Props first engine - Elmer Wobbler #25

[propforward]

I decided to go ahead and just post a few pictures of where I am so far on my first ever engine build.

I haven't got very far with it, but I figure I might as well just start, and use this as a build log, kind of thing.

I started with the crankshaft bearing, mainly because on the day I started it was the only item I had a suitable piece of material for. Here is my first attempt.



It's a bit rough, but it is also my first piece of brass turning.

I therefore called it a successful day on that particular item, and celebrated accordingly



Safety note - beers only come out once all tools are cleaned and put away. No activities in the shop except for pondering and sweeping when the relaxation begins.

Anyhoo, the next item I turned my attention to was the connecting rod.



That is as far as I have got with that item. I need to thread the little end, and machine flats and drill a pivot hole in the big end. Elmers plans call for flats both sides of the connecting rod big end, but am only going to do one, mainly because I think it might be more arty looking. If it looks rubbish then I'll do 2.

It took me three goes to get the con rod this far. I destroyed the other 2 because holding the part and turning the longish, thin diameter were difficult, and after reading Jos thread about her home made follow rest today, will be making one of those for myself for small work. In the end I machined the con rod in 3 goes - three short lengths at a time, so to speak. I managed to get the three sections blended fairly well, so I'm happy enough for now.

By this time I had acquired some larger diameter aluminium and some steel, and so I had a try at the flywheel, and also the jig pin in Elmers plans. I realise a lot of people just make use of their mills to place all the holes accurately on the support frame, but since I don't have a mill yet I thought I would try using Elmers ingenious jig approach for laying out the holes.

This picture shows first flywheel, jig pin and the con rod and bearing.



At the time, I had decided to leave the flywheel as a plain disc as shown in the picture. However, since then I broke a drill bit off in the flywheel attempting to drill the hole for a set screw, so I shall be remaking the flywheel. I have decided that I would rather make it in brass anyway, and I am not going to shy away from attempting a groove each side of it either.

Next up, I had a go at the crankshaft. So far all I have done is the main shaft:



I have yet to make the crank disc for the end of it.

I have also started work on the frame for the engine, and have rough cut it to shape, and drilled the bearing hole, the inlet and exhaust port holes, and the cylinder pivot hole. I need to do some finishing work on it, which will be done the old fashioned way by hand with files, and then various grades of emery paper, and if that looks good I'll post a picture of it.

The engine has taken a bit of a back seat for now while I make some other tooling, plus I have been working on motorcycle maintenance and repair over the winter break, but I should be able to attempt some more work on the engine this weekend, which is exactly what I said last weekend. 

Anyway, that's my wobbler so far.

[b.lindsey]

Those all look great to me!!  Given the magnification on the brass bushing, it looks plenty smooth enough too!!!  You're off to a good start there and I will be following along. THat first engine when it comes to life is really special.

Bill

[arnoldb]

What Bill said 

Thanks for posting up Prop 

Kind regards, Arnold

[Don1966]

Looks great to me also Prop, you are off to a good start like Bill said. It will progress faster then you would expect.

Don

[rleete]

Keep at it, one part at a time.  You seem to be doing well so far.

Only three tries at a small part is not a bad ratio.  I think the first time is just practice.

[ScroungerLee]

Looks great Prop, the moment that first engine runs is a great reward for making parts even when you make them two or three times like I end up doing

[zeeprogrammer]

For a first turning...I'm thinking excellent!
Nice start.

I know what you mean about turning small diameter long pieces. I've done a few using your method...turning a bit at a time keeping as much meat towards the chuck as possible. Another method I've used is turning a part with some sacrificial metal at the end and using a live center. Have to really prepare for that...it's a sad thing when you get close and find out you're going to hit the live center with the tool or the tailstock with the tool post.  I've gotten real good at that. Not preparing...hitting.

[propforward]

Thanks all, I really do appreciate your encouragement. When you start out, and scrap the first few parts you make it can be a bit of a downer, so a few positive words goes a long way. Hoping to make progress tomorrow! Today I was getting my new toolpost finished up. I will write a post about that elsewhere.

[steamer]

Looking good from here Prop.....keep at it!


Dave

[propforward]

Well I spent a little more time on this yesterday, and did some work on the cylinder and piston.

First time working with the 4 jaw is certainly enlightening. It all went "OK" I guess. I'm not super happy with these parts, a big part of me says "make them again", but on the other hand, why not go with them and see what happens?





Obviously the cylinder is unfinished yet. It still needs the port hold drilled, and then chamfers and finishing on the exterior.

The piston:



I am relatively happy with. I screwed up the position of the oil grooves, but I don't think they are critical at this stage. This will only run on compressed air, so I am going to go with this for the time being. It fits in the cylinder without flopping about, so that's a step in the right direction. 

Today I think I'll do a bit more work on the con rod and cylinder, and also on the frame.

 

There are getting to be enough parts that there is the possibility of a complete engine occurring eventually.

Also need to get some brass for the flywheel. Or maybe I'll make it in steel. That 12L14 machines up a treat, and isn't very expensive.

[b.lindsey]

Prop, those parts all look good to me. Elmer's engines are pretty forgiving in most ways so the oil grooves won't pose any problem and even a reasonably close piston fit will usually work just fine.

Bill

[swilliams]

Good stuff Prop. I'm enjoying your thread

Steve

[propforward]

I am actually excited about the fact that I made a flat bottomed blind hole in a piece of metal. It's the little things in life that keep you going!

Like bacon and eggs, which sounds pretty good at the moment. 

[zeeprogrammer]

There are getting to be enough parts that there is the possibility of a complete engine occurring eventually.

Cool. Get a family shot too. It's always neat to see all the parts together before the get together. 

[ScroungerLee]

Looking good!  At this point you should be able to feel resistance due to air pressure pushing the piston in and out of the cylinder since the ports aren't drilled yet.

Lee