I started work on the cylinder next because the body casting hadn?t been received yet. Quite a bit of time was spent fettling (sp) before the machining was started.
I ended up flipping the cylinder end for end in the lathe a couple of times because I wanted to make sure I didn?t back my self into a corner. There was minimal material on the OD at the top above the exhaust valve boss and I wanted to be sure it was running as true as possible.
Considerable time was spent indicating to be sure every thing was going to work out ok.
Here the cylinder is set up and aligned in the 3 jaw chuck for the initial cuts.
A skim cut was taken in the bore to clean it up and also a cut on the OD of the flange so there would be something to indicate when the cylinder was flipped around. Both of my 3 jaw and 6jaw chucks are set tru chucks; which makes them nice for this type of work.
The bottom end of the cylinder was roughed out and the cylinder flipped back around and chucked up on the newly machined skirt.
Now the bore is brought to with in .010? of final size.
Flipped around yet again (and indicated in) the register surface was cut under the cylinder flange. I don?t remember why I didn?t do this on the first set up; but I sure I had a good reason.
In the same setup the bosses for the water jacket cover were machined to size.
A final cut was taken in the 6 jaw chuck to bring the bore to the proper size for the shrink fit of liner.
I decided to drill and tap the water ports before the liner was installed so there would be plenty of space for the pipe tap. They are tapped 1/6? NPT which is also the same as 5/16-32 MTP.
Here is the cylinder set up in the mill to tap the water ports. The exhaust valve chest mounting boss had previously been milled. This is used as the angular datum for the bolt patterns and the other ports, water, intake, oil, and ignitor ports.
I didn?t take many pictures of the liner machining; here is an early shot drilling the cast iron bar stock.
The liner is a pretty straight forward turning job; however I did leave it a little long so I could face both ends after it was installed in the cylinder. About .005? was also left on each end of the cylinder for a finish pass after liner installation. This created an almost invisible joint.
With the liner now installed and bored (.003? was left for honing) the bolt patterns are being drilled. Notice the exhaust valve chest; mounting boss is positioned against the fixed jaw of the vise.
Now the cylinder is flipped over and indicated in to drill and tap the head stud circle. The two smaller holes are water passages; they intersect the water jacket space and will feed water to the head.
Here is the mostly finished cylinder. Left to do at this point is to finish the exhaust valve chest, mounting boss but I will wait until the valve chest is machined. The water jacket cover mounting holes need to be drilled and tapped and the ignitor holes finished.
Also completed at this point are the two oiler holes drilled and tapped ?-40 MTP and the intake port drilled and tapped 1/16? NPT
Thanks for checking in.
Dave