MadModder
Gallery, Projects and General => Project Logs => Topic started by: modeldozer on December 21, 2014, 02:55:12 PM
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For my first try at building a steam engine I have opted for Elmer’s no33 horizontal mill engine. To make it easier to do I have doubled the scale and adapted it to metric.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/MillAssem1.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/MillAssem3.jpg)
Shaft part of the crankshaft.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00001.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00002.jpg)
The crank pin
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00003.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00004.jpg)
Setting up a piece of material for the crank web.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00005.jpg)
Drilled and turned the boss end.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00006.jpg)
Then turned around, and turned the outside and faced off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00007.jpg)
The milling work has to wait until my mill is fixed.
Next were the eccentric, first faced and drilled and then offset to turn the journal.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00008.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00009.jpg)
More to follow.
Cheers
Abraham
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Great, Abraham, looking forward to this! :coffee: :coffee:
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brill keep it up
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Looking forward to following this 1 :thumbup:
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Thanks to all for following.
The piece of stainless steel that I wanted to use for the valve pushrod had a slight bend in it so I had to do a makeshift drive arrangement to turn it between centers.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00010.jpg)
Once true it was chucked in a collet chuck for a bit more rigidity while turning.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00011.jpg)
Ready for milling.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00012.jpg)
Next was the connecting rod, here turning the radii with a form tool.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00013.jpg)
Turning done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00014.jpg)
That’s all for now.
Cheers
Abraham
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Looking good! :coffee:
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Well this is another project I will keep tabs on and keep my mind off my non working lathe. (Blown diode in the controller, waiting for replacement parts and hopefully it will be a simple repair. :zap: ) Great work so far.
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Thanks guys, Might slow down a bit as i am still waiting for my mill's bed from the machine shop.
Cheers
Abraham
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Next up were the 4 spacers for the crosshead. Turned the outsides, drilled and cut off 4x.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00015.jpg)
Then set up a backstop.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00016.jpg)
And clean them up to the same length.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00017.jpg)
Then it was time for a cleanup as next I will be turning brass.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00018.jpg)
Turned the two main bearings.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00019.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00020.jpg)
More to follow.
Cheers
Abraham
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Hi all,
The packing nuts were machined from hex stock.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00021.jpg)
The cutoff ends were faced and the holes reamed to final size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00022.jpg)
Finished.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00023.jpg)
A piece of flat bar was centered to a punch mark.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00024.jpg)
A hole was drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00025.jpg)
And bored.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00026.jpg)
The piece was then reset.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00028.jpg)
And faced, then flipped over and faced on the other side.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00027.jpg)
Ready for some milling work to turn it into the eccentric strap.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00029.jpg)
Until next time.
Cheers
Abraham
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Well done, and nicely shown, Abraham! :clap: :clap:
It's nice to see you're back with us, again..... :thumbup:
David D
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Hi David,
Thank you for the encouragement. Am glad to be able to carry on with the hobby for a while longer.
Abraham
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:coffee: :clap:
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Well done. Might I ask which lathe that is?
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Abraham
A very well presented project, looking forward to more.
Well done
Cheers David
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Hi to all,
Thanks for looking and encouraging.
Crazymodder,
It is a highly moddified Realbull 7x14 sold here under the Einhell brand.
Cheers
Abraham
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Hello to all,
Hope everybody had a nice Christmas and Santa was very generous.
Next up was the valve chest and, as the mill is still out of commission, a piece of brass was fly cut to size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00030.jpg)
It was then centered lengthwise,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00031.jpg)
and the boss for the packing seal turned.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00032.jpg)
It was drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00033.jpg)
For the deep hole I had to make a long drill by soldering a drill bit into a length of bar.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00036.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00037.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00040.jpg)
Test fitting the packing nut and valve pushrod.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00041.jpg)
The part was then turned around and the boss on the blind side turned,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00042.jpg)
and parted off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00043.jpg)
The round over was done by file.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00044.jpg)
The piston pushrod was cut to length and threaded.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00035.jpg)
Tuning the pin for the valve pushrod.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00038.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00039.jpg)
Cheers
Abraham
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Hi all,
Next a slice of cast iron was marked and cut.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00045.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00046.jpg)
A layout was stuck to the slice and some further cuts made. The off cuts will be used later.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00047.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00048.jpg)
The main piece was centered in the 4-jaw chuck,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00049.jpg)
the outside turned to size and the gland boss turned.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00050.jpg)
Ready for drilling.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00051.jpg)
The left over piece had to be turned over and machined from the other end to make the blind head.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00052.jpg)
Being cut off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00053.jpg)
To hold the blind head for facing the outside an ER40 chuck was used. A slug of 25mm bar was placed in the back of the collet so it could close.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00056.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00054.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00055.jpg)
The finished pair.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00058.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00059.jpg)
That’s all for now.
Cheers
Abraham
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thats rely shaping up nice :thumbup:
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Coming along nicely! :thumbup:
The saw marks on the c/i, took me back to aching young muscles, in the apprentice school..... 1960. :(
It's going to be larger than I first thought...... :scratch:
Nice work Abraham! :clap: :clap:
David D
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Hi KRV and David
Thank you for the encouragement.
Unfortunately the only means for cutting things in my shed is elbow work and a hack saw.
Cheers
Abraham
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Hi all,
A question for the collective, with a CI cylinder what material would be the best fo the piston, CI, brass or mild steel?
Abraham
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I'd vote for CI.
Graphite containing, same rate of expansion as cylinder, less tendency to rust (with steam oil coating) than steel (for steam), no tendency to electrolytic action with cylinder. (as brass would, if damp).
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Abraham,
An interesting collection of tool holders you have hanging on the wall.
Dave.
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vtsteam,
Thank's for the quick response, will make it from the same as the cylinder.
Dave,
all based on Ralph Patterson's designs.
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Hi to all,
Hope 2015 is a happy, healthy and prosperous year for all.
Next up a piece of the off cut CI was turned to form the piston.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00057.jpg)
The hole in the piston ended up to loose a fit on the pushrod so the rod was brazed up and turned down for a tight fit in the piston.
The picture did not come out that well.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00061.jpg)
The piston was then finished while mounted on the pushrod.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00062.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00063.jpg)
For the next task I will be attempting to get the hidden flywheel from within a slice of CI.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00064.jpg)
A template was used to drill and tap some fixing holes in the slice.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00065.jpg)
It was then mounted and centered on the faceplate.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00066.jpg)
The outside skimmed, faced and center hole drilled and bored.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00067.jpg)
Then it was very slowly turning the recess.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00068.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00069.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00070.jpg)
The flywheel was then turned around and reset. The fist task now is to cut it to length by hand.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00071.jpg)
Until next time.
Abraham
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I love seeing the flywheel, slowly emerging, Abraham. :clap:
The fist task now is to cut it to length by hand.
More hack-sawing? :palm: :( Good luck/ muscles! :thumbup:
David D
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Hi David and George,
Thanks for the insparation.
BTW half a days hack-sawing later and am about 80% through the sclice. (done with frequent rest)
Cheers
Abraham
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Finally managed to cut off the excess.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00072.jpg)
Faced to size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00073.jpg)
And then the slow process of machining the recess was repeated.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00074.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00075.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00076.jpg)
Had little shop time and only finished this afternoon.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00077.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00078.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00079.jpg)
That concludes the turning work that can be done for now, unfortunately the milling machines bed is not back yet so will have to find an interim project to do while waiting.
Cheers
Abraham
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Looks like a great project! I like the photos of the parts with your prints.
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Finally got the mill bed back and fitted. Started machining the two pieces of the base square and to size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00080.jpg)
For the long facing cuts I experimented with a stepper motor as power feed.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00081.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00082.jpg)
For now am using a pulse generator of eBay but, it is not performing as I would like at slow speeds so will be building a different one.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00083.jpg)
Am quite happy with the finish.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00084.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00085.jpg)
A short video of it in action.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/th_BaseFaceing.mp4) (http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/BaseFaceing.mp4)
The one piece was quite a bit wider than needed and I do not have any means to slice it down so an end mill was used to cut it down, also under power feed and it cuts like butter.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00086.jpg)
Cheers
Abraham
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(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00065.jpg)
What do you use to glue down your templates? Just some random paper glue, like what kids use? Or is there something special?
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What do you use to glue down your templates? Just some random paper glue, like what kids use? Or is there something special?
CrazyModder,
Pritt Stick works for me. Cleans off with water.
Phil.
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Hi crazymodder,
I use clear contact adhesive, gives a good bond and "peels" of after.
Abraham
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Hi all.
Finally got the power feed working. The material for the base and sub-base was machined square and to size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00087.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00088.jpg)
The sub-base was drilled and the slots for the anchors cut, drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00089.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00090.jpg)
The holes from the bottom of the base was drilled, taped and counter sunk.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00091.jpg)
Flipped over and the top was drilled and taped. The slot for the crank was partially cut with an end mill, have a side and face cutter on order to finish the slot.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00092.jpg)
The top face was given a light skim to finish it off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00093.jpg)
And the two bases together.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00094.jpg)
Two strips of plate was squared and machined to size for the anchors.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00095.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00096.jpg)
Made a simple bracket to setup the rotab.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00097.jpg)
The rotab was used to round over the ends of the anchors. Things got a bit involved and I forgot to take any pics.
After mounting the anchors to the sub-base the assembly was given a face cut.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00098.jpg)
The base assembly so far.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00099.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00100.jpg)
Cheers
Abraham
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Looks great mind if I pull up a chair view the action.
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Hi Ginger Nut.
Thanks, feel free to view the action.
Abraham
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Nice! :thumbup: :clap:
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Tkanks Steve.
Abraham
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Hi fellow modders,
For the next part a piece of aluminium was machined square.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00101.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00102.jpg)
The centre was located.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00103.jpg)
And the top machined and drilled to form this,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00105.jpg)
A template was printed and fixed to the rotary table,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00106.jpg)
This was used to locate the part and machine the top radius.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00107.jpg)
The part was reset in the vice,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00108.jpg)
And split with a slitting saw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00109.jpg)
The bottom half was machined to length and the holes taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00110.jpg)
The two halves bolted together.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00111.jpg)
And fitted on the base assembly.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00112.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00113.jpg)
By now it should be clear as to what it is. The hole for the bearing will be line bored with both bearing posts in place.
For the other post a slab of aluminium was again machined square and to size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00114.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00115.jpg)
That’s all for now.
Cheers
Abraham
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Next up, the large hole was drilled and bored.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00116.jpg)
The mounting holes in the bottom was drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00118.jpg)
The top end was cut down and machined.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00119.jpg)
A ball nose cutter was used to finish the small radius on the sides.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00120.jpg)
Sides all done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00121.jpg)
The top end was done the same as the short post.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00122.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00123.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00124.jpg)
Made some studs in the lathe.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00125.jpg)
All the base parts together.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00126.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00127.jpg)
The cutter for cutting the crank slot arrived, so next up is making an arbor for it.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00117.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00128.jpg)
Cheers for now.
Abraham
-
Hi all,
Got so involved in building the engine I did not do any updates in a while.
Finished the arbor, to be used later.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00130.jpg)
Mounted a piece of 6mm mild steel plate on the mill and machined the long sides parallel and to size. Then using a spot drill some grooves was “engraved” lengthwise.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00129.jpg)
The mill does not have enough cross travel to do the sides, so the work was rotated and the one end milled square. Half of it was then grooved.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00131.jpg)
Then rotated 180º and the last groove picked up to finish the grooving to the end. The end was then milled square and to length.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00132.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00133.jpg)
The plate was flipped over and all the hole drilled and counter sunk.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00134.jpg)
All done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00135.jpg)
The base was mounted on its side.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00136.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00137.jpg)
The side and face cutter was used to finish the cutout for the crank and conrod. As the cutter has only a few teeth this was very slooow going.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00138.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00139.jpg)
With everything assembled the bearing posts was first drilled and taped for lubricators.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00140.jpg)
The assembly was then mounted on its side for boring the bearings.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00141.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00142.jpg)
Had to use one of my lathe boring bars to reach down both bearings.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00143.jpg)
With the bushes and a few bits added.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00145.jpg)
I did not like the fit of the bushes so they were remade.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00146.jpg)
With the help of a fixture the crank web was mounted on the mill.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00149.jpg)
The side and face cutter was then used to cut the curves on the crank. Can anyone notice something odd in this picture?
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00150.jpg)
The cutter was mounted other way around and the mill ran in reverse to get a better cut.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00151.jpg)
Hot off the mill.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00152.jpg)
After filling the end and a bit of a cleanup.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00153.jpg)
The end of the crankshaft was given a light knurl.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00154.jpg)
The crank was pressed on and tin soldered.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00155.jpg)
Cleaned up.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00156.jpg)
Cheers :beer:
Abraham
-
Astounding!
Your generosity in showing successive steps served as
the equivalent of attending a master class in machining.
Admire your talent. Shall try to emulate some of the clever
set ups that will be used in a project.
Thank you, Sir!
-
Hi Topos,
Thank you for the kind words.. I learned a lot from others in forum posts.
Cheers
Abraham
-
And the saga continues.
A couple of 5mm plate strips were machined square and to size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00157.jpg)
They were setup together and drilled,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00158.jpg)
to form the top bars of the crosshead.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00159.jpg)
Two pieces of calibrated bar was milled to size for the bottom parts of the crosshead. This took a bit of time, as the only material I had was 30 x 15mm and the parts are 22.5 x 9mm.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00160.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00161.jpg)
Mounting holes drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00162.jpg)
Setup on the mill to machine the cutouts.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00163.jpg)
A temporary end stop was set to get the other part located.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00164.jpg)
Both parts done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00165.jpg)
4 studs were made.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00166.jpg)
All the parts for the crosshead.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00167.jpg)
And fitted.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00168.jpg)
Cheers
Abraham
-
...Two pieces of calibrated bar was milled to size for the bottom parts of the crosshead. ..
What's a calibrated bar ?
Dave
-
Hi Dave,
Now you mention it I am actualy not sure of the correct english term, just directly translated the Spanish. It is a bright mild steel manufactured to closer tolaraces than normal cold roled and has good machining properties.
Abraham
-
Abraham,
I'll settle for BMS Bright Mild Steel as the most likely candidate.
It comes nice and square, shiny and oily.
Dave.
-
I watch for this project and read it every time. Great work Abraham! :bow: :clap: :clap: :clap: :clap: :beer:
-
Dave,
That must be it.
Steve.
Thank you for the kind words.
:beer:
Abraham
-
"Calibrated" may just equal "Gauge Plate" in a computer Span/Eng dictionary!
-
Will,
Well done that man.
When I lived in Germany my landlady once asked me if i had a prolongation she could borrow.
It took a minute to realise she meant extension.
Dave
-
Hi fellows,
Will, thanks for that one.
Mostly for my own curiosity I looked at a few UK steel merchants and what is commonly known here, as calibrated stock is Bright Mild Steel.
The connecting rod was set on the mill and the flats at the ends milled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00169.jpg)
To mill the small side a spacer was used at the other end to get it level for the first side.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00170.jpg)
Locating from the ends, the holes was drilled and reamed.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00171.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00172.jpg)
The finished connecting rod.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00173.jpg)
And posed on the base assembly.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00174.jpg)
Next a chunk of brass was, as usual, machined square and to size.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00175.jpg)
The slot for the connecting rod was machined.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00177.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00176.jpg)
The hole for the piston rod was drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00178.jpg)
And the hole for the connecting rod pin was drilled and reamed.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00179.jpg)
The steps on the bottom side were milled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00180.jpg)
The finished cross head.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00181.jpg)
I did not have any 3mm rod, so a 3.15mm-welding rod was sanded down to make the pin.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00182.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00183.jpg)
A M8 nut was drilled out to fit over the crank pin, and used as a guide to file the spanner flats.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00184.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00185.jpg)
And after a bit of fettling with a file and emery paper to get things operating smoothly.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00186.jpg)
Cheers :beer:
Abraham
-
That's looking superb Abraham! :bow: :bow: :bow: :beer:
-
Steve,
Thank you for the kind words.
Abraham
-
Its coming together well and looking very good Abraham :clap: :clap: :clap:
John
-
Hi all,
John, thank you for the encouragement.
Two pieces of brass plate was machined square and flat.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00187.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00188.jpg)
Steam ports were drilled in one plate.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00189.jpg)
And mounting holes drilled in both to make the valve plate and cover.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00190.jpg)
The steam chest was set up, mounting holes drilled and the pocket carefully milled out.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00191.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00192.jpg)
The steam chest parts.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00193.jpg)
After machining a small piece of brass square and to size, a pocket was milled in the one face.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00194.jpg)
It was flipped over and slots for the valve rod and nut was milled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00195.jpg)
And after a cleanup with some emery tape.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00196.jpg)
Thanks for looking.
Cheers.
Abraham
-
Hi everybody,
Done some of the smaller but time consuming bits.
For the valve nut a piece of flat stock was milled and lapped for a tight siding fit in the valve.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00197.jpg)
Then the ends were milled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00198.jpg)
A broken 6mm end mill was used to locate the centre.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00199.jpg)
and the hole drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00200.jpg)
Test fitting the valve components.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00201.jpg)
The valve rod was set up to mill flats on the end and cut the slot for the eccentric strap. I do not have a long enough end mill for this so I used a slitting saw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00202.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00203.jpg)
Then end was located,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00204.jpg)
and the connecting pin hole drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00205.jpg)
The connecting pin was set up as best I could and the split pin hole drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00206.jpg)
The assembled valve.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00207.jpg)
Next I will need to make a centering arbor and some attachments for the rotary table so the flywheel and some other parts can be finished.
Cheers :beer:
Abraham
-
To make the arbor a piece of material was faced and centre drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00208.jpg)
A MT2 dead centre was placed between this and the tailstock to set the angle for the compound.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00209.jpg)
A taper was turned on a length of rod. Here using the tailstock arbor to test the taper.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00210.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00211.jpg)
The end was turned down to 12mm and cut off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00212.jpg)
A couple of collars were made for a tight fit on the end and a retaining washer made for the bottom end.
One collar is for locating a chuck and the other for the eccentric strap.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00214.jpg)
Mounted in the rotary table.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00215.jpg)
With the eccentric strap mounted.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00217.jpg)
And with the flywheel.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00216.jpg)
Cheers
Abraham
-
Did not get a lot done.
The flywheel was set up on the rotab and centered.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00218.jpg)
Holes were drilled at all the comers of the cutouts.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00219.jpg)
The outer slots were milled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00220.jpg)
I did not realize how hard (abrasive) the cast iron was and destroyed and broken a few HSS end mills. Had to finish the operation wit a carbide end mill actually meant for aluminium, this also did not survive. :bang:
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00222.jpg)
To do the straight sections, I first gang drilled them and broke out the waist material.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00223.jpg)
Then started to machine the sides.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00224.jpg)
Still have to do 8 of 12 sides.
Cheers.
Abraham
-
Finally finished the flywheel cut outs. Milling this cast iron was very slow going.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00225.jpg)
Before removing the flywheel the rotab was centered.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00226.jpg)
The flywheel as it is at the moment.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00227.jpg)
The eccentric strap was set up and the outside milled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00233.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00234.jpg)
The slot was cut with a slitting saw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00235.jpg)
All done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00236.jpg)
The eccentric was set up and the grub screw hole drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00237.jpg)
The flywheel was set up with the aid of a mandrel and the grub screw hole drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00228.jpg)
The cut outs was cleaned and deburred with a dremel and a die grinder. It went back on the lathe for a bit of a polish.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00229.jpg)
And all the parts assembled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00230.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00231.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00232.jpg)
That’s all for now.
Cheers.
Abraham
-
All coming along nicely,Abraham :thumbup: . I do like the flywheel design,it looks very nicely proportioned and looks like it would scale up or down really well. Looking forward to seeing this baby running.....OZ
-
yep that's shaping up nice
-
Looks Great!!!! :clap: :clap: :beer:
ps. I had a tough piece of cast iron I couldn't drill. I stuck it in the orange embers in my woodstove for a bit and cooled it slowly in a bucket of wood ashes to see if I could anneal it, and sure enough, it softened right up and was a pleasure to work on the lathe with HSS tools. Haven't tried it on anything else since, but it did work that time.
-
Manxmodder, krv and Steve,
Tanks for the comments.
Steve,
Thanks for the tip.
Cheers
Abraham
-
Looks Great!!!! :clap: :clap: :beer:
ps. I had a tough piece of cast iron I couldn't drill. I stuck it in the orange embers in my woodstove for a bit and cooled it slowly in a bucket of wood ashes to see if I could anneal it, and sure enough, it softened right up and was a pleasure to work on the lathe with HSS tools. Haven't tried it on anything else since, but it did work that time.
I am currently building a Bengs Nick flame licker engine and when trying to drill the flywheel bosses I find they have been allowed to cool to quickly and as a consequence both have hard spots in the bosses.
I am going to heat them up to bright red and wrap them in glass wool insulation to anneal them to a machinable state.....OZ.
-
Oz, would the glass wool melt?
-
I'm only using it wrap them in after the torch has been switched off,but I think I'll just try it with a sample of scrap steel first to be sure.......OZ.
-
For the arm of the eccentric strap a piece of 3mm flat was machined flat on the one side and then the other side was set up with a shim on the left edge to machine it aper.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00238.jpg)
The wide end was machined square, using some aluminium wire to hold the part centered.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00239.jpg)
A hole was drilled in the other end.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00240.jpg)
The pieces were set up and silver soldered.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00241.jpg)
The joint was cleaned with a file and sand paper and the narrow end was rounded with a file.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00242.jpg)
All done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00244.jpg)
And installed on the engine.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00243.jpg)
For the cylinder a piece of cast iron was faced on both ends.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00245.jpg)
The cut line was marked all round with a slitting saw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00246.jpg)
The cut was completed with a hack saw and face milled. It was rotated 90deg. And the operation repeated.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00247.jpg)
The mounting holes and exhaust passage was drilled in one face.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00248.jpg)
The valve passages and mounting holes was drilled, milled and taped in the other face.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00249.jpg)
It was reset on end, making sure it was square in all directions, and the end machined to size. The centre of the cylinder was located and centre drilled, and the two cylinder head holes that are in line were drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00250.jpg)
The same was done on the other end. Then it was set at an angle and the steam passage to the end of the cylinder was drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00251.jpg)
And the other side.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00252.jpg)
To bore the cylinder I opted for doing it on the milling machine as it is more ridged than my lathe. Started by step drilling to 20mm and the switched to the boring head.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00253.jpg)
Only needs one finishing cut and the on to the lathe to turn the ends.
Cheers
Abraham
-
Some really helpful fabrication demos there. I particularly like the slitting saw grooving out the rough piece to be hacksawed. I definitely will find a use for that in the future. :thumbup: :clap: :beer:
-
Hi Steve,
As I do not have a band saw to make the cuts acuratly the orriginal idea was to slice it with the slitting saw, unfortuanatly my saw blades are all to small to make the cut, so came up with this method witch worked out well.
Cheers
Abraham
-
Abraham, marking wood with a square and then saw scoring all around before cutting through with a hand saw is the traditional Japanese joiner saw way of cutting a timber square without a miter box.
This is the same thing, with the added convenience of the slitting saw being held square and at the same height by the mill spindle while scoring all around.
-
Hi all,
Had a few household chores to do so did not get a lot done this week.
Amongst chores, took all my shavings and off cuts to the scrappy and managed to get a bit of funds for tools.
Finished the cylinder bore, leaving it a tad (precision engineering term) undersize to allow for honing. The steam passages on both ends were milled to the correct depth.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00254.jpg)
Turned a plug to go in the tailstock end to support the cylinder.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00255.jpg)
Turned down the outboard end.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00256.jpg)
Then flipped around and turned the inboard end.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00257.jpg)
After checking that the bore is running dead on centre, a small recess was cut to allow the head to fit.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00258.jpg)
Back to the mill to cut out the middle sections, again a very slow process.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00259.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00260.jpg)
Cheers
Abraham
-
Hi all,
Between a broken down compressor :bang:, visitors from South Africa and an extreme heat wave in Spain time in the shed was short and far between.
The middle sections were finally done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00261.jpg)
The cylinder was set up at 45 degrees to mill the comer off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00262.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00263.jpg)
It was moved to the rotab to round over the corner.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00264.jpg)
As I do not have any slot drills or centre cutting end mills, had to do lengthwise cuts in facets every one-degree.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00265.jpg)
While on the rotab the edge on the round ends was cleaned up.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00266.jpg)
The rotab was repositioned and the mounting holes were drilled in the heads.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00267.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00268.jpg)
The heads were then used as templates to drill and tap the cylinder ends.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00270.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00271.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00272.jpg)
All done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00269.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00273.jpg)
Had to re bore the cylinder as for some reason it was oval. Took the bare minimum out to get it round.
Then used a brake cylinder hone to finnish it.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00274.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00275.jpg)
The piston ended up with a bit more clearance than I would have liked, but decided to test it first before making a new one,.
Made the studs for the heads from threaded bar.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00276.jpg)
And the studs for the steam chest from bar.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00277.jpg)
The engine was assembled and I found a small error with the eccentric travel :bang:, somehow I machined it for only half of what is needed. Had no choice but to make a new one making double sure I had the travel correct.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00278.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00279.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00280.jpg)
And we have a runner, no gland packing or gaskets but it runs. :ddb: :ddb: :D :D :) :)
Not the best video but here she is.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/th_Running.mp4) (http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Running.mp4)
Need to make some accessories and tiding up a bit.
More to follow.
Cheers
Abraham
-
Very nice work Abraham :bow:
I would imagine that the cylinder became oval as the material relieved internal stresses as you machined the various outer features.
-
Lovely job,Abraham. That's a very nice looking engine you have there......OZ.
-
Well done!
-
Hi Andrew, OZ and Tom,
Thank you for the kind words.
Andrew,
You are right on the stresses plus this material has a lot of hard sections.
Cheers
Abraham
-
Been away for a couple weeks -- just catching up, so:
Great work Abraham, and Congratulations!!!
:clap: :clap: :clap: :clap: :clap: :thumbup: :beer:
-
Hi Steve,
Thanks for the kind worsds.
Cheers
Abraham
-
Hi all,
Made some oil cups for the bearings.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00281.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00282.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00283.jpg)
Drilled a lube hole in the connecting rod with a centre drill.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00284.jpg)
Made two more oil cups for the crosshead. Still need to drill and tap the mounting holes.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00285.jpg)
Set up the machine vice at an angle to mill the sides of the two bases with a “fake” draft.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00286.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00287.jpg)
The one side has a section at the bearing with no draft. It was first milled across to get a start for milling this side.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00288.jpg)
Next the vice was reset to normal and a setup made to mill the ends at an angle.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00289.jpg)
Both finished.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00290.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00291.jpg)
Cheers
Abraham
-
That looks even better! :thumbup:
-
in a word brill
-
Hi Modeldozer, I notice you used a digital protractor and this question is off topic I guess, but how do you go battery life wise? I find that my batteries will go flat in the drawer even though I routinely take em out when finished for the day. I may not need the protractor for a month or so and it's getting a tad bothersome. Perhaps it's the brand of battery? Or is it that I store them in the box with the protractor and naturally they get attracted to the magnetic base?
John B
-
Steve, krv,
Thank you kindly.
John,
Had it for a couple of years and is still on the orriginal batteries. I make a point of manually switching it off after use and leave the batteries in.
Cheers.
Abraham
-
I went to use mine the other day and they were flat also mind you I have to wonder if my son used it or not I'll have to pick up another and try round 2.
-
Really enjoyed following your project obviously a very good all round machinist-keep them coming very well presented as well
-
Thank you for the life span info of your batteries Abraham. I shall try some new ones and leave em in then see what happens. Wouldn't care too much if they weren't the more expensive size. There is an inclinometer app in my phone but naturally the phone body is slightly curved to assist handling - bummer that doesn't help.
-
Hi all,
Trapper,
Thank you for the comments.
Got a bit more finishing done.
The ends of the anchors also needed some fake draft, but as they are “complex “ curves and angles, they were milled on the CNC router.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00292.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00294.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00293.jpg)
Then the lathe broke down and spent a few days to repair it.
Printed some gaskets on gasket paper and made a few hole punches to cut the small holes.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00296.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00297.jpg)
Turned a mandrel for the piston to cut a groove for packing.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00298.jpg)
Also made a new piston rod from stainless steel.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00299.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00300.jpg)
At the moment busy polishing all the brass bits.
Cheers.
Abraham
-
Hi all,
The corners of the bearing posts and bottom crosshead guides were rounded over.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00301.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00302.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00303.jpg)
For accessories am adding a governor based on the one from Elmer’s twin rope drive.
For the throttle valve cover started by centering a piece of brass in the 4 jaw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00305.jpg)
Machined and threaded the boss.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00306.jpg)
Flipped around the end was faced.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00307.jpg)
For the throttle body started by drilling the valve bore and cover mounting holes in a squared and to size piece of brass.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00308.jpg)
A pilot hole was drilled through the length.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00309.jpg)
The pilot hole was used to center the part in the 4 jaw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00310.jpg)
A boss was turned, drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00311.jpg)
It was turned around and the other end was machined, unfortunately the photo did not come out.
The valve shaft was turned for a close fit in the body.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00312.jpg)
The parts so far.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00313.jpg)
The throttle was assembled and the pilot hole located to drill the passage through the body and valve.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00314.jpg)
Had to mill a piece of hex stock to a smaller size for the gland nut and lock nut.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00315.jpg)
It was drilled and taped in the lathe.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00316.jpg)
The nut was parted off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00317.jpg)
Both nuts done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00318.jpg)
And assembled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00319.jpg)
The various linkages were machined.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00320.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00321.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00322.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00323.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00324.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00325.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00326.jpg)
That’s all for now.
Cheers
Abraham
-
We have been away on a short holiday and I got so involved with finishing the governor that I am a bit behind in updating.
Because of a few tricky operations on the governor body it was made from aluminium. I could just squeeze it into a 25mm round bar.
The outer end was faced and turned down.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00327.jpg)
It was mounted in the collet chuck and the inner end faced and turned to size. The groove for the fork was cut with a parting off tool.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00328.jpg)
It was carefully drilled for the spring and shaft and the very end drilled through and taped for the adjusting screw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00329.jpg)
Then it was over to the mill to mill the ears flat, drill the holes for the weight arms and mill the slot for the drive pin.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00330.jpg)
After doing the same on the other side it was set up and the slot for the arms milled flush with the outer part. Holes were then drilled at the ends of the slot.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00331.jpg)
The slots were finished with a carbide single flute cutter that I normally use on the CNC router, as this is thin and long it was done very slowly.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00332.jpg)
The finished body. The “ears” will be filed round.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00333.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00334.jpg)
Next a piece of mild steel bar was turned down for the bearing end of the shaft.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00335.jpg)
It was swapped around and the end that fits in the body was turned down. A pocket was cut in the end for locating the spring.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00336.jpg)
It was then clamped in a V-block and set up on the mill to cut the two slots where the arms engage.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00337.jpg)
The V-block and shaft was then repositioned to drill the hole for the drive pin.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00338.jpg)
The shaft and body.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00339.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00340.jpg)
The weights were turned and then, after a bit of head scratching, clamped down like this on the fixed jaw of the milling vice to cut the slots for the arms.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00341.jpg)
For the arms a few pieces of 3mm plate was milled with a tiny upright on the one side (these will be filed to engage with the slots in the shaft).
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00342.jpg)
The other sides were milled down leaving material to file the pivot ears.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00343.jpg)
They were then held on their sides and the pivot holes located and drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00344.jpg)
Turning the pivot pins.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00345.jpg)
The pins were drilled for split pins.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00346.jpg)
Various other pins were made from 3mm and 2.5mm rod. Had to cut these with a cutoff disk in the Dremel as these rods are some mystery very hard material and could not me turned.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00347.jpg)
All the parts so far, after soldering, filling and a bit of cleanup.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00348.jpg)
The governor was assembled and tested in the lathe. A few different springs were tried until one was found that gave a nice smooth operation. With this spring it was at full travel around 600 RPM. Once fitted it might be tweaked a little more.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00349.jpg)
More to follow.
Cheers
Abraham
-
Superb work as usual,Abraham. This is going to be a very pretty engine indeed.....OZ.
-
OZ,
Thanks for looking in and the kind words.
Made a fixture to hold the levers for silver soldering.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00350.jpg)
Melted the one link a bit while soldering, unfortunately I only have 20% silver content rods.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00351.jpg)
Turning the small pulley using a thread cutting tool and feeding at halt angle with the compound.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00352.jpg)
Drilled out before parting off.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00353.jpg)
Turning the large pulley.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00354.jpg)
Both pulleys were drilled and tapped for a grub screw.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00355.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00356.jpg)
For the post a piece of aluminium was milled square and to size and then set up.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00357.jpg)
To drill the hole for the fork shaft.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00358.jpg)
It was flipped and the cutouts for the governor milled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00359.jpg)
And the shaft hole drilled.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00360.jpg)
Mounted upright to drill a oil hole with a small centre drill.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00361.jpg)
Flipped over and mounting holes drilled and taped.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00362.jpg)
Finished for now, some detailing might follow once tested.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00363.jpg)
Two bushes were turned from brass.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00364.jpg)
And fitted with retaining compound.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00365.jpg)
The floor was set up and the mounting holes were located, drilled and counter sunk.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00366.jpg)
With everything mounted the length for the connecting link was confirmed. The link was machined from a piece of 3mm plate.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00367.jpg)
Pins were silver soldered in, here with a coupling I made for the exhaust port.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00368.jpg)
All mounted on the engine, am waiting for some belt material to arrive.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00369.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00370.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00371.jpg)
Cheers
Abraham
-
With the collective parts all seen together the effect of all your painstaking detail work is really shining now.
Very impressive build :clap: :clap:.....OZ.
-
Abraham.
This build, just gets better and better! :thumbup:
Well done! :clap: :clap:
David D
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OZ and David,
Thanks for looking in and kind words.
The belt material arrived and a belt was made.
A video of the engine running and testing the governor.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/th_Test.mp4) (http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Test.mp4)
With the governor working, the post and valve was removed for some finishing work.
The post set up on the mill.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00373.jpg)
A few holes were drilled and bored.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00374.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00375.jpg)
The corners were rounded over.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00376.jpg)
The finished post.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00377.jpg)
The corners on the valve body were also rounded.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00378.jpg)
I needed a connector for the exhaust. Started by turning and drilling a piece of rectangular brass.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00382.jpg)
After cutting it off it was mounted in the collet chuck to face and put a radius on the outside of the flange.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00383.jpg)
I did not have any round brass for the outer part and had to turn down a piece of hex bar. The end was threaded 3/8-32 ME to take a commercial union nut. The inside was tapered with a centre drill for a union coupling.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00384.jpg)
The two pieces done.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00385.jpg)
The pieces were silver soldered together while soldering some other bits
The governor parts and exhaust connector after a bit of polishing.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00379.jpg)
The coupling mounted on the engine.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00386.jpg)
The governor remounted on the engine.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00380.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00381.jpg)
And finally a couple of videos of the engine running. (sound is unfortunately a bit bad)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/th_Finished1.mp4) (http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Finished1.mp4)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/th_Finished2.mp4) (http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Finished2.mp4)
I will be building a generator to go with the engine that I will post in a different thread. Once that is done they will be painted and mounted on a base.
Thanks to all for following along.
Cheers
Abraham
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.......Thanks to all for following along.....
:clap: :clap: :clap: :clap: :clap: :clap: :clap:
Thanks for taking us along for the ride.
Dave
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Hi all.
Am finally at the last stretch of this build.
For the base 4 pieces of wood had their ends milled at 45 degrees. The only way I had to hold them was an angle plate and two large gudgeon pins,
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00387.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00388.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00389.jpg)
They were milled to with.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00390.jpg)
And glued together.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00391.jpg)
Forgot to drill a hole in the one end piece and had to set it up on the lathe do drill it nice and square.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00392.jpg)
A mounting adaptor was turned from brass to fit in the hole in the base. A DC power connector will be fitted in the adaptor to supply excitation to the generator.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00393.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00394.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00395.jpg)
After the base was stained and varnished a DC motor speed controller and the connector were fitted inside.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00396.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00397.jpg)
Then the fun started with painting all the parts. In the end it took 4 tries and a change from brush enamel to aerosol spray. On the smaller parts the painting was done with an airbrush.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00398.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00399.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00400.jpg)
The cylinder was lagged using stained and varnished ice-cream sticks and bands made from brass shim stock.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00402.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00403.jpg)
The steam chest cover was engraved on the CNC router. (nearly 150000 lines of code and two and a half hours running)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00404.jpg)
And the background was painted.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00405.jpg)
Finally the completed engine set.
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00406.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00407.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00408.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00409.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00410.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00411.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00412.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00413.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00414.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00415.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00416.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00417.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00418.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00419.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00420.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00421.jpg)
(http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Elmer33/Image00422.jpg)
My dear wife assisted me in making a short video, it was a bit windy so the sound is not so good in a few places.
Thank you to for following along and encouragement given.
Cheers
Abraham
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VERY nice :bow:
And we promise not to tell your wife that you had it in bits on the dining room table :lol:
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Abraham - that is MAGNIFICENT - :bow: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap:
Dave
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What a lovely runner, the last finished pics were great i have enjoyed the build log. well done Abraham :beer: :clap: :clap: :clap: :clap:
John
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Perhaps I missed something but I don't understand the DC motor speed controller bit. If it runs on air/steam with a generator driven - why? OR is it a generator / motor thingy that you could use to run the engine that way if you had no steam or air?
:doh: :Doh:
John B
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Hi Andrew, Dave, John and John B,
Thank you all for the kind words.
John B,
The speed controller is used to set the excitation current for the generator which comes from an external 12V DC source.
Cheers.
Abraham
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Thank You Abraham,
I Learn heaps from this forum. Even if I do sometimes have to use a search engine to find out what an "Excitation Current" is. And, from my quick reading I think it is used in generators without permanent magnetic fields. Looking at your generator I see both armature and field windings so think I got it somewhat correct. OR is a generator without permanent magnetic fields called a Dynamo? That's what was on my push bike as a kid.
John B
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Hi John,
There is a bit more info in the build log of the generator here http://madmodder.net/index.php/topic,11170.0.html.
Cheers.
Abraham
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Thanks Abraham,
I followed the link and went right through that post again even though I recalled viewing it after a few posts. Well worth the refresher course and I can only echo other members, Great / Brilliant / Excellent work. Yea :clap: :clap: :clap: :clap:
John B
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Beautiful runner you have there! Thanks for taking us along on the journey! :beer:
Now that summer is coming I should get off my *ss and scratch my head about mine!
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Top marks to you Abraham :clap: :clap:,that engine is testimony to vast hours of painstaking detail work. It's a credit to your patience and skill,a real beauty :thumbup:
OZ.
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Beautiful job as always, Abraham. Thanks for sharing it with us.
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Hi Tom, OZ and Josha,
Thank you for the kind words.
Am busy with some machine mainanance and then have to decide on what next, quite fancy a beam engine, just need to find the correct plans.
Cheers.
Abraham
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Hi Abraham
Lovely job. :clap: :clap: I've followed the whole thread with interest. Thank you.
Russell
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Hi Russell,
Thank you for looking in and the kind words.
Abraham