Samuel K. Hodgson's 3 Cylinder Oscillating Engine

[yogi]

Like Art and Roger said, that's one complex wobbler!
Great work! 

[toolznthings]

Thanks Yogi !

I've been known to make the simple complicated at times !   

Brian

[toolznthings]

Machining the three pistons .....

Decided to do the pistons with a indexer and tail stock setup. Two pistons are the same and the third top vertical piston has a different end.

Made blanks for the pistons at the lathe with extra stock for holding in a collet in the indexer and extra stock for a tail stock center. The left side of the groove closest to the collet is the piston end. Picked up the end with a edge finder.
Doing the two lower pistons which have offsets first and need larger stock.

Milling and indexing to do all four sides in one set up.

With all four sides milled the wrist pin hole was drilled and reamed. I also used a pointed center to make a spot for dividers to layout the end of the piston as a guide to finish. Did this before drilling.

Similar set up for the top vertical piston.

Set up at the lathe to remove the excess stock and face the ends of the pistons.
The radius on the ends of the pistons were finished to the layout line on a belt sander and polished. ( picture later )

Last three pictures showing some machining on last piston.

More piston machining in my next post .......

[toolznthings]

Piston machining ....

The two lower pistons get the ends milled with a .394 wide x .375 deep slot measured from the center of the wrist pin hole. Total depth .687 from the end.

The set up in the vise.

Milling to size.

The pistons before the oil groove. Also drilled oil holes through to the .312 wrist pin holes. ( not shown )

Added a v-groove in each piston for oil.

A trial fitting of the cylinders and pistons on the main plate.

[crueby]

Looking great, getting close to running!   

[toolznthings]

 

Looking great, getting close to running!   

Getting there. Thanks for watching. 

Brian

[toolznthings]

Piston machining ...

Posted a picture out of sequence, but here is the last operations on the pistons.   

The two lower pistons get the ends milled with a .394 wide x .375 deep slot measured from the center of the wrist pin hole. Total depth .687 from the end.

The set up in the vise and milling to size.

The pistons before the oil groove. Also drilled oil holes through to the .312 wrist pin holes. ( not shown )

Back at the lathe I added a v-groove in each piston for oil.


 

[toolznthings]

Machining the crankshaft .....

Decided to make the crankshaft in two parts. The main body turned from 12L14 and the wrist pin from a 5/16" dowel pin.

Turning the .375 shaft diameter and the 1.500 diameter in one set up.

Finished. Ready for facing the 1.500 diameter to length.

Sawed off the bulk of material and finish faced to size.

Set up at the mill to bore the hole for the wrist pin dowel. It will be a press fit.

The set up with a v-block.

Indicating to find center and boring the hole for the wrist pin.

After boring and not moving from location over the bored hole I put the dowel pin in a 5/16" collet and used the mill quill to start the pin into the hole to insure that it was started straight. Finished the press in with the part between the mill vise jaws.

The finished crankshaft.

[yogi]

Hi Brian,
Very clever to start the crank pin with the quill! I like it. Another of your tricks to file away for future use! 
Thanks for sharing!

[Dave Otto]

Great work Brian!

I'm still quietly following along here and enjoying the updates; fun to watch a pro work!


Dave

[toolznthings]

Thanks for the interest and kind words, Dave

[toolznthings]

Thanks Yogi !

Sharing ideas is what it's all about.  Love learning from others !

Brian

[toolznthings]

Brass cylinder heads .....

Turning the brass cylinder heads next. This was my change in design to have thru bored cylinders.Turned and parted off and chucked to finish the top of the head.

Finished facing with a small under cut for looks.

Setting up at the mill using my small three jaw chuck fixture. Temporary spacers under the part to be removed for drill clearance.

Indicating the cylinder head.

With spacers removed and using the DRO bolt circle routine the clearance holes for the 0-80 SHCS were drilled.

[toolznthings]

Flywheel and crank bushing .....

Making a modification to the fly wheel by adding a hub for a set screw rather than having the tapped hole at a angle. To do this the crank bushing needs to be shorter than the print call out. With the set screw at 90 degrees to the crankshaft I will be able to add a flat for the set screw and will be able adjust the end play easier at assembly. Set screw will be 10-32.

Bored the bushing first.

Checking the fit and turning o.d. to finish.

Turning the first side of the fly wheel with the hub.

Rough drill and bore. Add chamfer. ( not shown undercut the face )

Facing opposite side of flywheel in soft jaws. Add center undercut and chamfer.

The finished flywheel at the lathe. Added the 10-32 tapped hole for the set screw with a set up at the mill.

[b.lindsey]

Lots of progress since I last checked in Brian. Still looking very nice!!!

Bill