Author Topic: Making a Deesil Pattern.  (Read 13608 times)

Offline stevehuckss396

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Making a Deesil Pattern.
« on: November 28, 2012, 03:00:12 AM »
Things have slowed down at work and I'm back on a normal schedule. One of the things I did while
working was shoot off my big mouth and agree to make a pattern for a crankcase. Well I am finally
getting it done after promising many months ago that I would do it when I got time.

The prez of my metal club Rick does casting demos at the engine shows and some other clubs in
the area. Someone approched Rick at one of the shows about the Deezil engine. This fellow has
one of the castings for the crankcase but is afraid to machine it. He asked Rick if he could cast
practice cases. Well we figured why not. After the cases are cast he could still use the pattern
for his demo's and give the cases away to anyone who wants to build the engine.

Because there is no way to cast the cases exactly like the original, here is the plan. The cases will
be cast with MDMC (Metro Detroit Metalworking Club) on the front of the block instead of DEESIL.
This way the blocks we cast will never be confused with the "real" Deesil cases. The case will
be machined and a new crankcase drawing will be on our website for download. All the other
original Deesil parts will fit. The plans can be purchased on CD ROM from ron over at Model
Engine News.

After reverse engineering the casting I drew up the case in Alibre. Then I assembled 4 cases
on a hub and saves it as a STL file. The STL file was opened in CamBam and all the tool paths
were created. CamBam created some 280,000ish lines of code. I took the Gcode to the computer
in the garage and opened it up with Mach3 and here is how it went.


First roughing pass. The material was provided by Rick. It is called Renboard? It's kind of like a
cross between plastic and wood. It's very dense and stable. Machines real nice.

First pass




Third pass




Fifth pass




Seventh Pass




Ninth Pass




Roughing out complete





The center section was finished using a 1/8 inch cutter. The cutter started on the left side and went down
following the contour of the part. The cutter moved to the right just a few thou and went back up. The
process was continued until the center section was finished.





Then because there were some tight spots to get into, a 1/16 inch cutter was used to finish the rest of the
pattern.





Then the entire thing was cut out to the correct thickness to complete the first of 10 pieces.




The other pieces are simple and should not take long to make.
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline Jo

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Re: Making a Deesil Pattern.
« Reply #1 on: November 28, 2012, 07:41:32 AM »
Wow :o,

You make it look so easy. How long did it take to design the pattern using Alibre and then to convert it into a machining program?

Jo
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Offline ths

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Re: Making a Deesil Pattern.
« Reply #2 on: November 28, 2012, 10:44:28 AM »
Fantastic pattern, Steve, and it looks to have a superb finish. Is shrinkage allowance built in, and is there a draw taper there as well?

I'm not familiar with the engine, is there a link to find out more?

Cheers, Hugh.

Offline steamer

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Re: Making a Deesil Pattern.
« Reply #3 on: November 28, 2012, 10:53:51 AM »
Cool Steve!...er ah "Bubba"!   Welcome Back!

I'm watching!

Dave
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Damned ijjit!

Offline maury

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Re: Making a Deesil Pattern.
« Reply #4 on: November 28, 2012, 01:55:48 PM »
'396, You are doing exactly what I'm trying to set up to do. Very nice work! I have been making all of my patterns in the wood shop, and while it's relaxing and fun, I find my accuracy could be better sometimes, and the complex curves are difficult to match on the cope and drag. CNC solves that.
I'm just getting into Solidworks, an absolutely awesome piece of software, and will be using BobCam for Solidworks.

Been learning tool path options this week. I have a few questions, don't know whether it would be better to take it off line, or share with everyone on the board, may just add a lot of fluff. First off, I had a friend CNC a pattern for ma on my last project, and he used what looks like your Ren Board. Really nice stuff, found Freeman Supply carries it, same place I get some of my other foundry supplies. What tooling do you use to cut it, (HSS or carbide), and what feed/speed would you use to cut it. I want to set it up as a material in BobCad.

maury
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Offline ScroungerLee

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Re: Making a Deesil Pattern.
« Reply #5 on: November 28, 2012, 02:09:25 PM »
The finishing pass with a 1/16 bit must have taken a loooong time!  It looks great, I will have to investigate this Ren board material.

Lee
Mmmmm.... Shiny!

Offline tvoght

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Re: Making a Deesil Pattern.
« Reply #6 on: November 28, 2012, 02:19:14 PM »
Steve,
First off, it was good to talk to you in Zanesville in October. Maybe you remember.

Some time ago, I bought the casting for the Deezil form Roger Schroeder. I started the build, and somewhere in the process, I ruined the casting. Since I had already accumulated some stock, and worked out procedures, and made some fixturing, I intended to get another casting and give it another try in the future. Sadly, in the meantime Roger Schroeder passed away.

Anyway, good and interesting work on the patterns.

--Tim

Offline stevehuckss396

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Re: Making a Deesil Pattern.
« Reply #7 on: November 28, 2012, 09:57:52 PM »
Wow :o,

You make it look so easy. How long did it take to design the pattern using Alibre and then to convert it into a machining program?

Jo

Rough guess?

Draw the case took about 3 hours because I would draw and then machine it in cad. When I finally got it to where I thought it should be I went back and added material for shrinkage and a little to machine off.

CamBam was only about an hour.

Cut time was about 5 hours. It takes a long time to finish when it only steps over a few thou at a pass.
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline stevehuckss396

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Re: Making a Deesil Pattern.
« Reply #8 on: November 28, 2012, 10:03:05 PM »
Fantastic pattern, Steve, and it looks to have a superb finish. Is shrinkage allowance built in, and is there a draw taper there as well?

I'm not familiar with the engine, is there a link to find out more?

Cheers, Hugh.

Shrinkage is considered as well as a 2 degree draft everywhere and all corners have a slight radius.

http://modelenginenews.org/engine_finder.html

Click this link and search for Deesil.
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Offline stevehuckss396

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Re: Making a Deesil Pattern.
« Reply #9 on: November 28, 2012, 10:07:35 PM »
What tooling do you use to cut it, (HSS or carbide), and what feed/speed would you use to cut it. I want to set it up as a material in BobCad.


I use HSS and usually a ball nose. I run the spindle flat out which is about 3500rpm. I rough cut at 60ipm and finish at 40.
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Offline stevehuckss396

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Re: Making a Deesil Pattern.
« Reply #10 on: November 28, 2012, 10:09:13 PM »
The finishing pass with a 1/16 bit must have taken a loooong time!  It looks great, I will have to investigate this Ren board material.

Lee

Yeah!  But I wanted to do the entire finish cut without a tool change and there are so many tiny little corners.
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Offline stevehuckss396

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Re: Making a Deesil Pattern.
« Reply #11 on: November 28, 2012, 10:11:42 PM »
Steve,
First off, it was good to talk to you in Zanesville in October. Maybe you remember.

Some time ago, I bought the casting for the Deezil form Roger Schroeder. I started the build, and somewhere in the process, I ruined the casting. Since I had already accumulated some stock, and worked out procedures, and made some fixturing, I intended to get another casting and give it another try in the future. Sadly, in the meantime Roger Schroeder passed away.

Anyway, good and interesting work on the patterns.

--Tim


If this goes well I'll send a casting your way. Rick always casts at names so if this pattern is ready by then, I'll make sure he saves one for you.
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline ths

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Re: Making a Deesil Pattern.
« Reply #12 on: November 29, 2012, 10:29:14 AM »
Thanks for that link, Steve, a thoroughly entertaining history of two terrible engines! I'm sure yours will will not carry on the weak genes of the line.

I'm assuming that the patterns are for sand casting - are cores involved? I can't see any core prints there, although the runners are very well sized.

Cheers, Hugh.

Offline stevehuckss396

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Re: Making a Deesil Pattern.
« Reply #13 on: November 29, 2012, 09:52:24 PM »
Thanks for that link, Steve, a thoroughly entertaining history of two terrible engines! I'm sure yours will will not carry on the weak genes of the line.

I'm assuming that the patterns are for sand casting - are cores involved? I can't see any core prints there, although the runners are very well sized.

Cheers, Hugh.

Nope, no cores. They are small and can be machined in a few hours i'm guessing.

It does have a poor history. I have heard that searches have failed to find even one person who purchased the engine from Gothem and got it to run. There were castings available to build your own so I assume there were engines running at the time.
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Offline DavidF

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Re: Making a Deesil Pattern.
« Reply #14 on: November 30, 2012, 12:51:44 AM »
After reading the story on the deezil it makes me want to build one and see if it runs and for how long. Would make an interesting contest too lol.