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Offline saw

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Building Stuarts Compound Steam Engine
« on: July 22, 2012, 04:12:12 PM »
 Building Stuarts Compound Steam Engine
Hello Gentlemen.
It was a while ago sense I have built something, in fact nothing sense I finish my D10. I have been full up with a lot of other activity..
For a while ago I manage to get my hands on a Stuarts Compound casting, it’s impossible to buy from Stuart Turner so I was very pleased to get my hands on this for a good price.

This casting is radar old I believe from 1980 but looks radar god, so now I am going to put up a building log here, I hope that you will like it   :D
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__609.jpgBuilding Stuarts Compound Steam Engine
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Rob.Wilson

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Re: Building Stuarts Compound Steam Engine
« Reply #1 on: July 22, 2012, 04:48:29 PM »
Evening Benni

I will be tuning in for this build  :thumbup: ,, the castings do look good quality  :med:



Rob
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Offline krv3000

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Re: Building Stuarts Compound Steam Engine
« Reply #2 on: July 22, 2012, 05:31:41 PM »
yep i will be tund in to this to
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Offline Don1966

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Re: Building Stuarts Compound Steam Engine
« Reply #3 on: July 22, 2012, 09:23:22 PM »
I am in on this built. I want to build a compound engine so I am in till the end.

Don
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Offline Dan Rowe

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Re: Building Stuarts Compound Steam Engine
« Reply #4 on: July 23, 2012, 09:15:07 AM »
Any marine engine will get my attention for sure, I have some old Stuart kits that will make it to the bench sometime so it will be fun to watch this build.

Dan
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Offline Don1966

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Re: Building Stuarts Compound Steam Engine
« Reply #5 on: July 23, 2012, 11:20:07 PM »
There is a built on http://compound.modelengines.info/ on the compound launch you made be interested in. Still following with interest.

Don
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Offline saw

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Re: Building Stuarts Compound Steam Engine
« Reply #6 on: July 26, 2012, 04:16:22 PM »
The Soleplate
Hello gentlemen.
Thanks for nice comments, I know that this project will take a long time for me to build, but who is in hurry?
Don1966: Yes I know this gentleman, in fact it’s thanks to Mr. John R. Bentley that I found this casting.The first picture shows the Soleplate from the top..
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__613.jpgBuilding Stuarts Compound Steam Engine
..and the next from the bottom.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__615.jpgBuilding Stuarts Compound Steam Engine
The first thing was to use a flat file to smooth over the bottom. Then check out where all the holes, and fixes the midline. After that some work in the millhttp://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__616.jpgBuilding Stuarts Compound Steam Engine

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__617.jpgBuilding Stuarts Compound Steam Engine

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__619.jpgBuilding Stuarts Compound Steam Engine
I was using a center drill to mark out the midline, and then I have to drill for the columns. http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__620.jpgBuilding Stuarts Compound Steam Engine
..and threading for the columns
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__621.jpgBuilding Stuarts Compound Steam Engine

After that I have to drill the whole for the main bearings and smooth the surface.

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__622.jpgBuilding Stuarts Compound Steam Engine
And even some milling on the edges http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__623.jpgBuilding Stuarts Compound Steam Engine

 And the bottom.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__627.jpgBuilding Stuarts Compound Steam Engine


 Then it’s was necessary to use a flat file emery cloth and a bit polish.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Soleplate/Soleplate__628.jpgBuilding Stuarts Compound Steam Engine
So far I am quite happy with the result  :) .  I have measured and measured again, but things seem to measure up. The soleplate is very important, everything here  must be correct otherwise I think I will have some problem..  :headbang:
I’ll be back.    :coffee:

 
 

 
« Last Edit: July 26, 2012, 06:14:13 PM by saw »
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Offline doubleboost

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Re: Building Stuarts Compound Steam Engine
« Reply #7 on: July 26, 2012, 04:24:20 PM »
Hi Benni
You are off to a good start  :drool: :drool: :drool:
I do like marine engines
Looking forward to future installments  :thumbup: :thumbup:
John

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Offline NickG

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Re: Building Stuarts Compound Steam Engine
« Reply #8 on: July 28, 2012, 10:16:00 AM »
Hi Benni, looking forward to this one too, bit different from the norm. Wish I could get my hands on some cheap castings as I am keen to have a go at some, however the price seems to have shot through the roof in recent years!

Nick
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Offline Alan Haisley

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Re: Building Stuarts Compound Steam Engine
« Reply #9 on: July 28, 2012, 01:26:44 PM »
Benni,

This looks like you will have a lot of fun with the build. I'm tagging along to share in it.  :drool:

Alan
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Offline saw

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Re: Building Stuarts Compound Steam Engine
« Reply #10 on: July 28, 2012, 04:11:07 PM »
Hello gentlemen.
Thanks for nice feedback, it always helps to make the project just a bit better when feedbacks are dropping in.
Columns.
Now it’s time for the columns, there are five and made of mild steel. According to Mr. John R. Bentley, it would be nice to make some small modifications comparing to Stuarts drawing.
They want to have 2BA on both ends, but I am threading 2BA on one end and the other with 4BA because the nuts will be too big with 2BA.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Columns/Column_629.jpgBuilding Stuarts Compound Steam Engine

With some turns in the lathe will give me the dimensions for threading 4BA.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Columns/Column_630.jpgBuilding Stuarts Compound Steam Engine

After all columns were finish I drill and thread the nuts.
 http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Columns/Column_650.jpgBuilding Stuarts Compound Steam Engine
 
The nuts fit radar good…
 http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Columns/Column_652.jpgBuilding Stuarts Compound Steam Engine
 
.. and it don’t looks so bad either.
 http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Columns/Column_631.jpgBuilding Stuarts Compound Steam Engine
 
This was just a small update but..
 
I’ll be back.  :headbang:
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Offline Stilldrillin

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Re: Building Stuarts Compound Steam Engine
« Reply #11 on: July 28, 2012, 04:33:10 PM »
I'm watching quietly, Benni.  :wave:

I have to say your machined surfaces are much brighter than Rob Wilson's...... Well done!  :clap: :clap:

Good luck with the build.....  :thumbup:

David D
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Offline rudydubya

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Re: Building Stuarts Compound Steam Engine
« Reply #12 on: July 28, 2012, 04:37:33 PM »
A really nice finish on the soleplate Benni.  I'm looking forward to following along with your build.

Regards,
Rudy
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Offline saw

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Re: Building Stuarts Compound Steam Engine
« Reply #13 on: August 01, 2012, 12:32:43 PM »
 Main Bearings
Hello Gentlemen
Thanks fore nice comments
Now it’s time for the main bearings, it’s a little tricky because it’s very impotent that the main bearings are in strait line to the soleplate for the crankshaft. Otherwise it will be a major problem.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_632.jpgBuilding Stuarts Compound Steam Engine

The first is to milling the edges…
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_633.jpgBuilding Stuarts Compound Steam Engine
… and the bottoms.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_634.jpgBuilding Stuarts Compound Steam Engine
Then mark out for the center line and the bolt holes.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_636.jpgBuilding Stuarts Compound Steam Engine
Drilling the bolt holes…
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_637.jpgBuilding Stuarts Compound Steam Engine
…and checking that all fits good together.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_638.jpgBuilding Stuarts Compound Steam Engine
Then marking up the centerline with a center dub.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_639.jpgBuilding Stuarts Compound Steam Engine
Milling the top for the nuts to fits better.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_641.jpgBuilding Stuarts Compound Steam Engine
Is it beginning to looks good?
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_643.jpgBuilding Stuarts Compound Steam Engine
Now with a ¼“ ball nose end mille mile the main bearings for the crankshaft…
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_645.jpgBuilding Stuarts Compound Steam Engine
…and also the soleplate.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_646.jpgBuilding Stuarts Compound Steam Engine
The last is to drill and reaming for full size. I first drill 6.5 mm then 6.8 then reamed for 7.00 mm. Then drilling for 7.5 and 7.8 and finally reamed for 8.0 mm.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_647.jpgBuilding Stuarts Compound Steam Engine
And here we go, it begins to looks radar good… http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_648.jpgBuilding Stuarts Compound Steam Engine
…and all dimensions are perfectly suited. http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Main_Bearings/Main_Bearings_720.jpgBuilding Stuarts Compound Steam Engine
I feel radar happy so far, but it’s much work to be done before I can see the end….  :)
I’ll be back.
 




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Offline NickG

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Re: Building Stuarts Compound Steam Engine
« Reply #14 on: August 02, 2012, 02:07:12 PM »
Hi Benni, I would never have thought of that method for the bearings - unorthodox but looks to have been very effective! Well done
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Offline mzt

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Re: Building Stuarts Compound Steam Engine
« Reply #15 on: August 03, 2012, 07:31:58 AM »
Hi Benni,

I have ideas that Your method of drilling the bearings worked because You went from 1/4" dia. to a round and straight (as much as reamers would do in those fields) 7 mm in light steps.

I had recently tried drilling a (large) split bearing I had bored undersize and then split using the remaing 'oval' as a guide for a larger drill.  --> Scrap
Next one, I tried milling a square groove on the bearing line, into the two halves. --> Scrap again.
What worked for me was milling an identical V groove on both halves of the third workpiece.
Not sure I will try Your method on next occasion. Neither sure I won't, though.

Nice work, btw.  I'll be following this thread.

Marcello

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Offline Stilldrillin

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Re: Building Stuarts Compound Steam Engine
« Reply #16 on: August 03, 2012, 01:12:51 PM »
Those bearings were very nicely done Benni!  :clap: :clap: :thumbup:

David D
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Offline sbwhart

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Re: Building Stuarts Compound Steam Engine
« Reply #17 on: August 03, 2012, 01:42:17 PM »
Looking good Benni I,ve bin following along quetly  :clap: :clap: :clap: :clap:

Stew
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Offline saw

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Re: Building Stuarts Compound Steam Engine
« Reply #18 on: August 04, 2012, 06:19:51 AM »
 The Crankshaft 
ThanksNickG, mzt, Stilldrillin and sbwhart for nice feedback.
You are so right this is not the ordinary way for drilling the main bearings, I tried many different ways and a lot of coffee before I came up with this solution. However it works and that is all that matters, right?

Now to the crankshaft, I am sorry, I use to take a lot of picture, but I have forgot some in the beginning.
I cut off tree pieces of 8 mm silver steel, one 150 mm, and two 19.1 mm. On the small ones I turned down a 4.95 mm long edge to 7 mm at both ends.
Then I cut off four pieces of mild steel...
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crankshaft/Crankshaft_735.jpgBuilding Stuarts Compound Steam Engine
… and market out and drill two holes, one 8 mm and one 7 mm. I drilled undersize and reamed to correct size.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crankshaft/Crankshaft_736.jpgBuilding Stuarts Compound Steam Engine
Then some turns in the lathe so I could get a smooth radio…
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crankshaft/Crankshaft_737.jpgBuilding Stuarts Compound Steam Engine
… and back to the mil for drilling holes for the pins.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crankshaft/Crankshaft_738.jpgBuilding Stuarts Compound Steam Engine
After that I assembled all the pieces...
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crankshaft/Crankshaft_740.jpgBuilding Stuarts Compound Steam Engine
… and drilled the holes for the pins, mount the pins and soldered the pieces together.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crankshaft/Crankshaft_795.jpgBuilding Stuarts Compound Steam Engine

And here we go, we have a crankshaft. I know that many people preform to turn the crankshaft in the lathe, I have tried that a couple of times so I took it safe rather than sorry.

So far so god but…  :med:

I’ll be back
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Offline NickG

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Re: Building Stuarts Compound Steam Engine
« Reply #19 on: August 05, 2012, 06:08:18 AM »
I like that method, same as I used for the 'poppin' flame lickers although I didn't pin as the power of them is so low. Didn't you fancy trying the cast crank then?

Nick
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Offline saw

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Re: Building Stuarts Compound Steam Engine
« Reply #20 on: August 06, 2012, 11:43:56 AM »
The Flywheel.
Hello Gentlemen
Thanks for nice feedback.
 Well, now it’s time for the flywheel. It’s not a tricky part, just a few turns on the lathe.
 First in the lathe, I fix the surface and drilled and reamed the hole for the crankshaft..

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Flywheel/Flywheel_730.jpgBuilding Stuarts Compound Steam Engine

…then then half of the outside…

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Flywheel/Flywheel_731.jpgBuilding Stuarts Compound Steam Engine

…after I did the same with the other side.
Then drilled and threaded for the stop screw.

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Flywheel/Flywheel_732.jpgBuilding Stuarts Compound Steam Engine

After some polish…

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Flywheel/Flywheel_733.jpgBuilding Stuarts Compound Steam Engine

Not too bad. This was just a miner update but…    :coffee:

I’ll be back.
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Offline saw

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Re: Building Stuarts Compound Steam Engine
« Reply #21 on: August 08, 2012, 06:10:27 AM »
Crosshead Guides.
Hello Gentlemen
The update continues, this time it’s the crosshead guide that need to bee done.
It is therefore critical that all dimensions must be exact.

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_721.jpgBuilding Stuarts Compound Steam Engine

I first begun with the fly cutter for a smooth surface…

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_722.jpgBuilding Stuarts Compound Steam Engine

… then some milling and …

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_723.jpgBuilding Stuarts Compound Steam Engine

…drilling and reaming the holes for the columns.

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_724.jpgBuilding Stuarts Compound Steam Engine


Then milling the radios…

 http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_725.jpgBuilding Stuarts Compound Steam Engine

…then drilling…

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_726.jpgBuilding Stuarts Compound Steam Engine

…and threading for the stop screw.

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_727.jpgBuilding Stuarts Compound Steam Engine

And now checking…

http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead_728.jpgBuilding Stuarts Compound Steam Engine

… and it looks like everything is ok.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Crosshead/Crosshead__796.jpgBuilding Stuarts Compound Steam Engine

Even this was just a miner update, but those things are necessary for the complete engine.
I’ll be back.
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Offline Ray

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Re: Building Stuarts Compound Steam Engine
« Reply #22 on: August 08, 2012, 08:19:56 AM »
That is really looking great. :thumbup:

Ray
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Offline Stilldrillin

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Re: Building Stuarts Compound Steam Engine
« Reply #23 on: August 09, 2012, 03:51:53 AM »
Quote from: saw on August 08, 2012, 06:10:27 AM

… and it looks like everything is ok.


And.... Everything looks ok from here too, Benni!  :clap: :clap: :thumbup:

David D
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Offline saw

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Re: Building Stuarts Compound Steam Engine
« Reply #24 on: August 10, 2012, 08:38:32 AM »
Hello Gentlemen.
Thanks Ray Stilldrillin for nice komments.
Oil Cups

You must be wandering what I am up to, but I feel to play around a bit with the oil cups.
Ones again I follow a suggestion from Mr. John R. Bentley  and I am not going to use brass, instead I am using hexagon steel bar.

 http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_797.jpgBuilding Stuarts Compound Steam Engine
As you can see on my skis, it’s a very simple oil cup, but it will stand out.
So, first in the lathe where I marked out the length and prepare for the threading.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_802.jpgBuilding Stuarts Compound Steam Engine
 
Then I threaded the oil cup…
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_809.jpgBuilding Stuarts Compound Steam Engine
 
… and some deep turns so the threading can go to the bottoms.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_805.jpgBuilding Stuarts Compound Steam Engine
 
Then some more turns on the lathe …
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_806.jpgBuilding Stuarts Compound Steam Engine
 
… so that I can shape the cups.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_807.jpgBuilding Stuarts Compound Steam Engine
 
Then drilling a 1 mm hole from the bottom.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_808.jpgBuilding Stuarts Compound Steam Engine
 
After cut off I turn the cup around and drilled 4.5 mm hole.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_810.jpgBuilding Stuarts Compound Steam Engine
 
And after some clean up I feel radar pleased.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_811.jpgBuilding Stuarts Compound Steam Engine
 
And they fit well with the rest of the engine.
http://i1123.photobucket.com/albums/l558/Benni_Svensson/Stuart%20Compund/Oil_Cups/OilCups_813.jpgBuilding Stuarts Compound Steam Engine
 
Again no big update, but now it will take a while before I post something new, I will begin whith the cylinder block.
I’ll be back
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Greetings / Benni
http://myprojecty.wordpress.com/category/steam-engine/
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