Author Topic: ME-1 Mill Engine  (Read 9522 times)

Offline Damau

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ME-1 Mill Engine
« on: April 23, 2013, 05:18:20 PM »
For many years I have been fond of the old horizontal steam engines used in lumber mills for pulling overhead line shafts that drove various millwork machines.  During my high school days our athletic field was located near a lumber company and the old mill engine could always be seen and heard especially during PE when we were outside.

I decided to build a model as my next project and selected the ME-1 plans.  It is an all bar stock engine and I plan to post the entire build here.

I started with the base plate and now have it completed.  It is made from 3/8" 6061 aluminum 3-1/2" x 7".  The plans indicated a need to flycut the surface where the various components would be mounted.  My X-2 Sieg milling machine did not have enough bed travel to allow using a flycutter that would cut the whole surface in one pass so I had to make 2 passes.  This resulted in tooling marks that I did not like so I decided to use engine turning to improve the appearance.

I used a 5/16" cap screw, faced the head, wrapped t-shirt material over it and taped it to the threaded part of the bolt.  I chucked it in the drill chuck and applied some valve grinding compound to the cloth and got a satisfactory finish.

The pictures below show most of the operation of the base plate from start to finish.

The 1st. picture shows the setup during the engine turning.  You can also see the tool marks that I was trying to hide.

The 2nd. picture shows the plate after the engine turning was complete.

The mounting holes for bearing stands, cylinder mount, etc. are being drilled and tapped in the 3rd. picture.  Even though my mill has a DRO I still to use my height gauge to mark out the hole locations.  I feel that is a good way to keep a check on me.  It seems a good way to cross check for possible errors.

In the 4th. picture I am milling out the flywheel clearance slot.  The plans call for using a 5/8" end mill and I didn't have one so I used a 3/4" but I don't think that it will be too wide to distract from the looks.

Picture No. 5 shows the completed base plate.  I may mill a decorative edge on it later but now it is time to move on the bearing stands, flywheel, etc.











Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Bogstandard

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Re: ME-1 Mill Engine
« Reply #1 on: April 23, 2013, 05:50:58 PM »
The only problem Dale, there is only so much damage engine turning can cover up.

Normal milling marks are not one of them.

I normally full width superfine flycut to get a surface good enough for ET.

When you get good clean engine turning, you should get an optical effect that gives a different pattern as the viewing angle changes, as seen between these two pictures. Plus of course, playing about with the spacing works wonders sometimes.




I am in no way criticising your work, everyone has their own rules to work to, I am just showing that with just a few more minutes work, it can go from good to exceptional, and that can only come from experience and practice, which I am sure, as you progress further, your work will become outstanding. :praise2: :NotWorthy: :praise2:

BTW, this plate took well over 4 hours solid to get the pattern and spacings correct. That is why I don't do a real lot of it.

This pattern is one right down the centre, then alternate sides of centre, sideways 50% backwards 50%, one of the easier ones to do.


John
« Last Edit: April 23, 2013, 06:00:37 PM by Bogstandard »

Offline Damau

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Re: ME-1 Mill Engine
« Reply #2 on: April 23, 2013, 05:57:27 PM »
Thanks John,

I agree!!  My engine turning did not cover the tool marks but did help to hide them.

Yours looks very good.  Thanks for your comments.
Dale Mauney, Shelby, NC
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Bogstandard

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Re: ME-1 Mill Engine
« Reply #3 on: April 23, 2013, 06:04:39 PM »
Dale,

Have a look at my signature line.

At least you had a damned good go, and got acceptable results, many wouldn't have even tried.

Keep up the good work, you're doing just fine.


John

Offline zeeprogrammer

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Re: ME-1 Mill Engine
« Reply #4 on: April 24, 2013, 01:24:37 AM »
Would it have helped to sand the machining marks out and then do the engine turning?
Not sure how flat it could be made on such a large surface, but would it have been flat enough?
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
"To work. To work."
Zee-Another Thread Trasher.

Bogstandard

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Re: ME-1 Mill Engine
« Reply #5 on: April 24, 2013, 07:35:47 AM »
I don't want to bog Dale's post down, so to answer your question quickly Zee.

As with everything you do in the shop, whether engine turning or wheel buffing, the smoother you can get the surface, the better the end result will be, and yes, flatting on a bit of plate glass ( or anything flat) with a sheet of wet & dry would certainly get rid of the machining marks. But you must be careful not to introduce ripples or curved edges.

John

Offline Damau

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Re: ME-1 Mill Engine
« Reply #6 on: May 31, 2013, 11:26:41 PM »
After spending (wasting) 2 afternoons in my shop, I got back to working on the ME-1.
My next door neighbor was trying to re-engineer the water pump on one of Henry Ford's Model A’s.  He came over totin' a hunk of brass that he wanted me to true up for him on my "lay".  One of my pet peeves is to hear someone call a lathe, a lay.  My thoughts of a "lay" does not in anyway make me think of turning brass!!!!!

His plan was to split the brass collar and clamp it around the water pump shaft to take out the end play.  He was going to drill and tap and tighten it around the shaft with 2 10-24 SHCS.  He asked me, "You got a 10-24 tap I can borree"?  I made an attempt to look for one and told him no because I knew what was going to happen.  He was going to break my tap off in his brass collar.

Well guess what?  The next day he came back totin' a piece of steel this time.  He had drilled it out to the shaft size, split it and drilled the holes for the clamping screws and wanted me to tap the holes. I wonder why he wanted me to tap the holes.  It seems that my prediction came true, he broke off a tap in the brass collar.

Folks, don't get me wrong here.  I am just providing some levity with what may seem as satire.  Maybe it is satire but it is true.  I believe in being neighborly and appreciate what others do for me.

That being said, I will move on with the ME-1 build.

The first picture show the milling of one of the bearing stands.

The second picture shows both stands completed and mounted on the base plate.


Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline Damau

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Re: ME-1 Mill Engine
« Reply #7 on: May 31, 2013, 11:52:20 PM »
The flywheel was the next part I chose to make.  It is pretty much straight forward turning for thickness and outside dimensions.  Ooops, forgot to mention drilling and reaming for the crankshaft.

One of the features of the Sherline rotary table is an adapter threaded the same as the lathe spindle that allows moving from the lathe to the rotary table without removing the part from the chuck.  The same can be done with the angle table that mounts on the mill.

Examples of both of these features will be shown in the pictures below.

The 1st. picture shows the flywheel still mounted in the lathe chuck as I milled out the recess and drilled the holes in the webbing.

The 2nd. picture shows the chuck mounted on the angle table as I drilled and tapped the set screw hole in the flywheel hub.

Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline b.lindsey

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Re: ME-1 Mill Engine
« Reply #8 on: June 01, 2013, 12:23:49 AM »
It's looking good Dale. That little adapter for transferring the lathe chuck to the RT is something i use all the time on the Sherlines as well...very handy accessory for sure. Much of my early learning of machining came from a fellow local to us who could and did do lathe work to tenths and kept his shop conditions, especially temp. consistent in order to do that. I have lost track of him over the last few years but I never heard him call it anything other than a "lay"  Maybe its a Carolina thing :) 

Keep after it, I'm looking forward to seeing more!!

Bill

Offline b.lindsey

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Re: ME-1 Mill Engine
« Reply #9 on: June 01, 2013, 12:32:10 AM »
Dale , just so others know where you are headed, I hope you won't mind if I post a picture or two of the finished engine. Of course your base already looks far better then this picture.

Bill




Offline Damau

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Re: ME-1 Mill Engine
« Reply #10 on: June 01, 2013, 12:53:14 AM »
Thanks Bill,  I am glad you posted the completed engine pictures.

I have made more progress than the log indicates.  I have completed the cross head guide, the cross head and almost finished the connecting rod today.  The plans and notes are well written and easy to follow.  Also the crankdisc is finished.

I will try to keep the posts more up to date.
Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline Damau

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Re: ME-1 Mill Engine
« Reply #11 on: June 01, 2013, 04:55:45 PM »
After finishing the flywheel I was anxious to see how the bearing stands lined up.  I cut the crankshaft from a length of 3/16" drill rod.  The only machining necessary was to face the ends.

I chucked the crankshaft in the lathe with the flywheel mounted to make the finish cuts on the OD.  The plans called for very light cuts but I had a problem with the flywheel spinning on the crankshaft.  I didn't want to over tighten the set screw for fear of stripping the threads.  I used a small dia. 90 degree end mill and cut a groove for the set screw to tighten into and that kept the flywheel from spinning on the shaft.  Even with the flywheel mounted more securely I continued taking light cuts until I reached the correct OD.

I mounted the shaft and flywheel in the bearing stands and it turned freely.......yea!!!!!! 

Here is a picture of the mounted parts.

Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline b.lindsey

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Re: ME-1 Mill Engine
« Reply #12 on: June 01, 2013, 07:36:58 PM »
Dale, another few parts on the base and it will begin looking like an engine!  Do you already have the base drilled for the crosshead guide and cylinder?

Bill

Offline Don1966

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Re: ME-1 Mill Engine
« Reply #13 on: June 01, 2013, 08:11:35 PM »
You engine is coming along nicely Dale. I have been following along quietly but with interest. I would enjoy seeing more photos if possible.

Don

fcheslop

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Re: ME-1 Mill Engine
« Reply #14 on: June 01, 2013, 09:28:12 PM »
Dale, that does looks a really nice engine I'm following along as well.I have a soft spot for the old mill engines.
Thanks for he pics Bill
best wishes
frazer

Offline Damau

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Re: ME-1 Mill Engine
« Reply #15 on: June 02, 2013, 04:22:04 PM »
Bill,

I do have all the holes drilled in the base.  In fact, I have the cross head guide mounted to the base.  The cross head guide, cross head, etc. will be covered in the next installment

Thanks
Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline b.lindsey

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Re: ME-1 Mill Engine
« Reply #16 on: June 02, 2013, 04:46:34 PM »
Looking forward to it  :)

Bill

Offline Damau

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Re: ME-1 Mill Engine
« Reply #17 on: June 02, 2013, 04:54:44 PM »
Don,

Thanks for your interest and comments.  I have a couple more pictures that I made during the machining of the flywheel.

As I mentioned in an earlier post, a nice feature of the Sherline rotary table is an adapter that allows removal of the chuck from the lathe and easily mounting it to the RT without removing the work piece from the chuck.

The 1st. picture shows the facing of the blank brass as I started on the flywheel and the 2nd. one shows the chuck transferred to the RT.

After the work on the RT was finished, the chuck was returned to the lathe and the hole for the crankshaft was drilled and reamed.  Another trip to the mill for drilling and tapping the set screw hole.  This time the chuck was mounted to an angle plate that also has a chuck adapter.  A picture of that operation was shown in an earlier post.

Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline vcutajar

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Re: ME-1 Mill Engine
« Reply #18 on: June 02, 2013, 08:08:03 PM »
Following along Dale.  Nice parts.

Vince

Offline Damau

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Re: ME-1 Mill Engine
« Reply #19 on: June 02, 2013, 08:24:03 PM »
Thanks Vince, 

I appreciate your comment and glad to add you to my audience!!!!!
Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline Damau

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Re: ME-1 Mill Engine
« Reply #20 on: June 03, 2013, 06:52:54 PM »
                                                   CROSSHEAD GUIDE


I made the crosshead guide from a piece of 1" x 1" steel that I found at a local scrap yard.  The plans call for 1.500" x .750" x .875 cold roll steel and what I had was hot rolled.  I used a fly cutter to bring it to the dimensions.

The 1st. picture shows the guide after the fly cutting was completed.

The 2nd. picture shows the .250" slot being milled in my Sieg X2 mill.

The 3rd. picture shows the guide after the .250"wide slot and .500" bearing surface was milled to a depth of .125" for the crosshead.  Only the mounting holes and guide cap holes remained.

The 4th. picture shows the guide mounted in the Sherline mill vise where I was drilling and tapping the holes for the crosshead guide caps.  It may appear that I am running the mill here but I use the drill chuck as a guide to keep the tap vertical.  This handy little tap holder works good with small taps like the 0-80 I was using.  I step off each hole position, drill the hole and without moving the XY axis, tap the hole.

The 5th. picture shows the crosshead guide completed with the guide caps in place and mounted to the base plate.  I don't have a picture of the guide caps being made.  They were made from 1/4" wide brass, stepped off and clearance drilled for the 0-80 screws.

I realize my descriptions and captions may seem elementary to many of the members here.  However, I also think there are quite a few newbees like me here also.  Actually, I am not a newbee in some respects, I am about 1/2 way into my 78th. year and I feel blessed to be here.




Dale Mauney, Shelby, NC
WA4BBN (Amateur Radio Callsign)

Offline b.lindsey

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Re: ME-1 Mill Engine
« Reply #21 on: June 03, 2013, 07:26:00 PM »
More nice progress Dale...its beginning to take shape now and looks great from what i can see.

Bill

Offline arnoldb

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Re: ME-1 Mill Engine
« Reply #22 on: June 03, 2013, 07:35:58 PM »
Good going Dale  :ThumbsUp:

The screw-on spindles may have a disadvantage here and there, but they sure make life a lot easier in general  :)

Kind regards, Arnold
Building an engine takes Patience, Planning, Preparation and Machining.
Procrastination is nearly the same, but it precludes machining.
Thus, an engine will only be built once the procrastination stops and the machining begins!

Offline dsquire

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Re: ME-1 Mill Engine
« Reply #23 on: June 03, 2013, 08:08:22 PM »
                                                   CROSSHEAD GUIDE

snip

I realize my descriptions and captions may seem elementary to many of the members here.  However, I also think there are quite a few newbees like me here also.  Actually, I am not a newbee in some respects, I am about 1/2 way into my 78th. year and I feel blessed to be here.


Dale

No appologies necessary for the descriptions. If there are too many for the more experienced then they can gloss over them. The less experienced like myself sometimes need that description to follow along.

Congratulations on working on your 78th trip around to sun.  :ThumbsUp: I'm 5 laps behind you but trying hard to catch up.  :old:  :lolb:


Cheers  :cheers:

Don
 
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