Bernay Build - MZT

[arnoldb]

Well done Marcello 

These 'finishing' tasks are never ending!

Too true.  But the additional effort does reflect in the final result!

Regards, Arnold

[mzt]

Fittings

Here?s that same item on the faceplate, for the first cut
 




The second, and the third...



 
The fourth cut went into a collet.



 
With pipes, ready to accept a soon to be re-threaded commercial fitting.




 
And a base, roughened with a knife tool and finished by filing.



 

Cheating on castle nuts

Self splanatory.




 
Yet another complete dismounting

For cleaning. But fun took its part into that.



 

And making studs

No fun at all. Really



 

Fitting the studs




What?s that screw on the R steam chest?



 

I had taken accurate measurements of steam chest thickness, plus washer, nut, twice the gaskets, added the screwed in length..




..and plainly forgot about the covers. That?s sixteen times no-fun-at-all work, again.
The second stud of the new set snapped flush with the die. Why do they sell half-split dies, BTW?



 

Of course, it was late at night, the only usable M4x07 die: tried everything, through drilling the jammed stud to be tapped M3 to
accept a SH screw to force it out. Nothing worked, till I put a thin cutting disk on the Dremel.
 



Now, I have a through split die.

Back on the castle nuts

Made the first using an hacksaw but results were too poor



 
The wooden rod (a brush handle) helped a lot into setting the nuts into the bottom of the vice
 






An oil cup for the crosshead insert,  filed on the lathe, drilled to whatever size and hammer broached with the best fitting allen key.




Wood base

It?s already cut, drilled, countersunk, sanded and painted: now waiting for some wax finish.

Marcello

[Don1966]

Marcello that is a beautiful job on the Bernay engine. It is amazing to see it run. I think Bob Jergenson built this engine if I remember correctly. Great job.

Don

[smfr]

Good stuff. I love seeing these finishing details.

Simon

[swilliams]

Great work Marcello

Steve

[mzt]

Flanged fittings

Gaskets soaked into oil




 
No way I could use a tubular wrench to tighten the flange nuts, the miniature wrenches box I have not seen for years.
Some filing work on one end of some pin I had into the salvaged parts box and here?s a tool I can use to get it done. 



 
Wood base fits

Fits well, and gave all kinds too.

I had ideas of sanding it smooth then giving it a wax finish only: as it went, I only had some liquid wax, the kind
used on wooden floors, and made use of it. Thought that several (generous) coatings would have done.
You may know what happens when You soak wet a piece of wood, however seasoned it is. It happened.

Had to pay another visit to my woodworking friend to get it flat again. He got the job done on the planer, not before
softening the plank by banging it hard on my head. Said it was an old woodworker?s trick.

Back into the shop, I decided I wanted a darker base: as easy as applying some impregnating agent. Ended with quite a
few thick, dark, wax stains all over the surfaces. Some chemical reaction, I suppose.
Nothing but sandpaper got rid of them, woodworker?s trick included.

Back at the starting point, and a much thinner base?

After applying another thin layer of liquid wax, I decided to go buying myself a can of the thicker kind, but it was
too late: the store was already closed. On the way home, I realized that base, being an engine base, was surely going
to get quite a few oil stains.
That gave me the idea: oil finish, You bet.

Here?s the bottom.




 
Top view



 

Left side




 
Flywheel




 
Right side



 

And front


 

Marcello

[steamer]

Excellent Job Marcello!    Wonderful work!

I like it just the way it is....nice save on the split die!

Dave

[sbwhart]

What a little cracker Marcello

Fabulous job 

 

Stew

[Bearcar1]

Simply magnificent it is! Man is that one good looking engine and of such unique design to boot! WOW! 


BC1
Jim

[swilliams]

It's wonderful

 
Steve

[smfr]

Great!    I wonder if we could be treated to a video of it running in its final form?

Simon

[NickG]

Never seen anything like this! Looks amazing and really interesting to watch, well done. Yes, final video please! 

[mzt]

Another video?


ASAP!
Thank You for asking.
Marcello







 

[mzt]

Dremel sanding disk

I chucked a 12mm rod into a collet, then turned a length of it to something less than 3mm dia (in steps:
about 4mm to finished size, then the next 4mm and so on..) for the shank, made the body about 7mm and left
the plate to 12mm. Having the workpiece reversed and held into a 7mm collet, I drilled, countersunk, filed
to shape  and parted the washer then faced, drilled and tapped the body.




Having held a disk of rubber roughly cut with scissors in it (between the two large washers now hanging on
the shank, I put it into a 3mm collet and made an experiment into turning rubber.
It came round enough for supporting sandpaper disks for the Dremel.



 

The Alu. Bernay

Managed to have her running again, though still on low speed, no power, high air consumption and little
reliability: time to give her a better fit. I might have said earlier I have ideas this one could do with
larger valves. So, I cut and filed some 2mm wide strips to be glued on the top and bottom of the valve faces




And, while waiting for the loctite to cure, gave another opportunity to the Bernays retaining rings I had made
and then decided not to use.   
What filing buttons they did!




? of the valve enlarging works were OK, the fourth is back in a vice with some more glue.



 
Giving a finish, they will never be decent, to the connecting rods was a real pain: the file clogged every
third stroke, however chalked or soaked into petroil it was. So, it was a matter of
-three filing strokes- turn the file-3 filing strokes- clean both file sides?.

And there were four connecting rod faces to do before I could start using coarse sandpaper, then finer
sandpapaer, polishing paste...
The best part of an afternoon went this way.

In the evening I could finally see all the Alu. Bernay parts finished, polished, washed  into petroil and
set on piece of cardboard waiting for their turn to go back in place.

Here they are :



 

Cross drilling jig

for the connecting rod shafts: a chamfered hole into an M6 nut, well tightened on the shaft on a few
stacked washers, acting as a guide for the .7mm bit. Once the bit is gone below the thread, I removed the
nut without disturbing the setup and drilled through the shaft.






 
I have ideas I have applied too much torque when tightening the drill chuck into the spindle.


Packed the pistons & gland nuts using Teflon tape: much quicker than the natural fiber I had used on the
other engine.  And a better seal, too.
The studs-fitting trick worked a treat into tightening the connecting rod shafts.



 
Was right in my fears about having overtightened the chuck: had to apply a piece of tubing to the key, to
have it  dismounted again.
The key exploded the same moment the chuck was released, it?s now shown band-aided with paper tape not to
loose the parts till the day I will try some fixings on them.


 


Marcello

[zeeprogrammer]

That's a lot of beautiful parts!

What do you mean the 'key exploded'? Pieces broke off at the business end?