Author Topic: Liney RV-1 - A New Double Wide  (Read 16871 times)

Offline sshire

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Liney RV-1 - A New Double Wide
« on: October 25, 2013, 03:03:13 AM »


Liney RV-1 - A New Double Wide

Part 1

“The way to succeed is to double your error rate.”
Thomas J. Watson
Chairman and CEO of IBM


I had the plans for the RV-1 on the bench for a few months while I was working on the boiler. I was following Bill Lindsey’s build and didn’t realize, until he finished it, that it was smaller than I had imagined. So, all dimensions times two seemed doable.

I printed a second set of the drawings and, with a calculator to check my math, wrote the new 2X dimensions on the plans.
I went through the brass and aluminum stores and ordered what I didn’t have.
Most pieces laid out on the bench all ready for their weight reduction.


The base plate, a .375 6061 piece, becoming square. First try with a high helix end mill. Much better surface finish on aluminum.



The 2” face mill gives a beautiful surface.



Even with the DRO, I feel better marking out the piece. That way, I have a better chance of catching a screwup before it happens.



After finding the 0,0 corner and zeroing out the DRO, I plunged an end mill and began making the cutout for the flywheel. I changed to a smaller diameter end mill for the corners and finishing pass.



With the flywheel opening cut and mounting holes drilled, it was good to see that each hole was perfectly positioned on the scribe lines.



I like to mill a bevel on plates. Cutting the edge against the fixed vise jaw makes everything work nicely with the bevels all around matching at the corners. Cut, turn 90 degrees, cut, turn, etc.



First part done. Of course, more sanding and polishing will come later.



The flywheel bearing “towers” are next. I had seen these acetal bearings with stainless steel balls and though that this might be a good engine for a tryout. They are described as “no lube” if run under 2500 rpm. Maybe.


The primary problem is that they are wider than the .5” x .5” brass square. Even though there appears to be plenty of room for a wider piece, I had another idea. And I’m not in love with straight square pieces.


That looks like it might fit.



A bit of drilling and boring got me just under what I need. The engineering data for the acetal bearings gives from 0 to -.003” interference. The bearing O.D. is .625.





I’m going to line bore the last 1 or 2 thou when the blocks are mounted on the baseplate. For now, the bearing almost presses in.



Good enough for now so I parted off two pieces.



I wasn’t overly concerned with the internal finish as that will go away when they are bored to size.



For the bottom of the bearing tower, I rounded off the corners of the .5” square bar.



The two pieces are roughly to length. The action then moves to the mill to make both the same length and to mill a recess for the round bearing shells.



Ready for their debut on the soldering stage.



That’s today’s output. More tomorrow. Don’t change that channel.







Best,
Stan

Offline Don1966

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Re: Liney RV-1 - A New Double Wide
« Reply #1 on: October 25, 2013, 03:35:26 AM »
Gee! Stan your just a go getter buddy, you spit out parts like tomorrow. Looking good though and I'll be following you until completion which will be a couple of days. Keep it coming man!  :ThumbsUp:

Don

Offline smfr

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Re: Liney RV-1 - A New Double Wide
« Reply #2 on: October 25, 2013, 04:11:12 AM »
Lots of good tips even in the first post! I like the tip about how to get an even bevel on all sides.

Simon

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #3 on: October 25, 2013, 06:35:40 AM »
Simon
I credit John Moore (Bogs) for showing me the bevel technique.

I did get an email from Doug at Liney. He recently put the RV1 in Alibre and is going to model it in 2x to see if there are any issues. Gotta love support like that.
Best,
Stan

Online sco

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Re: Liney RV-1 - A New Double Wide
« Reply #4 on: October 25, 2013, 06:40:03 AM »
Yeah I thought the bevel trick was neat too.

Thanks,

Simon.
Ars longa, vita brevis.

Offline mklotz

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Re: Liney RV-1 - A New Double Wide
« Reply #5 on: October 25, 2013, 05:12:08 PM »
Variants of Stan's bevel trick are useful in other oft-encountered machining operations.

Say you have a square plate and want to put a hole in each corner for hold-down bolts or some such.
Put one plate edge against the vise fixed jaw and but the adjoining edge against a work stop.  Drill the first hole, rotate the plate ninety degrees, drill again and so on.  Each hole will be located identically in relation to its plate corner.  With a bit of workpiece flipping, you can use this trick on rectangular plates as well.

It's a handy method of duplicating features on a workpiece.  Give it a bit of thought and I'm sure you'll find some personal applications.
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Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #6 on: October 25, 2013, 09:21:27 PM »
Very nice start Stan...already lookin g forward to tomorrow's update :)

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #7 on: October 25, 2013, 11:52:50 PM »
Thanks, guys. Here's your fix for today.


Liney RV-1 - A New Double Wide

Part 2


After silver soldering the bearing towers, I cut a piece of 2”x2” brass to rough size and then off to the mill to square it. This will be the valve block.



Switching rods in the depth mike to a 1” to 2”, I milled the block until it was close enough to a 2” cube.





Now a 1” diameter through hole for the rotary valve (tomorrow’s part du jour). Center was located and spot drilled.



Then a series of drills starting with about .25” and getting up to my largest, a .75 Silver and Deming.





I took the .75” hole out to 1” with the boring head. I really need a thicker shank boring bar that is long enough. This was the only bar I had that would go 2” deep. While the knee power feed moved up slowly, I kept fiddling with the VFD speed dial to keep the chatter to a “less than butt clenching” level.
Surprisingly, the bore had a good finish. I’m thinking that indexable boring bars might be a good idea.



The block is attached to the baseplate with 4 screws. The drawings show them as 2-56. At this scale, 5-40 look about right. Drilled and tapped.



After discussions here and with Doug at Liney, I did go with a 2x diameter hole for the intake and exhaust. Both the exhaust at the top and the intake in the back, have counterbores for the exhaust stack and intake piping. . Since I’m in the process of standardizing everything to ¼-40, thats what I drilled and tapped.





With the drilling and tapping complete, the last op on this part (aside from sanding and polishing) is milling the “cooling” fins.

.125 end mill. .25 movement for each cut. I marked out the lines for the stopped cuts.



So there is your part for today and I’m at this step. Rotary valve tomorrow.



Best,
Stan

Offline Don1966

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Re: Liney RV-1 - A New Double Wide
« Reply #8 on: October 26, 2013, 12:59:29 AM »
Nice chunk of brass Stan and some great progress. Shes starting to look like an engine already. Looking forward to tomorrow's fix.  :ThumbsUp:

Don

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #9 on: October 26, 2013, 02:09:20 AM »
Nice surprise as I wasn't expecting more until tomorrow. That valve body looks terrific Stan, as do your modified bearing stands.

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #10 on: October 26, 2013, 04:16:18 AM »
Trying to do a part a day. Something usually gets in the way but that's the plan.
Best,
Stan

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #11 on: October 26, 2013, 11:28:04 PM »
Liney RV-1 - A New Double Wide

Part 3

The Rotary Valve


The O.D. of the valve is 1”. The closest 6061 round I have is 1.5” and, since the largest 5C collet is 1.125”, the 5C chuck had to come off and the 3 jaw replaced it. I actually have a custom 1.25” collet but that wasn’t a help here.



The 6061 round was chucked in the 3 jaw and turned down until it fit. Then the 5C chuck was put back on. With the small live center in place, the piece was turned to 1.00”



As I got close, I kept checking with the valve block until it just slid on



Next, 1” of each end is turned to .5” diameter. I first marked the length with a parting tool.



Again, when the DRO indicated that I was close, I began measuring. This is close enough.



Then the part was marked for the 1" length of the .5" O.D. section at the other end.



The valve is 4” in length and is to have a .25” hole from end to end. This directs air (or steam) to the cylinders. With no 4” long, .25” drill, I had to drill from both ends and have the hole meet in the center.
That’s what I love about the collets and the Set-Tru chuck. Take parts out, put them back, flip them end for end and it still is correct.



This is not the center drill from the previous photo. It’s the .25” bit in as far as it would go. I must have pulled it out 20 times to clear chips.



The part was reversed in the collet and drilled from the other end.



The holes met perfectly. This ¼” tube slipped right through.



Moving to the mill.

The final op was the cross drilled holes to meet the air passage. I found center and then the edge.



And then drilled until it met the passage.





The finished rotary valve.



The progress photo.



Hoping to get an early start on the cylinders tomorrow. The football game starts at 1:00. (That’s the one where the ball has pointy ends)






Best,
Stan

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #12 on: October 27, 2013, 12:42:31 AM »
Looking great  Stan!!  What material will you use for the flywheel?

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #13 on: October 27, 2013, 02:01:32 AM »
It's coming along, Bill.
The flywheel will be cast iron from the nice fine grain hunk I got at Cabin Fever.
Best,
Stan

Offline Don1966

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Re: Liney RV-1 - A New Double Wide
« Reply #14 on: October 27, 2013, 03:54:19 AM »
Stan I can help but compliment you on the photos it's like reading a good book with all the details jumping out at you. Nice progress and beautiful work.  :cheers:

Don

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #15 on: October 27, 2013, 04:47:07 AM »
Thanks Don. Really appreciate it. I learned much of what I know from forums and hope that I can give back a little.
Best,
Stan

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #16 on: October 27, 2013, 09:18:44 PM »

Liney RV-1 - A New Double Wide

Part 4

Cylinders


The cylinders ride on the rotary valve. In my 2X version, they start with a 6” brass square bar - 1”x1”.



Off to the bandsaw to cut the piece in half.



Once again, I had to dismount the 5C chuck. The largest square, 5C collet is .75”. The brass is 1”x1”.

Mounted the 4-jaw and clocked the piece in. My plan is to turn the round sections and drill and ream the cylinders for the pistons. At that point, the round part will fit in a 5C collet and I’ll change back to that.



Turned to somewhere near .95” but not a critical dimension as it’s the outside of the cylinder.



If I’m not turning into a shoulder, I would use the tangential toolholder with a round toolbit. This gives a beautiful finish. The finish is not so beautiful here but a bit of fettling (I was dying to get that in) and Scotchbite made it acceptable.





Drilling and reaming the cylinder bore, repeat the whole process for the other cylinder and that finishes the 4-jaw.





Moving to the mill to drill and ream the .5” hole for the rotary valve.



A nice slip fit. Repeat for the other cylinder.



When I was involved with “whistle-mania” a few weeks ago, I made the decorative cap with a carbide wood-router bit. I wanted to make the end of the cylinder round and another carbide router bit was put into a toolholder and did a nice job.





We now leave your regularly scheduled built log so I can watch the football game (remember, the ball with the pointy ends)



Game over.

The cylinder end is drilled and tapped for 6-40 set screws to hold the cylinder to the valve,



Two more parts to add. More polishing to eliminate the final tool marks will come.



Not quite looking like an engine but getting closer.



Pistons tomorrow. Stay tuned.


 
Best,
Stan

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #17 on: October 27, 2013, 09:49:19 PM »
Another fine update Stan, and a nice result on those cylinders too!!  If you can would you put something in the next round of pics for size comparison. Not complaining at all, just trying to get a feel for how much larger it actually is. You are going to have a lot of new toys for CF  ;D.  And did the game come out to your liking ?

Bill

Offline kellswaterri

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Re: Liney RV-1 - A New Double Wide
« Reply #18 on: October 27, 2013, 10:02:52 PM »
Stan.great idea using the router cutter for a form tool ...

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #19 on: October 27, 2013, 10:09:23 PM »
Bill
The game was mediocre. That's why I had the single malt. (or, as Arnold calls it "Fine Scottish Produce")

The router bits work fairly well as form tools. I still haven't nailed down the procedure. The one I used for the whistle tops required pretty constant and aggressive feed. This one needed a very light touch. It is way easier than grinding one and at less than $10 on the bargain table at the woodworker's supply.

Best,
Stan

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #20 on: October 28, 2013, 01:05:31 AM »
Bill
This may help with scale

Best,
Stan

Online stevehuckss396

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Re: Liney RV-1 - A New Double Wide
« Reply #21 on: October 28, 2013, 01:16:03 AM »
Wow that's alot bigger than I would have thought.
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #22 on: October 28, 2013, 01:19:14 AM »
Yhanks Stan, that helps a lot. Yep...its big....the 1X easily fits in the palm of my hand.

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #23 on: October 28, 2013, 08:32:15 PM »
Liney RV-1 - A New Double Wide

Part 5

Pistons


Today's machine porn: the pistons.

The pistons are to fit in the .344 cylinder bore. Started with a stainless square bar; .375”
Initially, I took a cut with my Warner HSS tooling. and wasn’t completely happy with the finish.




I changed to this carbide tool with a really big radius and, with the lathe cranked up to about 1200 rpm, got a better result.



When I got close (.434) I slowly approached a nice fit for the piston. Make a cut, check the fit, move in a half thou, repeat. If I close off the valve hole with my thumb, the piston pops when removed and I can feel the suction. I’ll accept that as a good fit.



Then the usual sequence of spot drill, drill, ream and chamfer for the crank pin holes.





Two more parts in hand for scale.



Here’s where they fit.



Tomorrow, the cranks. Then a few simple bits and the flywheel. I’m thinking about a cast iron outer rim with a press-fit brass center, but that could change.
Best,
Stan

Offline angeloscuro

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Re: Liney RV-1 - A New Double Wide
« Reply #24 on: October 28, 2013, 08:56:13 PM »
My mother spectacular job you work this luxury being envious (healthy of course) luck and encouragement

Offline Tennessee Whiskey

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Re: Liney RV-1 - A New Double Wide
« Reply #25 on: October 28, 2013, 09:57:28 PM »
Yo professor, that's looking ducky. The surface finish is looking spot on for a final finish :cheers:. I think a part a day may keep Zee away :lolb: :lolb:

Whiskey

Offline Don1966

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Re: Liney RV-1 - A New Double Wide
« Reply #26 on: October 28, 2013, 09:58:08 PM »
Stan, what tool is that you are using with the round carbide and who makes them? Also, nice job on the pistons.  :ThumbsUp:

 :cheers: Don

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #27 on: October 28, 2013, 10:12:31 PM »
I saw the tool on one of Bogs' posts over a year ago. I thing his was a Glanze but I got the same tool under the Garvin brand from Bob Cumings at New England Brass and Tool. It's called a profiling tool and it's been useful for curves, etc.

http://brassandtool.com/Metal-Cutting.html

Eric
Must be working because I've been trying to arrange the quarterly brunch with Zee and a few others from HMEM and we haven't connected yet.

Best,
Stan

Offline Tennessee Whiskey

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Re: Liney RV-1 - A New Double Wide
« Reply #28 on: October 28, 2013, 10:27:16 PM »
Stan, we may all need to check and see if our suds tanks are stinking, he's been quite elusive as of late. :lolb:. I know he and T had the house to themselves for a few days, oh dear, you don't imagine :lolb: :lolb:

Whiskey

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #29 on: October 28, 2013, 11:36:39 PM »
Remarkable progress Stan. At this rate it should be running by the weekend :)

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #30 on: October 29, 2013, 12:39:21 AM »
Shooting for the weekend. The flywheel always takes me the longest.
BTW, just got this email from Doug at Liney.

"Stan,

I scaled the parts x2 with everything doubled including the valve holes. The assembly in motion shows everything working out correctly. In short go ahead and double the valve holes.

Sincerely,
Doug Cvelbar"

From the horse's mouth. Now, the only question is, how much pressure is this going to take to run?


Best,
Stan

Online stevehuckss396

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Re: Liney RV-1 - A New Double Wide
« Reply #31 on: October 29, 2013, 12:56:05 AM »
Now, the only question is, how much pressure is this going to take to run?

I have done this same thing with another type of engine. The bigger the engine the less air pressure it took to run. I built a double sized, double piston engine and it ran on less than one pound of air. The bore was 1/2 inch.

The two on the outside are full size then center is half and quarter scale. The smallest one needs 50-60 pounds of air and as they get bigger the required pressure drops.




Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #32 on: October 29, 2013, 01:39:44 AM »
Steve
Well, that's encouraging. Why is that? I'm really curious: bigger engine; lower pressure???????
Best,
Stan

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Re: Liney RV-1 - A New Double Wide
« Reply #33 on: October 29, 2013, 01:58:21 AM »
Steve
Well, that's encouraging. Why is that? I'm really curious: bigger engine; lower pressure???????

I am no expert but I think it's easier to get air thru larger ports.
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline grayone

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Re: Liney RV-1 - A New Double Wide
« Reply #34 on: October 29, 2013, 08:47:11 AM »
Steve
Well, that's encouraging. Why is that? I'm really curious: bigger engine; lower pressure???????

I am no expert but I think it's easier to get air thru larger ports.

If you double the surface area of the piston with the same air pressure you will get double the force.  Therefore if the friction in the system has not also doubled (unlikely) then it should run at a much lower pressure :happyreader:  If you double the diameter you will get 4 times the force  :thinking: so should run with an even lower air pressure  ;D
« Last Edit: October 29, 2013, 09:19:20 AM by grayone »
Growing old is mandatory, growing up is optional

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #35 on: October 29, 2013, 12:07:30 PM »
Thanks for the explanations. Can't wait to see what it does run on. Maybe I should have built it 8X then it might run by blowing into the intake :lolb:
Best,
Stan

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #36 on: October 29, 2013, 01:17:35 PM »
Ah yes Stan, but then the volume would get you !! :ROFL:

Bill

Offline Tennessee Whiskey

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Re: Liney RV-1 - A New Double Wide
« Reply #37 on: October 29, 2013, 05:58:55 PM »
my RV2 runs best on stupidly low air pressure. you may have a "lung runner" :lolb: :lolb:

Eric

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #38 on: October 29, 2013, 07:26:08 PM »
I'll make sure you try it at CF in April. Should make for a great picture.
Best,
Stan

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #39 on: October 29, 2013, 08:00:36 PM »
Liney RV-1 - A New Double Wide

Part 6

Flywheel


I was going to make the cranks, spacers and shafts today, but I needed some quality time with cast iron.
Big chunk here; a bit over 3” diameter.



I’d really hate to do this with a hacksaw.



Here’s my CoC with the Ballpoint Font.



Unbolted the step jaws and replaced them with my soft jaws. The spacer keeps tension on the jaws while I’m boring them. Since the soft jaws are bored in place, everything stays concentric and the part can be flipped to machine the other side without having to indicate anything. Since I started using these, no more wobbly flywheels. Less than 1 foot of 6061 and worth every penny.



I dug out the carbide tooling since I use my Warner indexable HSS and the tangential holder for damn near everything. Cast iron likes the carbide.



After facing and turning side one to diameter, I flipped the part and finished side 2.



Hogging out the center recess. I kept the depth to .200” to maintain the flywheel’s mass. Normally my flywheel webs are much thinner.

So that’s one side roughed out. Flip and repeat.



Since everything is concentric at this point, the part was drilled and bored to .249”
The .250 shaft will be a press fit.



Now to the Bridgeport to drill the decorative holes. After centering the flywheel with the Blake, I had the DRO do the pattern. Never trusting my “on the fly” dimensions, I ran thru the bolt hole circle and just touched off each one. Looks correct.



So off we go. Just turn the handles until the DRO reads zero, make the hole, display the next hole on the DRO and repeat.



Running through the hole pattern again for the chamfers.



Had some chatter at the outer edge of the web. The coarsest paper I had was 220 and removing the tool marks was taking forever. Ordered 60, 80 and 120 grit emery from McMaster to do the finishing,

Here it is with a size reference. 13oz (370gm).



Looks like one more day of machining to see if it’s a runner. Then finishing, fettling, polishing, and whatever else.

Try and remain calm, but no parts tomorrow. I have a bunch of things that must be done.
Look for the next installment on Thursday evening.


Best,
Stan

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #40 on: October 29, 2013, 08:27:57 PM »
And so what are we supposed to do tomorrow Mr. Stan??  :shrug:  Just kidding....the flywheel looks great and should be more than enough mass for a smooth runner.  Take your time...its still a long time till CF 2014 :)

Bill

Offline Don1966

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Re: Liney RV-1 - A New Double Wide
« Reply #41 on: October 29, 2013, 09:55:03 PM »
No, no you can't do that bud, you have to finish the engine. Oh come on Stan, just when it was getting good you leave us.  :lolb: OK I guess we will just have to wait. Nice looking flywheel though.  :ThumbsUp:

 :cheers: Don

Offline Tennessee Whiskey

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Re: Liney RV-1 - A New Double Wide
« Reply #42 on: October 29, 2013, 09:59:59 PM »
Now that is one nice looking flywheel, however, all time off must be approved by Dave ( Steamer) and myself. Let me give you a little clue, no more than we get, your chances are real slim :lolb:

Whiskey

PS, tanks fer the help ;)

Online stevehuckss396

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Re: Liney RV-1 - A New Double Wide
« Reply #43 on: October 29, 2013, 10:20:53 PM »
Thanks for the explanations. Can't wait to see what it does run on. Maybe I should have built it 8X then it might run by blowing into the intake :lolb:

My double double will run on lung power. Use a real light sewing machine oil and yours probibly will too.
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #44 on: October 29, 2013, 11:35:22 PM »
Steve
I'll try the sewing machine oil before I fill the displacement lubricator with steam oil. I was anticipating the compressor cranked up high for the first run. I'll start real low and see what happens. Video will, of course follow.
Best,
Stan

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #45 on: November 01, 2013, 01:38:07 AM »
Liney RV-1 - A New Double Wide

Part 7

Everything Else


I know you all missed having this captivating build log yesterday, so I did a major push today. All parts are made. Tomorrow: assembly, intake and exhaust port drilling and…

First the cranks. Brass round bar turned to size then drilled and reamed .251 for a sliding fit of the flywheel shaft. It will be held in position with 6-40 setscrews.



Parted off both cranks then it’s off to the mill.



I switched to a v-jaw on the vise and then indicated center.



The second hole for the crank pin was spot drilled, drilled and reamed .249 for a press fit.





Next, the cranks were smoothed out with the face mill.



I placed the cranks upright in the vise and used a 1-2-3 block to align the two holes, close-enough, to vertical. At one point, I was going to make a fixture with flat sides and dowel pins which would slip into the holes. I’d then chuck up the DTI to adjust for a vertical orientation. Never happened. Close-enough here won’t impact the operation of the engine.



After finding the centerline, I used a .50” ball end mill to remove what shouldn’t be there.





Quality time with Oliver to smooth out tool marks and to round over the sharp corners.



Two more parts for the “finished” box.



Next, two aluminum spacers, 1.25” diameter. These slip on the rotary valve between the valve block and the cylinders.



After drilling and reaming to .501”, both spacers are parted off.



Since the bearing towers are .5” wide and the bearings are .25” wide, I needed a filler to take up the space. I turned these to .001” over the I.D. of the ring. The center hole is .015” oversize so there isn’t any chance of interference with the shaft. When I looked at this picture, I realized that I need to do more fettling to blend the ring with the base.



Here’s the filler ready to press in.



And pressed.



The housing, flipped over with the bearing ready to go under the press. Anxious to see how these acetal bearings work out. They are supposed to be “No-lube” under 2500 RPM.



Two more for the “finished” box.



The cranks after sanding and polishing. The hole being done here will be for the 6-40 setscrew to affix the crank to the shaft.



Family portrait of all parts.



The shafts, after press fitting. Tomorrow, I’ll assemble everything and drill the intake and exhaust ports in situ.

Then, get some air in it and see if it’s a runner.










Best,
Stan

Offline Don1966

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Re: Liney RV-1 - A New Double Wide
« Reply #46 on: November 01, 2013, 01:48:02 AM »
Liney RV-1 - A New Double Wide

Part 7

Everything Else


I know you all missed having this captivating build log yesterday, so I did a major push today. All parts are made.


Yea Stan, please don't do that to often man, your giving us the DT'S.  :lolb:
Looking good bud. I see your making good use of the die filer, I know I love using mine. Waiting for the next fix.

 :cheers: Don

Online Kim

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Re: Liney RV-1 - A New Double Wide
« Reply #47 on: November 01, 2013, 03:46:09 AM »
Boy, you did make a lot of progress today! And it's looking great! :ThumbsUp: :ThumbsUp:
Can't wait to see it run tomorrow :)
Kim
« Last Edit: November 01, 2013, 01:52:21 PM by krt2 »

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #48 on: November 01, 2013, 04:53:47 AM »
Don
The die filer is one if the best buys ever. I use it a great deal and it does a much better job than I can by hand. I'm amazed by some of the guys here and their skill with a file.

Kim
You can't wait to see it run? I'll be in the shop early.
Best,
Stan

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #49 on: November 01, 2013, 11:46:16 AM »
Great update Stan....really looking forward to seeing it run!!  Are you going to do any detail painting on it or just leave it all polished?

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #50 on: November 01, 2013, 11:53:20 AM »
Thanks, Bill.
I'm thinking black base, red flywheel middle with the outside polished. All else, shiny.
Best,
Stan

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #51 on: November 01, 2013, 12:03:11 PM »
Sounds good to me....guess we will give you till tomorrow to get that done though  :lolb: :lolb: :lolb:

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #52 on: November 02, 2013, 03:17:25 AM »
Final build log tomorrow but....
IT'S A RUNNER!  :pinkelephant:
Now I have to take it apart, polish, paint, fettle.
<a href="http://www.youtube.com/watch?v=b4tYOLHrPJs" target="_blank">http://www.youtube.com/watch?v=b4tYOLHrPJs</a>
« Last Edit: November 02, 2013, 02:03:00 PM by sshire »
Best,
Stan

Online stevehuckss396

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Re: Liney RV-1 - A New Double Wide
« Reply #53 on: November 02, 2013, 11:38:15 AM »
How did you do on air pressure? Was it lower than you thought it would be?
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #54 on: November 02, 2013, 11:47:06 AM »
Fantastic!!  Congrats Stan on another fine model!! Will look forward to seeing the final pictures and review.

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #55 on: November 02, 2013, 02:01:09 PM »
Thanks, Bill. I had some major binding at first assembly. After screwing around with it for hours, I've now got it running very smoothly. After painting and polishing, I'll run it for an hour or so to see if I can get it down from the 15 psi it needed in the first few minutes I ran it.
Best,
Stan

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #56 on: November 02, 2013, 02:02:05 PM »
Steve
As I posted to Bill, I needed 15 psi to run it. Hoping for a major reduction after running in.
Best,
Stan

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #57 on: November 02, 2013, 02:29:16 PM »
That doesn't sound bad at all for a first run !  After running in I would expect maybe 8-10 psi but could be even better than that. I'm actually not even sure what it takes to run the 1X version, I'll have to check that.

Bill

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #58 on: November 02, 2013, 04:58:56 PM »
Bill
At least we know that a straight 2x conversion works. For your class project, are you going 1x?

Hey! I could be your guest lecturer. I've had 33 years practice and my AFT Local 2026 membership is still good.
« Last Edit: November 02, 2013, 05:03:33 PM by sshire »
Best,
Stan

Offline Don1966

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Re: Liney RV-1 - A New Double Wide
« Reply #59 on: November 02, 2013, 05:05:31 PM »
Hey it actually runs..... :lolb: Nice job Stan I like............ :ThumbsUp:



 :cheers:  Don

Offline b.lindsey

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Re: Liney RV-1 - A New Double Wide
« Reply #60 on: November 02, 2013, 05:24:23 PM »
I think we would go with 1X if only due to the lower materials cost. There was some talk about 1.25 or 1.5X and having the students scale up the drawings on their own. Nothing finalized yet. And unfortunately I will have less of a role going forward due to my new duties and position change. Hopefully I will still have access to some of the "toys" though like the CNC machines  :)

Bill

Online Kim

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Re: Liney RV-1 - A New Double Wide
« Reply #61 on: November 02, 2013, 06:24:54 PM »
Hey Stan!  Congratulations on a runner!  She's looking good :)

And you did that in a week!?!  Wow! :o

It takes me MONTHS to do anything!  This was a blazing build!  And it runs!  What more could you ask?

Thanks for sharing it with us!
Kim

Offline sshire

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Re: Liney RV-1 - A New Double Wide
« Reply #62 on: November 04, 2013, 05:23:04 PM »
Liney RV-1 - A New Double Wide

Part 8

Grand Finale


The speed build is done. Now to finishing and final assembly.

The base and flywheel will be painted. I cleaned them both with lacquer thinner. The base plate was bead blasted to give the primer something to grab.



I’ve had good luck with this self-etching primer. A few light coats and it’s ready for paint.





Also been happy with this masking tape. The paint does not creep under the edge. Since I had already polished the flywheel rim, I masked that.





While the paint was drying, I sanded and polished the valve block.



The baseplate and flywheel have three coats of paint and one coat of clear lacquer.

Assembly is begun with the flywheel and bearing towers.



Heading Bill’s advice about crank mis-alignment from his build, I rested both crank pins on a pair of
parallels and tightened the set screws.



The valve block was next in line.



The rotary valve was slipped through the valve block, then one piston and cylinder was attached with a set screw. The other cylinder/piston pair was slipped on.



That’s it. I’ve run it for about an hour and it’s down to around 10 pounds although the compressor gauge isn’t that accurate at low pressure so it could be less or more than 10 psi.

Thanks for watching.



Video will be posted in the Finished Projects section.
Best,
Stan