MadModder
Gallery, Projects and General => Project Logs => Topic started by: jim on December 20, 2009, 05:23:13 AM
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well after a few weeks of making my mind up i started on the "poppin" engine today.
left the radiator on high last night, so the shop would be warm, got myself a free day!!
first job was to cut some 2 1/2" brass for the fly wheels, bandsaw set in action :dremel:
noticed it making some strange clicking noises, Ah, thought i, blade is on its way out, so changed the blade :thumbup:
the noise stayed :( and it wouldn't run true, kept dropping out of the bearings :( :scratch: :scratch: :scratch:
had a look, all looks ok :scratch: :scratch: gave it one more try and one of the bl**dy bearings went CRACK, split and the balls dropped out :doh:
so i've now got a busted saw and most likely won't get new bearings till after christmas ( i emailed chester and i'll probably order some new ones off ebay later anyway)
Right now my heart ain't in it, so i've come into the house, Mrs Jim has took pity on me and is making me some hot sausage rolls :D
its turned into one of the days :lol:
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didn't give up!
(http://i58.photobucket.com/albums/g270/jimmyocharlie/DSC00146.jpg)
that'll do for now, its been good to start :dremel:
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Yer off to a flyer Jim! :clap:
Great teamwork, between you & Mrs Jim....... Well done! :thumbup:
David D
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Good stuff Jim, don't give up, I don't have a power saw so I know it's annoying having to manually hacksaw through big dia. bar. You've done it now though!
As you know I'm doing a similar type engine, and if I can't get mine working I'll be giving poppin a go so watching with great interest.
Nick
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Yeah, Jim, that little metal cutting bandsaw is probably the most under-appreciated tool in the workshop. It's amazing how everything can come to a screeching halt when the bandsaw goes on the fritz! One of the reasons why I always keep extra blades in the shop.
Chuck
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Looks good from hear!!!
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well, got as much as i could before the festive day :D
drilled and bored the holes in the fly wheel sides.
got some 8mm o/d 4mm i/d bearings in the post today :) :)
i've made my first design stage to the plans today :scratch: i've made a "big end" bearing with a ball race rather than the plain bearing in the plans. i'm going to use a screw in conrod, theory being i can alter the piston travel easily (if needed).
:worthless:
i know, got called in and don't think it would go down to well with Mrs Jim to go back in the shed now with my camera :lol: :lol:
boxing day should see the crankshaft done
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Nice work Jim. Can't wait to see.
Nick
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got the cylinder and head done today, made a mistake with the flange thickness, but as its finished it'll have to do!
(http://i58.photobucket.com/albums/g270/jimmyocharlie/DSC00154.jpg)
the conrod with bearing
(http://i58.photobucket.com/albums/g270/jimmyocharlie/DSC00151.jpg)
holes bored in flywheels
(http://i58.photobucket.com/albums/g270/jimmyocharlie/DSC00150.jpg)
the only picture i took of something actually on a machine :doh:
(http://i58.photobucket.com/albums/g270/jimmyocharlie/DSC00153.jpg)
thats it for today, crankshaft is next on the list :scratch:
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Looking good jim. Yur making pretty good progress there :ddb: :ddb: :ddb:
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Some nice looking parts there Jim! :thumbup:
David D
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Nice 1 Jim,
I wouldn't worry about things like flange thicknesses either.
On the cylinder cover did you machine the angled recess on the rear? Also do you know why the flywheels have separate bosses? Is it just to make them easier to machine or something?
The ball raced conrod looks like a useful mod.
Nick
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On the cylinder cover did you machine the angled recess on the rear? Also do you know why the flywheels have separate bosses? Is it just to make them easier to machine or something?
i did the angled thing on the heads, i think that the seperate bosses are for ease of manufacture! if i'd realised i'd have made them all in one, but not to worry!
one thing i'm learning already is, next time i'll spend a bit more time with the plans AND a ruler BEFORE starting :lol:
important thing is that i'm enjoying it (so far)
Any joy with your flame gulper yet Nick?
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It looks like you are making some pretty good progress there. Thanks for sharing!!!
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Jim,
I thought it must be ease of manufacture, thanks. Well I've been looking at the plans incase I go down the poppin route! But with my experience on the other one I am now loathed to change anything and just build to print. Even the flywheel I didn't expect to be so critical but it now one of the things I'm looking at changing on mine! I fancy doing Poppin now anyway to be honest, more as an exercise to see if I have the skill it takes to get one running or it's me that is the problem! I will have to look to see if there's anything that really isn't critical. Like your con-rod, that is definitely a sensible modification.
No joy with mine yet, I haven't had a chance to get in the workshop over christmas thus far. I plan on going in tonight and every night until the 3rd Jan in a last ditch effort to get a runner. That could involve making a lighter flywheel and reaming the cylinder with an adjustable reamer to make sure it's round and parallel - but then I don't have any more cast iron to make the new piston and valve. I really need to get some otherwise I'll be introducing another variable with a different material! I was on you tube last night and found one that appeared to have a bronze sleeved cylinder with aluminium pistons though!
Anyway, back to your engine, you're doing great. What are your plans for the cam? Are you going to turn the larger OD then mark up and file the other bit or do you have something clever planned with the rotary table? I could really do with one of those next!
Nick
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Nick,
i made the bits to go in the flywheel today, i really would recommend doing that as a one peice flywheel!
did the piston, took a very long time polishing to size, i reckon its got a few tenths clearance, not sure if thats going to be too tight :scratch:
i was going turn a central recess on the piston, to reduce drag. but as you've pointed out, i need to walk before running!!!
i was going to mark out the cam and cut/file to size, the idea of using the rotary table is one i will be using :thumbup:
i want to get the crank done next (i've been putting it off), when i get the bandsaw going i'll do the frame for it. i think thats going to be the most involved part of this engine. i'm going to make a few alterations to this (but keep the dimensions the same).
biggest problem i'm having is not knowing what i can get away with sizes, at work i get a drawing with limits on :lol:
i'm looking forward to your "got it running!" post :proj:
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Jim,
Yeah, couldn't really see the point of the flywheel hubs - fair enough if you're going to use that tapered collet method, I wonder if it's just so he could get the grub screw in normal to the bore. Might as well turn in one at the same setting while it's all running true etc.
Not a bad idea on the piston might hold some oil in there too. What material is your piston / cylinder from and how did you lap / polish them them?
Will be interested to see your take on the crank then, you planning on cutting and machining from solid then? I think that's a step too far for me, I'll try the fabricated method!
Yes, since I started work I've yearned for model engineering drawings that are fully toleranced! Still - I'd probably have no way of measuring some of the geometric ones so doesn't really matter I guess! It'd give a nice warm feeling if we were making things inside the limits though :lol:
Fingers crossed. Other people have done it successfully so it can only be my fault really!
Nick
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made a bit more progress, still no bandsaw bearings :(
so rather than spend ages sawing some ally by hand, i found a bit that is (just) big enough, i'll have to mount it on a stepped base later now.
(http://i58.photobucket.com/albums/g270/jimmyocharlie/DSC00156.jpg)
(http://i58.photobucket.com/albums/g270/jimmyocharlie/DSC00155.jpg)
its a work in progress :lol: :lol:
i still need to drill a couple of holes for the valve bits.
making a bearing for the "big end" caused a small problem on clearance, but just needed to mill an extra bit of clearance, so no problem.
spins over ok and if i put my finger over the hole in the cylinder head, it won't turn over, its got a very good seal :thumbup:
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Not a bad idea on the piston might hold some oil in there too. What material is your piston / cylinder from and how did you lap / polish them them?
Will be interested to see your take on the crank then, you planning on cutting and machining from solid then? I think that's a step too far for me, I'll try the fabricated method!
too be honest, i'm not sure what material i've used. told an old guy at work what i was doing and they gave some some bits of bar, it cut ok(ish) :scratch:
i've done the crank to the drawing, it runs well. i'm learning a lot as i do this and having thoughts on my next engine. this one could be done by next weekend.
i've been really inspired by your engine :thumbup:
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By `ek Jim!
That`s looking good...... :clap:
David D
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Jim,
:bugeye: Wow you've made a lot of progress -nearly there and sounds promising. :thumbup:
Thanks - it's nice to know my engine inspired someone!
I'll won't take my eyes off this one, should be a little cracker.
Nick
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Jim,
Can I ask how you milled the frame? The instructions suggest keeping the stock longer and milling it on it's side, which is how the radii are formed, but I would be more comfortable milling with it upright if you understand what I mean, which would produce square corners.
Nick
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Nick,
first thing i did on the frame was to dill two holes, with it on its side, to give the rads.
next i milled the slot to blend in to the rads at the sides and bottom.
i then milled the part the crank goes into. once i'd got the sides to size, i drilled the pinch bolt holes for the crank bearings.
next was to flip it on its side and drill/bore to suit the bearings. once that was done i milled the slot that allows the crank to pass through.
next time, i'm going to take photos!
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Jim,
That sounds like a better method. Think i'll do it your way. I wanted to put a ball race on the big end as well, did you loctite your crank together? I can see it's pinned too, I was worried about the loctite getting into the bearing for the big end if I did that!
Nick
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Hi Nick and Jim,
I've been following your threads because I built a small flame gulper years ago that I never did get running, and while I made many changes and fixes, including some that made a difference in its reactions, never enough to get it to even turn over once on its own. I intend to return to a flame gulper when I am done with my current radial, and I'm interested in the "poppin" design, rather than go back to the one I didn't get running. Can you tell me where to get the plans for it? With regard to material, cast iron is among the easiest to scrounge, at least here in the states. A good source of fair quality cast iron in scrap is an old lawn mower engine, using the crank for shafting, and various lumps for what they are a good size for. Iron plates from weight lifting machines, or even new bar bells can be decent cast iron and useful, as well as being fairly large chunks.
It looks like you're on the way to a successful engine build, and just a few bits of work away from showing it off, Jim, looking forward to it running.
mad jack
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i'm still working on it, just need to get the valve to seal better!
no time this weekend, work to do :doh:
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Mad Jack,
yes, they are tricky little things to get running and I had to persevere a lot to get my other one going! I am not expecting this one to be easy either!
Jim, good luck. Unfortunately I haven't started mine, have been quite busy with other stuff which is why I haven't been on for a bit.
Nick
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mines still awaiting the the final push!
been busy on other jobs :(
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great joy!!!
it runs!!!!
spent a couple of hours in the shed, got it to run!!
took me a good while to get the .002" shim valve to seal, but once it was sorted, it ran!
i'd left the camera on, so that had a flat battery, by the time i'd got my phone out to film it, it was running great. filmed it and now can't upload the video to the computer!
but, it was fantastic to see it run!!!!
i'm now settling down with a few cans to celebrate!!!
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"Oh happy day"....... :ddb: :ddb:
Blummin well done Jim! :clap:
Can see your smile from here....... :thumbup:
David D
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Brilliant Jim, I think we would all love to see the vid when you can manage it.
Well done, that's a neat looking engine :clap: :clap: :clap:
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I will give it a clean down and have another run at the weekend.
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Well done Jim, :thumbup: :thumbup: brilliant aren't they, very difficult to get running at all so 1st time - respect for that :bow: :beer: really need to get motivated and back in the garage to finish mine! Other obstacles got in way in the workshop and out unfortunately.
Nick
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Well done Jim, :thumbup: :thumbup: brilliant aren't they, very difficult to get running at all so 1st time - respect for that :bow: :beer: really need to get motivated and back in the garage to finish mine! Other obstacles got in way in the workshop and out unfortunately.
Nick
the worse part was getting the valve to seal, i need to lengthen the valve shaft and try a thicker shim. now i know its a runner, my enthusiasum has returned!!!
how's yours going??