This update will be a long one. After hurricane Matthew came through I lost all communications for a while. Oddly enough, I had power and water through the whole thing and no real damage. With the plant shut down for a few days I had time to get lots done on this project. Let's get started. The next parts were the bearings. I started by drilling the holes undersized.
Then I turned the profile and parted off the parts.
Then I put them away. I will ream them to size once they are installed into the frames. Next up was the cylinders. I squared up the stock and then drilled and reamed the bores.
Then the parts were placed on their sides and the hole for the pivot pins drilled and counterbored.
Then both cylinders were placed in line on my adjustable angle block and the corners were milled off.
Next are the pivot pins. I decided to change Elmer's design here. Instead of a cross hole and wire pin I decided to thread the pins 3-48 for retention of the spring.
Next I soldered the pins into the cylinders. That turned into a bit of an ordeal. I just couldn't get them straight. When I did get them straight I realized I had overheated the pins and partially melted them. I remade the pins and round 2 went without a hitch. While the cylinders were pickling I used the fixture to mark out the valve holes on the frame assembly.
The valve ports were then drilled to depth.
Then I used the laser to transfer the port locations onto the end of the frame and drilled the intake and exhaust ports.
The next parts were the pistons. Elmer shows them made in one turning but I decided to fabricate them. I started the piston by drilling and reaming the hole for the piston rod.
Then I turned the oil groves and took the outer dimension to size.
Then the piston rod was turned to fit the piston.
Then the piston rod was placed in a collet block and the flat was milled and drilled for the crank pin.
The piston rods and pistons were set to length and locktited
together. Next up was the crank disks. The stock was drilled and reamed on the lathe and then placed in a collet block on the mill. I used the coaxial indicator to center the stock and then offset and drilled the crank pin holes.
The disks were parted off and then drilled and tapped for setscrews.
The crank pins were locktited in and those parts were done. I then made the axel. The bar was placed in a collet block and then the required flats were milled into it.
That leaves us with this.
That was the original end of the post. Since I was unable to send it I will go into hurricane overtime. Next up is the flywheel. The stock was placed in the chuck faced, drilled and reamed.
Then a decorative groove was cut and the flywheel was parted off.
The part was flipped and the back side was cleaned up and grooved.
Next it was over to the mill to drill and tap for the set screw.
The flywheel was mounted on a mandrill and trued up.
Next the port holes in the cylinders were marked out and drilled using the jig.
Then I gave the frame a light polish and pressed in the bearings. After the locktite had cured I reamed the bearings to size.
I then blued the flywheel and polished the cylinders. I started to assemble the model when I realized I need to order some hardware to complete the build. Next time you see this engine should be in the showcase.
Tony
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