Nick

Excellent work - it is really great seeing your design and then you going the step further into making it.

I have just purchased Alibre and have to say that I`m struggling a bit with its use. I have followed a few "step by step" tutorials but then it all fails when the tutorial shows X thing happening and on my screen Y happens! Anyway, I`m sure I`ll get use to it! Quick question in reference to your plans, does alibre allow you to not only model the 3D design but then revert back to 2D to attain plans such as those you are working from - i.e standard CAD style plans?

Chris

EDIT: PS. after the few models that I have made, I now appreciate even more the need for the correct tooling. I think 50% of my time is taken measuring up, 20% finding my damn tool in the first instance, 20% swapping tools and the rest doing the job. I think a QCTP will reduce to tool swapping and finding and after my mill X axis power feed that I am working on, it is my next project before I go any further.
Title: Re: Modified Rocking Engine
Post by: arnoldb on September 04, 2009, 05:22:28 AM: Good start Nick :thumbup:

Looking forward to the rest :D
Title: Re: Modified Rocking Engine
Post by: NickG on September 04, 2009, 06:00:06 AM: Thanks for the replies guys! Feeling a bit more up beat this morning, there are 12 components left, but some aren't as fiddley as that one, so if I get my finger out, I could do it in a week I think! Beware though, i've made these sorts of bold claims in the past and a month later I'm still applying finishing touches!

Chris,

With regards to Alibre, the way 3-D CAD systems work is that you create all of the geometry from 3D building blocks as it were stuck together to form 1 part. From that, the computer can generate / project the 2D geometry by just looking at it from different view points. That's all you do when you create the 2D drawing. It asks what views you want and you just place them on a sheet of paper. If you have your preferences set right it'll automatically dimension it for you, however, I'm not a fan of that, it sometimes jumbles them up and doesn't necessarily put the dimensions on that you or I would knowing we have to make it next! Then you can do other things like sectioned views and detailed views where you blow a small feature of a part up to a larger scale for clarity. Once you have the 3D model and 2D drawing they're linked. If you update the model and save it, the drawing automatically updates. Similarly, with the assembly, which is a file with all the parts mated together, this will update if you update any individual part.
With the assembly you can mate parts with the correct constraints they would have in real life, therefore giving it the degrees of freedom it would have in real life which means you can grab the flywheel and spin it over! Unfortunately this version of Alibre doesn't have the animation add on which is an extra so you can't get it to do it automatically. Keep going with it, you'll love it. It takes a bit of practice, I've used various 3D CAD systems for years and they all work in a similar way, think that's why I picked Alibre up so quickly, have to say it's the most intuitive one of the lot.

With regards to your comment about tooling, that is spot on, that's exactly what happened to me last night!

Keep watching and I will post regular updates!

Cheers,

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 05, 2009, 08:24:40 PM: Hi all,

got a little bit more done but am afraid this thing is going to take longer than I thought, probably 2 or 3 weeks!

After doing that little pedestal I couldn't face doing another 2 yet ... bored of that! (No patience!) So, I decied to do the cylinder and cover. I'd been mulling it over in my head overnight and thought that if I get the cylinder done except the bolt holes, then the cyl cover finished, I could transfer the holes from that into both ends of the cylinder and the frame when that's done. Then everything will definitely line up.

Unfortunately after 3 hours in the workshop I cam out with no finished components! :doh:

I've got the cylinder and cover part done, just need holes drilling in cover, transferring to cylinder then those tapping 8ba.

I made a bit of a mistake on the cylinder which is annoying as there couldn't really be a simpler component! I didn't bore it out quite long enough ... thought I had allowed a good 1/8" extra when I drilled it, but I must have stopped boring short of the drilled hole. This was probably due to boring a blind hole ... at least I can learn a lesson from this, bore it right through. Anyway, this has resulted in the cylinder being 1/16" shorter than it should be. So I'll need to change the drawings, I'll need to make the crank throw shorter and move the bearing hole further away! :bang: I was going to use an adjustable reamer I'd found to finish the bore, but I found the surface finish from boring good enough. Just as well because for the adjustable reamer I'd need to have bored right through anyway. I found a nice piece of phosphor bronze for the cylinder.

I originally called for steel for the cyl. cover, but saw a bit of that nice aluminium so used that instead. Pretty simple turning job. I always used to find it difficult turning little registers for a good fit in the bore but on this lathe I seem to be able to get it spot on. The sali machines really well and I parted it off with on the slowest none back gear speed and the slowest cross feed. Worked superbly. Had to put back in the chuck to finish the outside so put a bit of aluminium from some old vanishen blinds around it to protect it from chuck jaws, nipped the jaws and used the tailstock chuck to push it to run truew whilst rotating at slow speed.

Apart from the silly mistakes i keep making it's going quite well. Still frustrated by how long it takes to change lathe tooling etc though. What I am happy with is the surface finish I'm getting. If I keep this up, I prob won't be trying to bling anything, just a quick polish with a rag and some silvo to keep the dirt away, or eve just with oil and abit of wire wool. I really need to get a polishing attachment for the grinder if I want to bling stuff.

Anyway, here are the part finished parts! Look a lot better in real life, camera never does stuff justice!

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0600-28-23_0003.jpg)

Nick
Title: Re: Modified Rocking Engine
Post by: Brass_Machine on September 05, 2009, 09:07:24 PM: It is a neat thing to see an engine (or whatever) go from design to build!

Way to go Nick!

Eric
Title: Re: Modified Rocking Engine
Post by: NickG on September 06, 2009, 06:28:14 PM: This is going slowly! I need :poke: :poke:

All I got done today was finish the cylinder and cover.

I put the cover in the lathe and made it run true the same way as I did before, brought the tailstock up to it whilst nipped in chuck and running slowly.

I marked the positions of the 6 holes by lightly scoring a circle of the right dia. with the cutting tool on the inside face, then indexed using the 3 jaws of the chuck and a small spirit level on each jaw getting them as near as I could to horizontal each time and scoring across the circle with the cutting tool.

Centre drilled and drilled through, it's tough stuff this aluminium though, made me realise both my no 50 drills were blunt so had to go through with 52 first.

I then put the cover on the cylinder and spotted through the holes on both ends. The 6 divisions are good enough not to be able to notice by eye but they won't line up in any position, only 1! I need a rotary table with compatibility to lathe chuck but this will do the job, so long as I spot the frame holes with the cover too.

I opened up the holes to 8 BA tapping size in the cylinder and started tapping the holes. Used a taper tap in the drilling machine to get them square then thought i'd just do it by hand with the plug tap so I could get more feel.

All was going well and I was just thinking to myself, I used to break taps like this .. I was so careless back in those days, am much better now. 10 mins later this thought came back and bit me in the @rse and the tap snapped! :doh: :bang: Think my taps were pretty blunt. Without thinking I tried to get it out using a centre punch, which didn't work, just made a few scratches on the end face of the cylinder and a bit that pinged off hit me in the cheek. Could have been nasty if it were a bit higher, I wouldn't care, I'd had my glasses on 90% of the time too. Always wear safety glasses.

After conceeding I wouldn't get it out I thought well, I don't really need to. Luckily it was in the end that bolts to the frame, so all I'll have to do is tap that hole in the frame and put a dummy bolt in instead of drilling clearance size. 5 bolts are more than enough to hold it.

Here are a couple of pics. First of the frame end with the broken tap. :bang: :( :wack:

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0622-19-19_0003.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0622-18-20_0002.jpg)

No one will be able to tell once it's together. Hopefully no more mistkaes!

On another safety note, does anybody wear gloves whilst they're in the shop? I know there are other hazards associated with gloves and machinery but I'm for ever getting little shards of metal stuck in my hands which can be painful and difficult to get out. How do people avoid this ...guess never touching swarf with bare hands would be a good start but I can't seem to avoid it.

Nick
Title: Re: Modified Rocking Engine
Post by: raynerd on September 06, 2009, 08:02:22 PM: Looks good to me !! :thumbup: :thumbup:
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 07, 2009, 01:59:06 AM: Nick,

As you know, gloves are a definite no-no when working on moving machinery, but for picking up swarf they are a must. I use the very thin woven cloth ones that have like a layer of some rubbery solution on the fingers and palms.

I usually use a small rake when moving curly swarf about, and for brass needles it is the vacuum that is the only safe way, NOT by blowing it away with an airline. That is like sewing a mini skin minefield all over your shop and machinery.

I don't think you will ever get over the skin penetration problem of brass, in fact I got one the other evening on an inside thumb joint, but didn't notice it because it was so small. The next morning when I woke up, it was all pain and puss which required microscopic surgery on my part. I have just felt something in the bottom of my foot, so I will get the wife to do the necessary on that.

A good barrier cream does help in keeping the instant infection down, but as you can see, it still got me.

I suppose surgical gloves would be OK, but from experience, any more than half an hour is too long for me, even though you don't realise it, your hands sweat profusely, and they soon become very uncomfortable. I tend to use the blue vinyl ones rather than latex, I find them much stronger and able to cope better with the rigours of the workshop.

John
Title: Re: Modified Rocking Engine
Post by: NickG on September 07, 2009, 05:06:45 AM: Thanks John,

The one on the thumb joint sounds painful!

I've tried surgical gloves but find they tear pretty easily with the sort of stuff we do. Although we use some green ones for work, can't remember what the material is called, they are a bit tougher, might try those. Keep your hands clean too. I still don't like wearing them really though, even though they are thin, you don't get the same dexterity.

Going to try to get in the shop every night this week as I'm away a 3 nights next week.

Will probably go for the frame next.

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 07, 2009, 06:23:09 PM: Not a great deal to show tonight! Just some straight forward milling for the aluminium frame.

Can't remember whether I mentioned, when I moved into the new garage, er I mean house :wack: there were some shelves that needed to come down. The brackets were over a foot long and bend from 3/8" x 1 1/4" aluminium bar! Thought that would come in handy!

Anyway, I didn't actually know it was 1 1/4" wide until tonight, which was handy as that is how wide I designed my frame ... good guess!

Cut out a lump long enough for both parts so that i could machine it down to size, as I said, didn't need to touch the width, so just milled both ends square. I found I had to climb mill to get a decent finish, the alloy must be very soft and it was picking up all the swarf if I didn't climb mill.

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0720-55-06_0002.jpg)

The bar was slightly over 3/8" but didn't correlate to any particular metric size either! So took 60 thou off each side. The quill DRO was really handy here, wish I had a full proper dro on both machines, would be superb!

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0721-01-49_0005.jpg)

Got a pretty good smooth finish and that's with an old 5/8" slot drill. I used that because it's how I'm going to cut the hole to match the cylinder bore in the square piece, however, I need to change the cutter anyway to cut the rads on the corners so it was floored logic! I should have tried one of my cheap chinese brand new cutters on this soft stuff, would prob get a good finish whacking the speed up with a new cutter.

Here's the bit of metal

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0721-30-29_0006.jpg)

Hacksawed it in 2 and put both pieces back in the milling vice.

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0721-37-32_0007.jpg)

Finished the sawed ends to length. Milled to marked lines by eye then measured and I still needed to take another 10 thou off both times. Did this with the hand wheels, they aren't that accurate but it's only about 2 thou over size ... good enough.

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0722-01-07_0008.jpg)

Left it at that tongiht and quite while I was ahead! Or at least not made any mistakes! I was going to leave that set up and basically finish using the handwheels but I think I better take them out and mark up as a check. Might even use marking blue - any tips on that? I've never really used the stuff before, not sure on the techniques!

BY this time tomorrow I should (touch wood) have those 2 frame pieces done and a part assembly that should start to resemble an engine of sorts!

Nick
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 08, 2009, 01:36:42 AM: Hi Nick

Nice work :thumbup: I usually put marking blue on with a soft brush leave it for 10 - 15 min to hardeb off.

Next time your at RG ask the guys on engineering if they can get you some "Showa" gloves, their cotton coated with some durable rubber especially developed to prevent cuts, better still give them a ring and get them to post you some up.

The big problem with surgical gloves is your hands start smelling like feat :lol:

Have fun

Stew
Title: Re: Modified Rocking Engine
Post by: NickG on September 08, 2009, 03:20:43 AM: Stew, will give it a go. How do you get the stuff back off? With emery cloth? Although these bits have a really smooth finish you can still see lots of machining marks from the end mill so think I might give them a rub on emery to get rid of that. Might look a bit un finished if it's got all those swirl marks on it.

Will make some enquiries about the gloves!

Having fun so far! I think the problem I might get with this ali frame is cutting threads. It seems really soft stuff. 5 threads to cut, is there any kind of lubericant you can use to imrpove this? Paraffin?

Nick
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 08, 2009, 06:24:34 AM: Hi Nick

Meths, Turps or just a squirt of WD40 will get it off.

Have fun

Stew
Title: Re: Modified Rocking Engine
Post by: NickG on September 08, 2009, 06:42:47 AM: Cheers Stew :beer:
Title: Re: Modified Rocking Engine
Post by: No1_sonuk on September 08, 2009, 07:47:02 AM: Quote from: NickG on September 08, 2009, 03:20:43 AM
Stew, will give it a go. How do you get the stuff back off? With emery cloth?
If you mean the marking blue, I use IsoPropyl Alcohol ( IPA ). You can get it from Maplin in a spray can.

http://www.maplin.co.uk/Module.aspx?ModuleNo=28994

You won't need much - even the small can will go a long way.

Spray on and wipe off with tissue, paper towel, etc. Also works spraying some on the tissue, then wiping.
You can also use it to "re-wet" the blue that hardens on the brush.

Emery cloth will mark the surface. IPA and tissue won't. :thumbup:

IPA will also remove "Sharpie" ink...
Title: Re: Modified Rocking Engine
Post by: Bluechip on September 08, 2009, 08:32:01 AM: Well No1_sonuk .. you must be flush with cash to use Maplin £7.49 for 400ml :bugeye:

Little wonder they have it 'in stock', as far as I'm concerned, they can keep it there.

http://www.rapidonline.com/Tools-Fasteners-Production-Equipment/Service-Aids/Cleansers-Solvents/Isopropyl-IPA-cleaning-solvent/61590

Or a bit less from above.. needs 15% vat on it tho .. P&P requirements about same

As an aside, knowing their prices, do anyone use Maplin now? I stopped about 12 yrs ago.

Dave BC
Title: Re: Modified Rocking Engine
Post by: NickG on September 08, 2009, 08:51:59 AM: Dave,

:offtopic: I occasionally use maplin for bits and pieces. Just because they have a shop you can go into, and for resisters and stuff it makes little difference whether it's 3 p or 30p if you're just getting 1 or 2! The last things I got were a few ceramic resisters to replace the wire wound ones in the wifes heater fan controls. Also, I bought a timer circuit kit for about £8 which I wired through relays and all the rest of it to keep the anti perc fan switched on for a set time after I switched engine off on Renault 5 turbo! It worked a treat and it was great fun soldering the circuit together and getting it to work .. took me back to my youth!

I know what you mean though, my dad used to be a technology teacher and they always used rapid electronics. Remember one of my christmas presents about 15 years ago when I was 14 was one of those sets of little drawers full of electronic components from Rapid electronics along with a few bits of strip board! Was one of the best presents ever! Still got most of it in the same little drawers! Had a few hobbies down the years!

Nick
Title: Re: Modified Rocking Engine
Post by: No1_sonuk on September 08, 2009, 11:19:42 AM: I only suggested Maplin as it's easier to get at. Industrial supply places would be cheaper.
I bought mine soooo long ago, I can't remember where it came from. :scratch:
It really doesn't take much.

:offtopic: I usually use Rapid, CPC, or Farnell for my parts requirements. Maplin ceased being little more than a high-tech toy shop several years ago. Shades of the "What will happen" thread...
Title: Re: Modified Rocking Engine
Post by: NickG on September 08, 2009, 11:47:27 AM: :offtopic: Very true! Forgot I bought an electric trike for my 3 year old from there too! Those things were several hundred pounds when I was a nipper ... £29.99!

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 08, 2009, 06:22:41 PM: Hi all, unfortunately I didn’t get done what I planned tonight. I could have stayed out longer but when it got to 10:15 ish I was getting a little tired and had enough really.
Basically, I got the hole drilled in the cylinder support part of the frame, the rad cut on the corner and the ring of bolt holes to fasten the cylinder on. Still need to drill and tap the holes that will fasten it to the other part of the frame that supports the bearing and the hole for the pedestal to stand it on.
I blued the bits up then forgot to mark them out! So thought sod it and just used the hand wheels to position the hole! I worked out how far in graduations it took from one side to the other though then split it, since I know my hand wheels aren’t very accurate.

Drilling the big 5/8” hole with the slot drill.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0820-25-13_0001.jpg)

Drilling the rad with the ½” slot drill.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0820-36-28_0002.jpg)

Copying the holes from the cylinder cover to the frame. Note bottom hole was only spotted, this needed to be tapped 8ba in frame for dummy screw to account for snapped tap in cylinder!
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0821-05-03_0004.jpg)

Tapping hole for dummy screw
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0821-19-49_0005.jpg)

Progress so far
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0821-57-08_0006.jpg)

Not going as fast as I would have liked, but I’ll get there!

Nick
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 09, 2009, 01:27:31 AM: Coming along nicely Nick :thumbup:

Have fun

Stew
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 09, 2009, 03:45:47 AM: That`s looking good Nick! :thumbup:

David D
Title: Re: Modified Rocking Engine
Post by: NickG on September 09, 2009, 04:56:53 AM: Plan for tonight is to get this frame finished and possibly do the bearing! But you've seen my outlandish claims before and by now probably realise I'll only get the frame done!
:poke:
Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 10, 2009, 03:52:44 AM: Hi,

Didn't get the bearing done. Had a busy night. Badminton, then England game which I forgot about - what a result by the way, then 3 hours in the shop! I got the frame finished but it was 1am by that time so was too tired for the write up! Will have to be a double installment tonight!

No more milling left on this project except for the wooden base, got the bearing, crankshaft, flyhweel, piston, inlet nozzle, & two pedestals to do along with the base.

At least I have a bit of an assembly to show now, starting to look like an engine of sorts!

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 10, 2009, 07:43:49 PM: Hi,
Bit more progress tonight, I’ve done the bearing. Starting to look like something now.
Here are some pics from last night doing the frame and tonight the bearing.

Set up in mill for drilling holes. Tried marking out with the blue this time, worked well I thought.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0922-43-01_0001.jpg)

After holes were centre drilled I cut the radius on the corner, opened out the bearing hole and tapped 5/16 x 32 TPI. I actually did this under power. Never tried that before, the mill has a 1000W DC motor and even at just a few rpm I couldn’t stop the spindle with my hand. I didn’t go mad tightening the tap in the collet incase it jammed, this way the tap would just slip inside the collet. It was fine though, tapped a nice thread which surprised me in this soft aluminium.

Then I opened the two bolting holes to tapping size. You’ll see why later.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0922-56-53_0002.jpg)

Holes were drilled and tapped in bottom for pedestal support thingies! I made the mistake of trying to tap these under power too, big no no, was much smaller 4ba thread and I managed to mess up the top of the thread on one hole, luckily I stopped in time and there are enough good threads underneath.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0923-06-43_0003.jpg)

This is why I only drilled the bolt holes tapping size, so I could accurately transfer to the other half of the frame.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0923-54-51_0004.jpg)

Once this was done I could open them to 4 ba clearance size.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-0923-59-27_0005.jpg)

That was the frame finished then.

Tonight’s exercise was to make the bearing. I faffed around for ages trying to find a bit of brass, at one point I thought I was going to have to turn down some square, but then I found a big length of about ½” or 5/8” brass hex that I was allowed to take home from work!
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1022-11-16_0007.jpg)

Turning down to size
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1022-12-56_0008.jpg)

Cut 5/16” x 32 tpi thread, I just used a die for this applying light pressure with the tailstock to keep it straight.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1022-36-38_0010.jpg)

Drill the hole for the crankshaft with no 12 drill. The size is not mega critical since I will turn the crankshaft to suit.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1022-44-44_0012.jpg)

Part off to length under power after making an undercut on thread.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1022-57-17_0013.jpg)

The bearing:
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1023-02-01_0014.jpg)

Tightening bearing into frame in chuck so I can drill oil hole in correct place.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1023-07-01_0015.jpg)

Oil hole drilled, csk and all completed components test assembled.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1023-22-16_0016.jpg)
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1023-22-45_0017.jpg)

Sorry about the quality of these pictures. Really need a better camera or learn how to use existing one better!
Note I didn’t tighten the bearing back in since it all needs to come to bits to be cleaned, so the oil hole looks wonky!
Quite pleased so far, if I can keep this standard of finish and fit up I’ll be chuffed, if of course it works! (Touch wood)

Nick
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 11, 2009, 01:12:04 AM: Looking good Nick

Stew
Title: Re: Modified Rocking Engine
Post by: spuddevans on September 11, 2009, 01:57:47 AM: That's looking really good, you'll have a runner there before long :thumbup:

Tim
Title: Re: Modified Rocking Engine
Post by: NickG on September 11, 2009, 03:57:13 AM: Do be totally honest, I'm not convinced whether it will run. After I started I got thinking about how i'd designed it. I'm not sure whether I've made the conrod too long, hence on the return stroke the piston might not rock to a large enough angle to vent sufficiently. The problem this could cause is that there is still too much force on the piston for the flywheel to carry it over to the next power stroke. The air should find the easiest route but it just depends on that balance of forces. Need :smart: really! This may be why the small bore ones are so effective too. You can see that if you put the pressure too high, it won't carry over so low pressure might be the order of the day.

Time will tell, :zap: it could be back to :coffee: :lol: to fix it I may be able to shorten the frame, reposition the bearing and shorten the piston rod - well, that means a new piston as it's 1 piece in my design. Unless I keep a plain diameter for the piston rod until I have it running instead of wasting away the section between the big end and the piston.

Nick
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 11, 2009, 12:49:44 PM: Nick,

It WILL run! Relatively slowly, mebbe........ Have faith...... :thumbup:

David D
Title: Re: Modified Rocking Engine
Post by: rleete on September 11, 2009, 01:00:05 PM: Quote from: NickG on September 11, 2009, 03:57:13 AM
I'm not convinced whether it will run.

I've found my rocker to be very forgiving, and actually runs a lot better not that it's loosened up. As long as the piston doesn't come out of the bore on the back stroke, or bottom out, it should be fine.
Title: Re: Modified Rocking Engine
Post by: NickG on September 11, 2009, 01:36:14 PM: Will have to see, because I've changed the parameters. I might not have heavy enough flywheel relative to the bore and stroke, and I might not have designed it to 'rock' the piston enough. I maybe should have scaled this part from a known working one, but I just did it where it looked right to me. I'm about 50% certain it'll run :lol:

Hopefully will get a bit more done tonight. Not sure what to start on though, should I tackle the crankshaft, probably the most complex turning job if doing it in 1 piece, should I do the inlet .. should be straight forward but quite interesting with the taper and the steps, should I do the 2 pedestals ... was a bit fiddley first time around. could do the piston I suppose, then I can turn the crankpin for a good fit in the big end. Or the wooden base?! Decisions decisions ...don't suppose it matters really, all needs to be done!!!

What will it be... come back tomorrow or very late tonight to find out! :lol:

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 11, 2009, 01:38:26 PM: PS, forgot an important bit ... don't think it'll run without a flywheel! :lol: Not doing that tonight though, can't be @rsed to hand saw through 2" of steel, not sure how well it would part off.

NIck
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 11, 2009, 02:33:43 PM: Nick,

Don't rush it, I made that mistake yesterday, and cost me a couple of hours machining time, plus a bit of material.

It isn't going to get up and run away (unless you've got gremlins in your shop). Just take your time and do it at your own pace.

Bogs
Title: Re: Modified Rocking Engine
Post by: NickG on September 11, 2009, 07:07:09 PM: Hi all,

You're right Bogs, I need to calm down a bit. It doesn't really matter if it takes another week or another month, hence I've come in at 10:30 - pratted around on internet for an hour instead of writing this up and now I'm tired! :bang: It just initially annoyed me when I got back in the shop after a while off as I’m used to the alarming rate people churn things out on here! :poke:

Tonight I just made the inlet nozzle. I had to do a couple of modifications on the fly. The first was that I had run out of my 5/16" hex brass bar. I knew I had some quarter inch steel hex so looked for that. To be honest, 5/16" would have been too big in any case. The 2nd mod before I even started was to change the hole through it from 1/8" to 3/32". Looking at the drawing it was getting a bit too thin at the front of the nozzle with the 1/8" hole. I will update the drawings to reflect this if it works, then other people can have a go if it's any good.

I decided it’d be best to do the nozzle end first, can’t remember why, but this turned out to be a mistake! Will get on to that in a min!

Must apologise again for the quality of some of these photos, I just haven’t got the light right or something but don’t really have time to mess around with that at the mo.

Plain diameter turned, note compound slide now set over for taper cut.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1120-15-01_0001.jpg)

Taper cut, drilling hole through.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1120-29-24_0004.jpg)

Not a very good shot but it’s supposed to be of the tool I ground to cut the grooves - Is this called a barb? I ground the tool to 50 thou thick with a 21 deg angle on the end – this was guessed – it’s not really critical. There are 5 grooves / flanks whatever you want to call them over the 1/4 “ nozzle.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1120-52-16_0005.jpg)

The nozzle end finished.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1120-52-25_0006.jpg)

Quite pleased with how that went I was admiring it when I suddenly thought, how the hell am I going to turn the plain dia and cut the thread on the other end now, since I only have 3/16” hex left to grip – and I would be machining right up to the chuck at that.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1121-03-09_0007.jpg)

If I had done it the other way around, I could have tapped a bit of rod and screwed it into that to cut the nozzle end, but this way I had no chance. Unless, I used the ER collet chuck from milling machine – so this was the plan. I would grip the very small parallel section on the nozzle end and take light cuts to get the thread dia down to size then cut the thread with a die.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1121-04-58_0008.jpg)

It fell out once, hadn’t tightened the chuck enough, but luckily there was no damage and it lived to have another go. I put a drill down the middle so it wouldn’t crush anything and nipped it up pretty tight. It worked. I used the small grooving tool to make a thread undercut.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1121-04-58_0008.jpg)

Inlet nozzle added to assembly.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1121-41-21_0009.jpg)

At this point I thought I’d cut my losses and just started to gather the materials together for the remaining components.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1122-00-19_0011.jpg)
The wood is for the piston, brass hex for the flywheel and large dia steel bar to give it a nice sturdy base. Not really, just checking you’re still awake! :lol:
Unfortunately I couldn’t find any round brass for the piston, the only suitable brass I have is the 3/4 “ hex, so it’ll have to be made from that. Seems a shame but it’s not really wasting it is it.
Stew, you might recognise the steel for the flywheel, it’s an old proof shot nose! If I recall correctly I’ve machined this before and it’s pretty tough but not that bad. Not looking forward to sawing it though!
I couldn’t find any steel round bar big enough for the crankshaft either, until I looked in another box under the bench and remembered I had a large length of what I think is some sort of chromium steel? Just to prove I use a hacksaw:
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1121-57-33_0010.jpg)
Not much fun but I timed it and it took exactly 5 mins to get through this 1 ¼ “ bar.

Stuck it in the lathe and did a quick machining test. Took a few facing cuts across. Left a good finish and didn’t seem too hard. Then turned down a bit, this didn’t give such a good finish but this was at about 300 rpm. Gave the tool a rub with water of air stone and it gave a much better finish, so I think I’ll just need nice and sharp tooling for the finishing cuts. I think it’ll take a while to whittle this down to size though.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1122-21-48_0012.jpg)
On the diameter it gave a bit of a weird finish, it was fine, but sort of a bit rough to touch. Like very very fine sand paper. Almost as if it’s left microscopic tears all over the surface. I wonder if my rake angle is too high and it would prefer a shallower one like brass? Never the less, all it would need from there was a very slight rub with emery cloth to make it nice and shiny.

Bit more pleased with my progress now, there’s still a bit to do but at least I have a bit to show for it now.
There are a couple of straigh forward components and a couple of critical ones but they are straight forward really. Apart from the crank, I remember what a pain it was to set off centre in the 4 jaw last time. This time I might try to make a split collet and do it in the 3 jaw.
Still to do :-

2 Off pedestals
Wooden Base
Crankshaft
Flywheel
Piston / rod / big end combo

So, that’s only 3 more bits to see if it’ll run – 2 more if I rob a flyhweel off something else! No, that’s cheating. I might even make the base and pedestals first so it stands up by itself!

Thanks very much for following and for all your comments / advice.

Nick

Ps. hope you are enjoying this as much as I am. If you have any suggestions about how I should write the thing up please let me know. I do tend to waffle a lot and I’m not sure some of this is worth putting in, there’s a lot of straight forward turing / milling.
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 11, 2009, 10:40:40 PM: Thats a lot better Nick, you are not out of breath any more, just a slight wheeze.

Nice write up and description.

I will just add a bit about barbs on inlets.

I use silicone fuel tubing for my air transfer, and if you do the same, you should not have any sharp edges on your inlet spigot. If silicone is 'nicked' it will split and tear straight away. I use undulations on my spigots, filed on and shaped by hand, with nice rounded edges.

Bogs
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 12, 2009, 01:38:23 AM: Going well Nick write up is just fine :thumbup: keep em coming.

Have fun

Stew

PS Yes I did recognize that bit

Stew
Title: Re: Modified Rocking Engine
Post by: raynerd on September 12, 2009, 01:59:34 AM: Hi Nick - coming on nicely! :clap:

Chris
Title: Re: Modified Rocking Engine
Post by: arnoldb on September 12, 2009, 04:29:36 AM: Good going Nick

I like your write-up - good couple of bits in there put a smile on my dial :thumbup:

Cheers, Arnold
Title: Re: Modified Rocking Engine
Post by: NickG on September 12, 2009, 01:38:38 PM: Cheers guys, thanks for the support.

Bogs, I usually use the soft fuel type tubing too, didn't think of it tearing, I was trying to make it so it wouldn't come off. May need to round those off with a file. I think i've made the taper too steep anyway to be honest.

Well I should be telling you about what bit I made today. Originally, I was going to get some time in the workshop today during the day, the wife and kids were supposed to be going to meet up with the mother in law on their own. But this morning she started moaning and asking me to go too, I wasn't going to but thought that would come back to bite me, so I did! I was supposed to get a bit of 'shop time' when we returned but we decided that seeing as it was such nice weather, we'd have a bbq. This meant I was in the workshop but was fixing the bbq! :bang: It's very fragile cast iron and my son kept knockin it over in the old house. He'd snapped one of the brackets off for the thing you rest the grill on. So I had to cut a bit off that, drill and tap 1BA and add a little bracket of my own. I found a bit with 2 holes drilled in the right place from an old project and even a csk screw with it! Just shows never to chuck stuff out! :lol: I think this material was ali bronze, the colour is sort of, well, somewhere between aluminium and bronze, like a very pale shade of brass. Will take a pic later.

I think I might even give the crankshaft a go later. I just remembered I have some steel much nearer the size, so getting a sweat on cutting that 1 1/4" chromium steel could have been for nothing! Although this other stuff has previously been forged so it might be a bit tough ... when it's machined on the cnc's at work it squeels like mad! :dremel:

Hopefully will update you all later.

NIck
Title: Re: Modified Rocking Engine
Post by: NickG on September 14, 2009, 02:29:11 PM: Right,

Back onto this ... i've missed two nights installations as had a bit of a nightmare over the last couple of days, well not as such, just things didn't really go to plan.

It seems there's been a hive of activity on the forum, I almost couldn't find my thread after replying to all the new / updated stuff! Looks like it's going well. I think Bogs thread a couple of months ago really kicked things into life.

On Sat night I started on the crankshaft. Didn't get in the garage until 10pm, and didn't get out until 2am - hence no write up!

The crankshaft didn't really pose too many problems, just took a lot longer than I thought. There was a lot of material to remove.
Luckily I found this whacking great tool that was probably sharpened by my grandad god knows how many years ago. But because of that, it worked well!

(http://img.photobucket.com/albums/v287/NickG24/2009-09-1222-24-24_0003.jpg)

The swarf was a bit scary though, didn't really like this task.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1221-58-04_0001.jpg)

(http://img.photobucket.com/albums/v287/NickG24/2009-09-1222-24-41_0004.jpg)

The thing started to shape up, I was taking pretty large cuts, probably around 1/8" at first but ended up taking 10 and 5 thou cuts as the diameter reduced.

(http://img.photobucket.com/albums/v287/NickG24/2009-09-1222-50-06_0005.jpg)

I thought I'd left it a couple of thou oversize but did a test fit in the bearing, at which point it slid merrily in. Probably marginally looser fit than I would have liked but once it's got a film of oil in there it's good, I want as little friction as possible really. As long as the flywheel doesn't wobble and I don't think it will. I later found out (when making a different component) that the problem was my cheap digi verniers. There is some error between the internal measuring bit and the external. I should use the starret ones my grandad gave me, they'll be a damn sight more accurate, just so fiddley to use and hard to see. Maybe I need to get another pair of digi ones as they are so convenient.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1222-52-42_0006.jpg)

Anyway, marginally happy with that so part off a couple of thou over, I like taking a facing cut after to ensure better finish, get to spot on length and to get rid of the pip.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1223-02-24_0007.jpg)

(http://img.photobucket.com/albums/v287/NickG24/2009-09-1223-29-58_0010.jpg)

Found a bit of aluminium for the split bush...I said I'd do it this way instead of messing around with the 4 jaw. I'm not experienced enough with that yet and it would have taken me hours.

Face to length
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1223-26-47_0009.jpg)

Mark where to drill hole:
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1223-32-38_0011.jpg)

I missed the pic of drilling but did it in the mill with a V block to keep it vertical.

More trusty hacksawing, I didn't go right through, just left a couple of mm holding it together - glad I did that or it would have been fiddley.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1300-06-27_0012.jpg)

Crankshaft was a nice tight fit in bush:
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1300-10-09_0013.jpg)

In the lathe ready for the offset turning.

(http://img.photobucket.com/albums/v287/NickG24/2009-09-1300-17-52_0014.jpg)

Note different cutting tool below, I managed to mess up that big one by trying to sharpen it! Don't know what it was but I put a steeper rake angle on it ... normaly about 20 deg for steel, where as before it was pretty flat. The tool below is the one I use for brass so only a couple of degrees rake angle, this forged steel likes that for some reason, maybe more rigid?
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1301-33-57_0015.jpg)

Finished crankshaft. It just took ages, I didn't like turning along the spindle axis so I did it by taking facing cuts across the piece until it left a pin of about 3/16" dia, then took the pin down to size. It still took a long time but there wasn't all that chatter etc.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1301-48-42_0016.jpg)

Pretty pleased with it, although I can see that part of the disc is thicker, it won't affect performance as it's on the back face, not sure why though, must have got the hole in the bush wonky somehow. I did the same thing on my hot air engine and that was straight in the 4 jaw though ... not sure why!

Assembled with rest of engine:
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1301-50-14_0017.jpg)

I'll post last nights component as another reply as this may crash!

NIck
Title: Re: Modified Rocking Engine
Post by: raynerd on September 14, 2009, 02:49:57 PM: I can`t wait to see this one running, it is looking great!!

Chris
Title: Re: Modified Rocking Engine
Post by: NickG on September 14, 2009, 02:51:13 PM: :jaw:

Brass turning nicely with that same tool as the crank! Took a big enough cut to get past the hex bit ... no problem.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1321-06-40_0001.jpg)

Lot of material to come off here too ... had to double the longitudinal feed speed otherwise I'd still have been there! I must be getting lazy, don't like turning the handwheel now!

(http://img.photobucket.com/albums/v287/NickG24/2009-09-1321-10-55_0002.jpg)

All going pretty well, couple of finishing cuts on the rod.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1321-34-36_0003.jpg)

The middle was to be wasted down further still.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1322-02-39_0004.jpg)

Started parting off, then filed the radius in situe. A test fit on the cylinder resulted in lots of swearing as it was already quite a bit undersize ... good rattling fit which wouldn't have worked. I put this down to getting different measurements between the internal and external jaws of my digi caliper .. piece of cheap cr@p! 'Buy cheap, buy twice' as someone always said to me at work ... not always the case, but in this case buy cheap, make twice, buy twice! :lol: actually, don't know whether to :lol: or :( !

So:
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1322-23-25_0008.jpg)

No, I didn't do that in my temper, although I felt like it :bang: ! I had a cunning plan, it was a good job I stopped there, I could turn that down to rod size and part off a bit further along then cut a thread on the end, make a disc from the remaining bit, tap it to suit and screw em together. By this time it was about 11:45 ... again, hence no post last night!

Disc drilled & tapped, parting off.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1322-49-29_0009.jpg)

Rod in collet chuck again ready to turn down and thread end.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1322-58-45_0010.jpg)

Disc screwed on, faced to length and profiled with needle file. This time checking fit in cylinder. It's still not spot on though, very easy to go a tincy bit too far with the file.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1323-14-08_0011.jpg)

Missed the step of drilling the hole in, the pin was quite a tight fit in the big end but waggled it about a bit with some oil and it's loosened off. Still might be a tad tight, no it should be ok, spins quite freely.
(http://img.photobucket.com/albums/v287/NickG24/2009-09-1323-52-25_0012.jpg)

The ~~good~~ news is, when I blow into the cylinder it gives a decent power stroke, but on the exaust stroke I can feel a bit of a power stroke too if you know what I mean. I mentioned this before, it was my fear that the piston doesn't rock sufficiently to vent the air pressure. I have a 4" dia cast flywheel which just happens to have the right bore, so I tried that ... i could get it to turn over a few times on lung power until I ran out of puff. So, I think it will run, at certain pressures, but I think it's a marginal design. I might have to experiment a bit with the flywheel, the one I've designed might not have the inertia required to counter act pressure forces on the piston. Also, the best configuration to run these in is probably vertically with the power stroke upwards. Then you also have gravity helping on the exhaust stroke.

Will have to see.

I want to do the 2 pedestals next then the wooden base, so when I've done the flywheel it is properly finished and ready to run! This should, all being well, be Sunday night. I'm away in South wales for the next couple of days so the plan is Thurs night: Pedestals Fri Night: Base, Sat & Sun night, Flywheel, Polish, Assemble, Run!

Nick
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 14, 2009, 03:24:52 PM: Nick,

You will get that back pressure on the return stroke because of it not having any valving.
It is the flywheels' job with the stored energy from the power stroke to overcome that reduced return pressure, and so keeping the engine running. It is a fine balance, but I don't think you will have any worries on that score, as long as there is a differential pressure.

Bogs
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 14, 2009, 03:46:34 PM: This will be a runner Nick even if its upside down these little engines seem to be sensitive to orientation.

Could you post a pic of it up against a ruler to give us some idea of size.

Cheers

Stew
Title: Re: Modified Rocking Engine
Post by: arnoldb on September 14, 2009, 03:55:42 PM: Looking good Nick :thumbup:

I've not yet gotten my "baby" compared to your's rocker to run on breath power - flywheel's a tad too heavy. But after a couple of demonstrations to friends it seems more and more eager to do that; maybe just some run-in required, you could have a similar problem :scratch:.

Enjoying your thread :) might just have another case of :proj: coming up :lol:

Cheers, Arnold
Title: Re: Modified Rocking Engine
Post by: NickG on September 14, 2009, 04:51:24 PM: Bogs, good point, and I dare say there is more differential pressure than in a stirling engine of the same size so it should run.

Stew, will take a pic with a ruler, I always forget to put something in for scale. I know some people use coins, that is a good idea, will starting doing that ... if I can find any!

Arnold, I think it will get better with run in, as I haven't lapped the bore it's probably not as good as it should be so a bit of wear should help. If it doesn't run, then I'll pay more attention to that, it's pretty smooth anyway. I specifically designed it with quite a large bore to make it run on low pressure. So on mine the pressure isn't a problem, it's just the volume of air required to keep it going ... especially as on the rocking engine you lose a lot on the exhaust stroke!

So you should have :proj:!!! Most people have made one of these rocking engines now, if you don't you'll be the odd one out :lol: So go on ... get started!!!!

Nick

ps The start of my last post was meant to say, the pics were taken with the new camera I wen't halves with the wife on ... so please say they are far superior to the old just to make me feel better! £165 that cost me!!!
Title: Re: Modified Rocking Engine
Post by: arnoldb on September 14, 2009, 05:44:23 PM: :lol: :lol: Nick, Have done here (http://www.homemodelenginemachinist.com/index.php?topic=5504.0) :lol: :lol:
But I'm due for another secondary infection :doh: have to finish one for my one sister before mid October for her birthday; she just said "I want one" - and that sorted out the b-day gift :lol:

Cheers!
Title: Re: Modified Rocking Engine
Post by: NickG on September 15, 2009, 02:45:51 AM: Sorry Arnold,

I don't know what I was talking about below, one sentence I was talking about your rocking engine, the next I was saying to build one! Will blame it on being tired! :scratch: :doh: :wack:

That's a good idea, it would make a great present! :thumbup:

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 18, 2009, 04:50:40 AM: Not much to report on this. Last night I did make the 2nd of 3 pedestals that support the frame. There wasn't any point taking pics as it was the same as the first one. everything went to plan except underestimated how long it would take again. Just under 2 hours in total, what a fiddley little thing it is! Oh well, only 1 more to do.

If I can get in the garage at 8 instead of 10 tonight (had to watch a film to keep the wife happy last night) I should be able to make the final pedestal and I am hoping the bit of brown stuff for the base.

Then tomorrow night I'll make a start on the Flywheel, that I am sure will need 2 nights - mainly because of the hand sawing!, but you never know, I might surprise myself! Even if I do finish that on sat night, I'll still need sun night to strip it down, clean / polish and reassemble with gaskets.

So that's the plan, hopefully it will be a finished article by the end of this weekend. I will then update any drawings as necessary and publish on here incase anybody wants to have go ... :proj:

Nick
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 18, 2009, 06:27:26 AM: You have almost doomed it to failure Nick.

Every time I try to guesstimate times like that, something goes pear shaped :lol:

John
Title: Re: Modified Rocking Engine
Post by: NickG on September 18, 2009, 08:38:56 AM: Bogs you're probably right ... could be 2 months on and still no chuffing sounds! :doh:

On my hot air engine project I had a long stall in the middle of it when it started getting difficult, but this time I'm nearly finished so it will take a lot more to stop me! I just need a few :poke: and :whip: and I should cross the finish line soon!

You're right though, I shouldn't have tempted fate .. never learn! :bang:

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 18, 2009, 07:29:08 PM: Hi all,

Tonight went pretty well .. in the end!

I made a start on the base with some brown stuff.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1819-32-29_0001.jpg)

It creates funny swarf … faster to saw than that 2” steel bar though!
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1819-38-24_0002.jpg)

Milling it square and to size
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1819-44-16_0003.jpg)

The sizes I designed it only just fit in the milling vice with the jaws removed … just!
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1819-58-05_0004.jpg)

Funny stuff this brown stuff
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1820-01-22_0005.jpg)

Drilling the holes … in the wrong place ... grrrrr! The brown stuff must have known I was taking the mick and got its own back … bloomin awful stuff!
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1820-21-26_0006.jpg)

Just before I chucked it at the wall I decided I could turn up a plug out of the small off cut of wood I kept .. knew it would come in handy! Turned it for a knock in fit.

Putting the chamfer on with the countersink … this worked pretty well.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1820-43-29_0008.jpg)

Counterboring the underneath for the nuts to hold it down.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1820-59-33_0009.jpg)

The finished base, pretty happy with it. You can see the plug but I even turned it the right way to get the grain going same way! Actually, it’s a really nice bit of wood, machines really well! Didn’t split or anything once.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1821-15-27_0010.jpg)

I also managed to get the other pedestal done, and all pretty early too, by about 10:45!

Trial fit of engine on base:
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1822-49-27_0011.jpg)
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1822-49-51_0012.jpg)
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1822-50-20_0013.jpg)

Quite happy with it, looking quite good, or will do when it’s cleaned and polished!

Just the flywheel to do … I even made a start on that ..
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1822-50-43_0014.jpg)

Well, it’s a start!

Looks like Sunday is still on for a running engine (fingers and toes crossed!)

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 18, 2009, 07:35:27 PM: ps, forgot to put anything to judge scale on again, sorry!

Don't know what those funny patterns are on wood, it almost looks like filler on the photo, sure it can't be though. I thought it was when I sanded it as I used a bosch vibrating 'mouse' sander, but looking at the first photos, the pattern is there before I sanded it. It's strange, like some bits are really close grained. Looks a bit daft in the pictures now.

Nick
Title: Re: Modified Rocking Engine
Post by: Darren on September 18, 2009, 07:59:27 PM: That's an Oak grain pattern Nick. I'm quite fond of oak as wood goes... :thumbup:
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 19, 2009, 01:47:09 AM: Nice going Nick looking good

:thumbup: :thumbup:

Are you making the fly wheel from plastic ?. if so be carful its not glass filled it'll do your machine no good, make sure you keep your ways covered and have a good clean up.

Have fun

Stew
Title: Re: Modified Rocking Engine
Post by: raynerd on September 19, 2009, 02:35:00 AM: Excellent NickG !! Like the base as well :headbang: Whole engine looks great on it.
Title: Re: Modified Rocking Engine
Post by: NickG on September 19, 2009, 04:51:11 AM: Ah ... at least that's cleared up! When I was making it, I actually found myself wanting woodwork equipment like marking gauges and stuff ... weird! Actually I do have some sand paper and a wood saw, it was just my attempt at a joke using the hack saw and emery cloth on the wood :lol: it worked though!

No it's not plastic Stew ... should have said, it's a bit of steel that I think has been phosphated in the past.

Cheers guys, can see the finish line now!

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 19, 2009, 08:09:19 PM: Right, had a mixed night tonight!

Started on the flywheel .. .still on track to complete tomorrow night, not worked out how I'm going to fix flywheel onto shaft yet as I've found some little alen key grub screws but I don't know what thread ... don't think they're ba and I don't have any other taps that small. On my other engines I've always had a screw sticking out but it looks a bit messy.

Anyway, started by sawing through the 2" steel with a hacksaw. That took 15 minutes, was pretty hard work but quite impressed as I got the cut fairly straight for once :lol:
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1922-17-21_0001.jpg)

Facing it to true it up
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1922-29-01_0002.jpg)

Finished flywheel blank
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1922-34-58_0003.jpg)

Turning recess ... at first I had a smaller tool, then changed to this as it has 2 cutting edges so thought I could save time just swinging it around, however, it was too big, so had to go with individual left and right handed cutting tools.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1923-32-41_0004.jpg)

Note, by this point I had already drilled the hole and done a trial fit on the crankshaft ... it was very tight and managed to get it stuck. I was turning it to get it off with my hands and slipped. The sharp edge of the wheel scratched my thumb ... or I thought it had, then 30 seconds later I looked down and saw it was covered in blood, sort of pulsating with splashes on the floor. One of those where you don't realise, then when you see it get quite a shock! Think it's going to be sore tomorrow. I tried to take a picture of it but it doesn't look much, the plaster has pulled it together quite well, think it's going to scar though.

Anyway, soldiered on to get the recess done on 1 side but I was trying to de-burr it with a needle file and one of the chuck jaws caught the file, could have pushed it straight through my hand, I was lucky ... don't actually know what I was thinking really. At that point I just stopped and came in. All the machinery and I go and lacerate my thumb on a burr. It just shows how many hazards there are in a workshop.

I need a :wack:, safety is drilled into us so much at work this sort of thing shouldn't happen to me.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1923-51-37_0005.jpg)

Trial fit on the engine:
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-1923-52-55_0006.jpg)

I actually quite like the look of it without the holes but still think I'll put them in. Also unsure whether to paint the inner bits red, that has become a bit of a trade mark of mine!!

Nearly there!

Nick
Title: Re: Modified Rocking Engine
Post by: chuck foster on September 19, 2009, 10:30:21 PM: looking goiod nick :thumbup: :thumbup:

can't wait to see a video of it running :D

chuck :wave:
Title: Re: Modified Rocking Engine
Post by: Darren on September 20, 2009, 01:50:05 AM: Ouch Nick, finishing for the day sounded like a good idea....hope your thumbs ok, sounds 'orrible....

Engines looking great.... :clap:
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 20, 2009, 02:04:31 AM: Hi Nick

Hope you filled in an accident report for the cut thumb :thumbup: and don't forget the near miss report for the file incident :D.

Just take care Nick you did the right thing and quitting for the night you may have bin on the tired side.

Engine coming along great, have you thought of supper glue or loctite for fixing the fly wheel thats what I've used.

Have fun :- Safely
:beer:
Stew
Title: Re: Modified Rocking Engine
Post by: arnoldb on September 20, 2009, 04:04:30 AM: Looking very good Nick :thumbup: - pretty much ready to run

Well, you've now got the blood and the sweat covered; I hope the tears will be of joy !

Cheers, Arnold
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 20, 2009, 04:05:51 AM: All looking good Nick! :thumbup:

When I wor a lad, they used to say...... By the time a turner/ fitter retires, there`s been enough bits knocked off to make another of `em! ::)

Let`s be carefull out there......

Re your flywheel recess tool. I used this one.

Didn`t have to disturb settings....... Forward rotation for rim area..... Reverse rotation for boss area......

(http://i110.photobucket.com/albums/n95/Dayjo/p8210002-1.jpg)

David D
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 20, 2009, 12:42:17 PM: Many moons ago I did an article on making recesses in a flywheel.
Unfortunately the accompanying vid went pear shaped ages ago, but there is enough on the post to give you a good idea of how to do it and what the tool looked like.

http://www.homemodelenginemachinist.com/index.php?topic=844.0

If you go to the middle of the post, there is another link that will take you to where it shows you how to make flywheels out of plate material.

http://www.homemodelenginemachinist.com/index.php?topic=228.0

Bogs
Title: Re: Modified Rocking Engine
Post by: NickG on September 20, 2009, 01:47:06 PM: Thanks for the replies guys, appreciate it :mmr: hopefully I'll have something to show later on tonight! :ddb:

The thumb has been aching a bit today, was deepish but at least it's only a cut! I took the plaster off this morning and it hasn't fused back together yet, started opening up so new one has been on all day, should be ok now. It's amazing how much harder things are without your right thumb though, so guess the only good things to take out of this are that I shouldn't do it again, and it's just a little reminder that you definintely can't afford to lose one.

David D, I like that tool, it would save quite a lot of time.

Bogs, looking at your tool, I'm not sure whether it would chatter on my lathe, probably not though, shouldn't do. Interesting about grinding tools, I often get colour into them and do hack a lot off, basically until it's too hot to hold so I'm doing it all wrong. I have started quenching in water but only when I can't hold it! Might try that tool profile on the other side tonight. My recess is only 1/16" deep though so I would probably just do it in about 4 cuts. Will be interesting.

I still haven't decided whether to drill the holes in the flywheel yet. I was liking the look of it plain, but it's a bit more fancy with the holes and I was trying to jazz this one up a bit with the columns and, radii and bolts so maybe I should stick to my original plan ... hmm! It will probably make the flywheel function better taking more mass away from the centre getting the moment of inertia up too.

Stew, I didn't think of loctiting it to the shaft, don't know why but I like to be able to take things to bits! That loctite that's been in the fridge at work is 648 which I think is the high strength stuff, had a look the other day and it's never been opened, will ask if I can have it! I was going to loctite the columns in and the bearing but I don't think the bearing needs it and I've just realised taking that out gives enough clearance to assemble the piston onto crank and into cylinder short of taking all the 8ba bolts out which is a PITA! Very fiddley to get back in when the piston rod is in the way!

Nick

ps if I can do a video, not sure how effective it'll be, I don't really have a good compressor, if it runs it'll probably run from the car tyre pump thing but that is dead noisy, will have to make some sort of adaptor too.
Title: Re: Modified Rocking Engine
Post by: Gerhard Olivier on September 20, 2009, 02:38:03 PM: That rocker of yours is coming on a treat - Very impressed with your engineering a block of wood idea.

Have fun, safely. Hope the thumb ok now.

Gerhard
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 21, 2009, 03:42:10 AM: Quote from: bogstandard on September 20, 2009, 12:42:17 PM
Many moons ago I did an article on making recesses in a flywheel.
Unfortunately the accompanying vid went pear shaped ages ago, but there is enough on the post to give you a good idea of how to do it and what the tool looked like.

http://www.homemodelenginemachinist.com/index.php?topic=844.0

If you go to the middle of the post, there is another link that will take you to where it shows you how to make flywheels out of plate material.

http://www.homemodelenginemachinist.com/index.php?topic=228.0

Bogs

John,

I remembered this one......

http://modelsteam.myfreeforum.org/ftopic8791-0-asc-0.php

My try, (then), with your recess tool, resulted in terrific chatter...... So, I went & did something else instead....... ::)

It might be ok now, with the taper bearings installed. :thumbup:

David D.
Title: Re: Modified Rocking Engine
Post by: NickG on September 21, 2009, 05:31:38 AM: Well,

It's finished ... about time really, a rocking engine that some people made in a few hours turned into a month long project for me - probably not worth it, I could probably have done a flame licker like I have always dreamed of in that time, done now though, I felt left out with everybody doing these rockers.

I know :worthless: but you'll have to wait until this evening for a proper write up! It was far too late by the time I got in, it must have been a record of some sort how late I was in the workshop last night!

Not going to say any more now without the pictures .. but will there be a video? That's the question because (http://img.photobucket.com/albums/v287/NickG24/Temp/untitled.jpg)

Nick
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 21, 2009, 05:39:59 AM: Nice one Nick! :thumbup:

David D
Title: Re: Modified Rocking Engine
Post by: NickG on September 21, 2009, 05:21:13 PM: Hi all,

This is the final installation of my rocking engine, barring a better video once I get some sort of air supply sorted. I'm telling you up front, the video is rubbish so you don't get your hopes up! I still have a headache from being the human compressor!

I turned the recess on the other side of the flywheel, I was going to grind the proper tool up as in John's thread but I thought I'd leave that for another time since I already had the 2 tools and packing pieces that I needed to hand.

I then decided I would drill the lightening holes, in attempt to get it done quickly, I thought I'd try to plunge them with a slot drill ... that was a mistake! I think the cutter was blunt and tried to run off, then the flywheel moved :doh:, don't really know what I was thinking but I didn't fancy centre drilling then gradually opening 6 holes up to 3/8". I remember last time it was a bit of a pain, I just did it on the bench drill but with the centre web being quite thin it was snatching a lot.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2022-00-32_0001.jpg)

So abandoned that idea, just wish I hadn’t bothered wasting time marking it out etc. Luckily I was able to take a small skim to get rid of the nasty marks from the nasty slot drill!

Next I mounted it on a mandrel in the lathe to skim the OD … it was pretty concentric anyway but I coouldn’t seem to shift the phosphate coating or whatever it was just with emery cloth. As John said, don’t try machining the whole thing like this, it’s not rigid enough. Just enough to take a very light skim really. I found a bit of 3/16” silver steel so just put a 2ba thread on one end as I knew I had a nut and washer. Gripped it tight in the lathe chuck and tightened the nut on so it squished the flywheel against the chuck jaws.
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2022-32-29_0002.jpg)

All that was left was to drill and tap an angled hole 8ba to fasten it onto the crankshaft. I still need a decent screw …for the flywheel that is! :lol: I then painted the recess red!
I tried to bling it all a bit but am not very good at that / don’t have the right stuff. The aluminium from the shelf brackets I got over excited about … it’s pretty naff material, too soft. It won’t even polish very well, see the finish compared to the high strength stuff on the cylinder cover!

Just lots of pics to follow now, it’s a bit of overkill but it shows it compared with my CAD model.

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2102-14-03_0006.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2102-14-17_0007.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2120-31-16_0001.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2120-33-18_0002.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2120-33-39_0003.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2120-33-55_0004.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2120-34-09_0005.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2120-34-37_0006.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/2009-09-2120-35-12_0007.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/Assembly3.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/Assembly2.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/Assembly1.jpg)

Now for the video .. sorry about this, it’s the best I could do for now short of taking the car tyre compressor into the car and shooting a video in there, or busting a gut!
(http://img.photobucket.com/albums/v287/NickG24/Rocking%20Engine/th__0009.jpg) (http://smg.photobucket.com/albums/v287/NickG24/Rocking%20Engine/?action=view&current=_0009.flv)

I’m quite happy with it, there are a few mistakes but it’s turned out pretty much how I expected, just glad it runs!
Now I will make sure all the drawings are correct incase anybody else wants to have a go ..probably not as it’s way over the top for a rocker but it’s one for the internet archive anyway!
My next project is going to be the restoration of my 3 ½” gauge ‘mabel’ locomotive (same design as Stew’s) so probably no machining for a while. Unless I decide I need a break and if that happens I’ll be making a QCTP with 4 holders … according to my project plan! :lol: But as you have all seen how well I stick to plans, don’t take my word for it! :proj:

Thanks for all the replies, support and advice :mmr:

Nick
Title: Re: Modified Rocking Engine
Post by: Darren on September 21, 2009, 06:00:11 PM: That's a very nice Looking engine Nick. Really like the design....and the wood..... :thumbup:

I suppose I'll have to have a go and make one........sometime.......when I have some spare...... :D
Title: Re: Modified Rocking Engine
Post by: raynerd on September 21, 2009, 06:55:55 PM: 5 Stars: *****

Really enjoyed this entire thread, it has been great seeing your cad drawings and then piece by piece turning your ideas into parts. Really chuffed it works for you! :) :thumbup: :thumbup: :thumbup: :thumbup:
Title: Re: Modified Rocking Engine
Post by: chuck foster on September 21, 2009, 07:50:44 PM: :thumbup: :thumbup: :ddb: :ddb: way to go nick :ddb: :ddb: :thumbup: :thumbup:

i have been following the whole build of this engine and have enjoyed it very much :beer:

chuck :wave:
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 21, 2009, 08:59:28 PM: Nick,

You ought to take up bagpipe playing, I can only get my tiny one to run half that time before I fall over with the dizzies.

That was a well done post, and a great finished article, many thanks for showing us your journey.

John
Title: Re: Modified Rocking Engine
Post by: dsquire on September 21, 2009, 11:52:49 PM: Nick

Great job. You persevered and you won. That engine looks real nice. :ddb: :ddb: :ddb:
That base looks great even though you insulted it with a hacksaw. :lol: :lol:
But the overall result is something you can be proud of. :D :D
Cheers :beer:

Don
Title: Re: Modified Rocking Engine
Post by: sbwhart on September 22, 2009, 01:21:18 AM: Well done Nick great project, you've taken a design and put a bit of yourself into it, its quite a bit bigger than other rockers made interesting that it can be scaled up, impressed that it runs with lung power as well.

:clap: :clap: :clap: :clap: :clap: :clap:

Good luck with your Mabel rebuild

Don't forget the pics

Have fun

Stew
Title: Re: Modified Rocking Engine
Post by: spuddevans on September 22, 2009, 01:34:39 AM: Well done Nick, I knew you'd get it running :clap: :clap: :clap: :clap: :clap:

Tim
Title: Re: Modified Rocking Engine
Post by: arnoldb on September 22, 2009, 03:50:01 AM: Great going Nick - I'ts a treat :thumbup: :ddb: :ddb: :ddb:
:beer:, Arnold
Title: Re: Modified Rocking Engine
Post by: NickG on September 22, 2009, 04:19:11 AM: Thanks for all the comments guys.

I like that alibre CAD programme, I could have done it with a few sheets of paper and a pencil, but it's easier to visualise things in 3D, quick and easy results ... you'd think I worked for them :lol: I don't honest!

A few learning points have come out of this project ... my wish list is growing! ...QCTP, Power Hacksaw, Rotary table, tailstock die holder, set of standard carbide tools?, Compressor (not sure if I have high enough speeds for that) Also, shelf bracket material is cr@p!

Right, onto the next project! :coffee: :dremel: :proj:

Nick
Title: Re: Modified Rocking Engine
Post by: NickG on September 22, 2009, 05:31:54 AM: Bogs,

I had a banging headache this morning funnily enough! :bang: Not going to try that again!

I can get it to run longer by blowing the air in timed pulses, but then I realised that was cheating ... I was acting as the valve! :lol:

Nick
Title: Re: Modified Rocking Engine
Post by: raynerd on September 22, 2009, 06:57:00 AM: lol - why don`t you pick up a cheap compressor and try it with that. I think I got mine for about £7 off an indoor market! Sure, it gets hot after about 10 mins and it can only blow out a few PSI but it does a job and gets my little engines moving. Don`t get me wrong, I`m looking out for a larger compressor and tank when one comes along at the right price but the little one has its place.
Title: Re: Modified Rocking Engine
Post by: NickG on September 22, 2009, 07:19:24 AM: Chris,

Do you mean the car tyre type of thing or is it a proper compressor? Never seen them.

Nick
Title: Re: Modified Rocking Engine
Post by: Bernd on September 22, 2009, 08:04:51 AM: Hey Nick,

That's quite a set of lungs you have there. :lol: Engine ran nice on lung power.

Painting that flywheel and that wooden base make for a nice looking engine display.

Bernd
Title: Re: Modified Rocking Engine
Post by: Gerhard Olivier on September 22, 2009, 11:00:24 AM: Very nice engine well done

Thanks for enjoyable post.

Gerhard
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 22, 2009, 12:23:19 PM: Very well done Nick........ Engine, & blow! :clap:

Gave me palpitations just watching! :lol:

David D
Title: Re: Modified Rocking Engine
Post by: raynerd on September 22, 2009, 05:37:24 PM: Nick, it is identical to the one at RDG sells for £45 but I got mine much much cheaper of the market about 5 years ago! http://www.rdgtools.co.uk/acatalog/COMPRESSORS.html
I got it with an airbrush set when I was spraying parts for my old MGF - I never used the airbrush as I found I could get a better finish with a spray can if I took my time! RDG also sell theres to be used with an airbrush set but I guess they have other uses.
Title: Re: Modified Rocking Engine
Post by: NickG on September 22, 2009, 06:57:36 PM: Cheers Chris,

Will have to look out for one of those.

:offtopic: I used to have an MGF too ... a VVC, I got a sports stainless exhaust from Moss and it sounded amazing! It was the first thing I spent all my money on after starting work and loved it, but sold it to my dad after a few months as I got a good deal on a new ZS180 at the time, that went to dad after a couple of years too! Both great cars but had all sorts since then, I get bored quickly!

(http://img.photobucket.com/albums/v287/NickG24/Temp/mgf3.jpg)
(http://img.photobucket.com/albums/v287/NickG24/Temp/mgf5.jpg)
(http://img.photobucket.com/albums/v287/NickG24/Temp/MyZS180-2.jpg)
(http://img.photobucket.com/albums/v287/NickG24/Temp/MyZS180-3.jpg)

Nick
Title: Re: Modified Rocking Engine
Post by: Divided he ad on September 25, 2009, 03:40:48 PM: Sorry to have missed most of your build Nick..... I've been very absent of late!

Still.... It looks great and will no doubt run really well with some real force behind it?

Speaking of which, I hope that was your mouth making that noise at 8 seconds in and not the other release valve? :lol:

MGF..... You do realise it's a butchered Metro under there don't you? .... Sorry MGF lovers but it has to be said!

Anyway... Back on course, you should certainly be very proud of that little fella, from concept re-design to completion very nice job :thumbup:

Ralph.
Title: Re: Modified Rocking Engine
Post by: raynerd on September 25, 2009, 04:25:53 PM: A metro!!!!!! It is a prime sports car!!

:offtopic:

(http://www.raynerd.co.uk/images/CL1.jpg)

(http://www.raynerd.co.uk/images/CL2.jpg)

The British racing green one was mine, VVC, this was at the start/meeting point of a rally! Some good fun and great guys.... Infact think that is me looking at it at the far side of the picture so now idea who took this!!
Title: Re: Modified Rocking Engine
Post by: NickG on September 25, 2009, 06:18:10 PM: Ralph,

Thanks for the comments. I haven't got to try it on proper compressed air yet unfortunately will be interesting to see how it runs. I wondered if anyone noticed that slip out, it was my mouth ... honest! A safety valve of sorts I guess!

On the MGF, fortunately for you there probably aren't that many avid MG fans on here :lol: ... Butchered metro or not, they were fantastic cars! Best selling roadster, great fun to drive, quick, agile and British! I'm a big fan of MGs but I really think they had the MGF just about right. Ok, build quality was not a great strong point, and yes it did 'borrow' some other bits and pieces from metro's too but it didn't really deter much from the experience! I'd have one back now! A lot of people used to wind me up with the fact that my MG ZS was just a rover 400 too, but it was a tad different to any rover 400 when you were behind the wheel believe me! I think Tiffany Dell dubbed it the "best handling front wheel drive car in the world" when it came out ... quite an achievement from what people thought was a grandads car!

Chris, I always regret never getting involved with a group and going on runs etc, would have been great fun!

Nick
Title: Re: Modified Rocking Engine
Post by: raynerd on September 26, 2009, 04:15:15 AM: I actually did it all off the internet, it wasn`t the official MGF owners club, it was actually the MG-Rover forums - MGF sub-forum North West group. It was great fun, I was young at the time, I`m 25 now but I was only 22 when I had the MGF and I use to have a right laugh. We use to park up on a pub car park and open the hoods and just walk around the cars. We all had something to show - I`d taken all the interior out of a scrapped top model MGTF - gorgeous green and black leather. Was absolutely amazing! I`d fitted loads of Mike Sattur stuff and it looked great - handled really well.

Anyway - I`ll shut up about MGF - back to topic :lol:

I`d definately consider buying another - only problem is the expense of repairs. The engine compartment is so enclosed that every job costs a fortune as you have to remove everything to get in there. To do the jobs yourself is just a pain in the arse! Did I just say I`ll shut up about MGF...ok sorry!! :bang:

Chris
Title: Re: Modified Rocking Engine
Post by: Divided he ad on September 26, 2009, 06:38:36 AM: Quote
A metro!!!!!! It is a prime sports car!!
:lol: :lol: :lol:

I've MOT'd, driven and fixed them. Nuff said!

Oh, ok..... I'll have to let this lie.... it'd get ugly fast!

Back on topic...

I seem to have noticed that you're posting the plans somewhere too.... I'll have to have a look later, I'll probably add them to my collection and maybe one day decide to add my own little twist to them..... I really can't just seem to make "off plan" ::)

I've really got to get my rocker finished.... It's been ages!

Don't read too much into the MGF thing guys, until recently I owned a Laguna diesel bus :lol:

Ralph.
Title: Re: Modified Rocking Engine
Post by: NickG on September 28, 2009, 05:03:37 AM: Back :offtopic:

I was 22 when I had mine too Chris, it was a great car to drive. They have a lot of faults and the engine is difficult to work on but it still didn't detract from the experience really.

I guess it depends what you're trying to compare them to. I know Mazda MX5s get good reviews but they just don't have the same character in my opinion. MR2's are supposed to be good too, no boot though!

:lol: We know the MGF is really not a good car but still like them!

Back on topic!

Yeah Ralph, the plans are in the design section. It's quite a nice looking engine but is probably a bit fiddley to make for what it is, I will have to try it properly on some compressed air. Like you, I don't just like making stuff to existing plans. In fact, I never have done yet ... will have to give it a go though!

Nick
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 28, 2009, 05:54:20 AM: Quote from: craynerd on September 22, 2009, 05:37:24 PM
Nick, it is identical to the one at RDG sells for £45 but I got mine much much cheaper of the market about 5 years ago! http://www.rdgtools.co.uk/acatalog/COMPRESSORS.html
I got it with an airbrush set when I was spraying parts for my old MGF - I never used the airbrush as I found I could get a better finish with a spray can if I took my time! RDG also sell theres to be used with an airbrush set but I guess they have other uses.

Thanks for the link Chris! :thumbup:

Look what I got coming...... :D

(http://i110.photobucket.com/albums/n95/Dayjo/Comprssr.jpg)

David D
Title: Re: Modified Rocking Engine
Post by: Divided he ad on September 28, 2009, 07:12:23 PM: Quote
Like you, I don't just like making stuff to existing plans. In fact, I never have done yet ... will have to give it a go though!

But it's really hard to do!! I just can't seem to force it to happen?!
Tried it a few times, but once a slight mistake appears that's is! All bets are off and the bling fairy gets a full boot in! :lol:

I'll find the plans soon enough.... Still playing major catch up on topics!

Ralph.
Title: Re: Modified Rocking Engine
Post by: NickG on September 29, 2009, 07:20:15 AM: Nice 1 David, should be useful. Any particular reason you chose the 2 cylinder one?
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 29, 2009, 08:06:12 AM: Quote from: NickG on September 29, 2009, 07:20:15 AM
Nice 1 David, should be useful. Any particular reason you chose the 2 cylinder one?

I already have a window rattler, which I don`t use/ need often.

I have a small compressor from a dehumidifier, which will not be man enough for the upcoming job of powering a 4 cylinder Mamod engine. ::)

Soo...... Seeing how little difference there was in the prices, I bought the largest! :thumbup:

David D
Title: Re: Modified Rocking Engine
Post by: raynerd on September 29, 2009, 10:12:13 AM: Give us a review David when it comes, if you will?
Title: Re: Modified Rocking Engine
Post by: NickG on September 29, 2009, 11:35:03 AM: Oh right, nice 1! :thumbup: The only thing I noticed on the twin was that it didn't have a tank, it's the same price as the single with the tank so guess that's the only thing to weigh up.

I think I'll go for a bigger one though that can power tools and things if I do get one, as the larger ones can be had for about the same money ... then it can support my other hobby (cars) too!

Nick
Title: Re: Modified Rocking Engine
Post by: bogstandard on September 29, 2009, 11:58:30 AM: http://www.machinemart.co.uk/shop/categories/search/diy-semi-professional-air-compressors-2
Title: Re: Modified Rocking Engine
Post by: Stilldrillin on September 29, 2009, 11:59:59 AM: Quote from: Stilldrillin on September 29, 2009, 08:06:12 AM
Quote from: NickG on September 29, 2009, 07:20:15 AM
Nice 1 David, should be useful. Any particular reason you chose the 2 cylinder one?

I already have a window rattler, which I don`t use/ need often.

I have a small compressor from a dehumidifier, which will not be man enough for the upcoming job of powering a 4 cylinder Mamod engine. ::)

Soo...... Seeing how little difference there was in the prices, I bought the largest! :thumbup:

David D

There`s a slight glitch with the calculations.......

The new one`s being delivered tomorrow, and we got us a crackin` runner....... With the little compressor...... ::)

(http://i110.photobucket.com/albums/n95/Dayjo/p9290018.jpg)

David D
Title: Re: Modified Rocking Engine
Post by: NickG on September 29, 2009, 02:01:49 PM: :lol: Oh well, it'll come in!

The good thing about the little compressor is it'll be quiet as it's a diaphragm type.

Nick