Author Topic: 20 cc Horizontal 2 Stroke Diesel  (Read 49612 times)

Offline fumopuc

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #15 on: December 13, 2015, 07:24:55 PM »
A short more physical interlude cutting of the piece of 50mm dia. cast iron for the cylinder and head. It's at times like this I get out the catalogues and look for small bandsaws and power hacksaws although I don't really have space for one.
Hi Roger, nice progress. My little band saw found its place under the table. I have to go on my knees to cut something, but I enjoy it.
« Last Edit: February 21, 2016, 07:27:03 PM by fumopuc »
Kind Regards
Achim

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #16 on: December 14, 2015, 07:05:39 PM »
Thanks Achim, unfortunately the space under my table is already occupied by my tapping guide and arc welder  :headscratch:

I core drilled out the center of the cylinder and as with the block will put it away until after Xmas to relax.
Best regards

Roger

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #17 on: February 06, 2016, 11:05:25 AM »
Another member has asked for some details of this engine and as I can't attach anything to a message here is the current drawing.
Best regards

Roger

Offline Brian Rupnow

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #18 on: February 06, 2016, 12:33:19 PM »
Wow Roger--You don't mess around, do you. I will be following this thread with great interest.--Brian

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #19 on: February 07, 2016, 09:58:51 AM »
Thank you Brian  :ThumbsUp:
Best regards

Roger

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #20 on: February 21, 2016, 07:25:00 PM »
I've started to look at the ports/timing in more detail. I put the dimensions from my first sketch into the calculator on the MEN website. These seemed a little soft compared to the recommendations in ETW's book so I moved the top of the ports up and recalculated. This second set appears to be reasonable so I will base the design on these dimensions.
Would it be more sensible to start with the port heights 0.5mm lower and then raise them if required? It's much easier to remove metal that to add it  ::)
Best regards

Roger

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #21 on: February 22, 2016, 08:01:59 PM »
Moving on with this I made the baseplate for the cylinder from a piece of 10mm thick aluminium plate. I drilled the start of the hole rather than using a hole saw so I could keep the centre.
Best regards

Roger

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #22 on: February 22, 2016, 08:10:01 PM »
I then set up the cylinder on the Keats angle plate for boring. This was on the limit of the length of my lathe, but the compound slide just cleared the tailstock. As my 25mm barrel lap is 25mm diameter I took the bore to 25.1mm to give a little clearance. Both ends were within 0.01mm according to my callipers (I don't have any internal mikes). The finish is quite good, but at the end I realised I was still using the aluminium insert from cutting the baseplate  ::) I then turned the stub to fit the baseplate before turning it around to face to length and machine the water passages.
Best regards

Roger

Offline zeeprogrammer

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #23 on: February 22, 2016, 10:18:16 PM »
Following along Roger.
I'm learning a lot. I hope to do something like this someday.
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
"To work. To work."
Zee-Another Thread Trasher.

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #24 on: February 25, 2016, 07:27:04 PM »
Thanks Carl, I'm learning a lot as well  ::)

I turned the water space on the other end of the cylinder. I will make a cast iron sleeve to fit over it which will be Loctited in place. As expected the radius turning tool chattered a bit.

The next stage will be to cut the ports and as these are a fairly complex 3D exercise I decided to make a trial aluminium piece to see if I get the angles correct.
Best regards

Roger

Offline Brian Rupnow

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #25 on: February 25, 2016, 07:43:15 PM »
Nice work Roger. There is a big similarity between what I am building and what you are building right now. I learn from your continued updates.---Brian

Offline fumopuc

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #26 on: February 27, 2016, 06:40:48 AM »
 Hi Roger, good to see more swarf at this project.
« Last Edit: February 28, 2016, 08:14:24 PM by fumopuc »
Kind Regards
Achim

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #27 on: February 28, 2016, 07:12:09 PM »
Thank you both for your interest  :ThumbsUp:

I was intending to try cutting some ports in my trial block but unfortunately I had a dig in whilst milling the flat for the exhaust port and broke the drive belt on the mill  :( I've ordered a couple of spares but they will take a few days so I decided to continue with the crankcase.

I set it up in the 4 jaw chuck, bored through at 60mm and then cut the clearance groove for the big end. I started with the boring bar set at an angle and finished of with my homemade grooving tool.

I then started turning the crankcase sideplates from a barely wide enough piece of 75mm diameter aluminium.
Best regards

Roger

Offline Roger B

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #28 on: February 28, 2016, 07:16:06 PM »
Parting off the sideplates was a little tense as the swarf tended to jam, but it worked. I ended up with around 1mm clearance between the parting tool holder for the second one. Enough but not much to spare  ::)
Best regards

Roger

Offline fumopuc

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Re: 20 cc Horizontal 2 Stroke Diesel
« Reply #29 on: February 28, 2016, 08:26:15 PM »
Hi Roger, looking good. What's the diameter of your chuck, 80 or 100 mm ?
Kind Regards
Achim