MadModder

The Shop => Metal Stuff => Topic started by: doubleboost on March 11, 2011, 05:28:42 PM

Title: Mill Engine
Post by: doubleboost on March 11, 2011, 05:28:42 PM

Hi
I seem to have gotten bogged down with my v twin marine engine  :( :( :(
 So i have started another project.

Going to build a big mill engine :D :D :D :D
I made a start on a pattern for the cylinder
I want it to have a 4 inch stroke and a bore of at least 2 1/2 inch no bolts smaller than 5 mill  :) :) :) :)
It will be double acting with a slide valve , nice and big and simple  :) :) :)
Once i have my cylinder i will be able plan things out
Glued some magic wood together last nite
(http://i261.photobucket.com/albums/ii63/john970s0/P3100001.jpg)

Started to square up the ends for the driving dog
(http://i261.photobucket.com/albums/ii63/john970s0/P3110010.jpg)
Poor boxford is contaminated again  :( :( :( :(

Title: Re: Mill Engine
Post by: saw on March 11, 2011, 05:32:02 PM

What happend with your'e v twin marine engine ?  :smart:   

Title: Re: Mill Engine
Post by: doubleboost on March 11, 2011, 05:37:27 PM

It is about 80 % done just seem to have lost interest  :( :( :(
It will come back and i will finish it :D :D :D :D
Just needed a change from fixing machines and making tooling  :doh: :doh: :doh:

Title: Re: Mill Engine
Post by: saw on March 11, 2011, 05:41:55 PM

Ok I missundersud you, I thought som shocking hade happend (dropped on the floor ore something
). I can understand that you need something else to do.  :thumbup:

Title: Re: Mill Engine
Post by: Bernd on March 11, 2011, 07:35:34 PM

Neat idea of using the spindle for a clamp.  :clap:

Bernd

Title: Re: Mill Engine
Post by: doubleboost on March 12, 2011, 03:49:42 PM

Got a bit more done on the cylinder pattern
(http://i261.photobucket.com/albums/ii63/john970s0/P3120013.jpg)

MDF needs to run fast with a heavy cut  :D :D :D

(http://i261.photobucket.com/albums/ii63/john970s0/P3120016.jpg)

(http://i261.photobucket.com/albums/ii63/john970s0/P3120005.jpg)

(http://i261.photobucket.com/albums/ii63/john970s0/P3120006.jpg)

(http://i261.photobucket.com/albums/ii63/john970s0/P3120002.jpg)

Title: Re: Mill Engine
Post by: saw on March 12, 2011, 04:00:54 PM

Looking good.  :thumbup:

Title: Re: Mill Engine
Post by: doubleboost on March 13, 2011, 07:46:15 PM

More sanding and filling :( :( :(
(http://i261.photobucket.com/albums/ii63/john970s0/P3130012.jpg)

(http://i261.photobucket.com/albums/ii63/john970s0/P3130009.jpg)

(http://i261.photobucket.com/albums/ii63/john970s0/P3130016.jpg)

getting there
(http://i261.photobucket.com/albums/ii63/john970s0/P3130025.jpg)

Title: Re: Mill Engine
Post by: doubleboost on March 20, 2011, 04:01:21 PM

Today i managed to turn the wood in to bronze
TWICE  :( :( :( :(
(http://i261.photobucket.com/albums/ii63/john970s0/P3190002.jpg)
Pattern all ready to go
(http://i261.photobucket.com/albums/ii63/john970s0/P3190004.jpg)
Core mould and cores
(http://i261.photobucket.com/albums/ii63/john970s0/P3200009.jpg)
Top half of mould showing feeder and riser
(http://i261.photobucket.com/albums/ii63/john970s0/P3200016.jpg)
Core in place
(http://i261.photobucket.com/albums/ii63/john970s0/P3200017.jpg)
Top half of mould showing "gate "
(http://i261.photobucket.com/albums/ii63/john970s0/P3200036.jpg)
Smoking core
(http://i261.photobucket.com/albums/ii63/john970s0/P3200041.jpg)
Looking good
(http://i261.photobucket.com/albums/ii63/john970s0/P3200052.jpg)

The finished casting
You can see how the metal has not filled the port face fully
Rob Wilson came over for an inspection
We re cast it with the same result.
Some mods to the pattern and moulding method and the job should be a good one

Title: Re: Mill Engine
Post by: saw on March 20, 2011, 04:14:51 PM

Good luck with redone the job.  :thumbup:

Title: Re: Mill Engine
Post by: doubleboost on March 27, 2011, 04:59:28 PM

Took Rob Wilsons advice and split the patern the other way. :thumbup: :thumbup: :thumbup:
This also gave the opertunity to add the exhaust port flange and cylinder drains.
After much sanding and filling the finished patern
Hopefully this will be cast this week  :) :) :) :) :)
(http://i261.photobucket.com/albums/ii63/john970s0/P3270054.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/P3270056.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/P3270057.jpg)
(http://i261.photobucket.com/albums/ii63/john970s0/P3270058.jpg)

Title: Re: Mill Engine
Post by: Rob.Wilson on March 27, 2011, 05:13:16 PM

 :clap: :clap: :thumbup: Looking great john


Rob

Title: Re: Mill Engine
Post by: doubleboost on April 03, 2011, 03:58:35 PM

Today the plan was to turn the nice red patterns into bronze
I have been looking forward to this all week
Yesterday i baked the cores and rammed up the moulds
These were carefully assembled ready to cast today
Extended risers were used to make sure the mould would fill completly
(http://i261.photobucket.com/albums/ii63/john970s0/P4030070.jpg)

Rob Wilson called in to oversee the pour
(http://i261.photobucket.com/albums/ii63/john970s0/P4030069.jpg)
Cylinder we cast last time ready to melt
Fired up the furnace soon had a nice crucible of liquid bronze
The pour went ok but i seemed to be short on metal
The pattern is biger than last time

(http://i261.photobucket.com/albums/ii63/john970s0/P4030076.jpg)

Not looking to bad

(http://i261.photobucket.com/albums/ii63/john970s0/P4030075.jpg)

Not enough metal
On closer inspection the core had collapsed
(http://i261.photobucket.com/albums/ii63/john970s0/P4030074.jpg)
Rob examined the miserable looking casting his verdict

The damp casting sand had softend the core ccausing it to break up during the pour
Wont be making up any more moulds the night before
Going to cast it in aluminium tomorrow nite just to make sure the crucible holds enough metal
If it was easy every one would be doing it

Title: Re: Mill Engine
Post by: Bogstandard on April 03, 2011, 05:21:57 PM

John,

Quote

If it was easy every one would be doing it

And most probably walking on water as well. :med:

I find you learn more from making mistakes than doing it right first time, and thanks for showing that we all have problems sometimes.

I'm sure you will have a Cheshire Cat grin soon. :D


John