Author Topic: AOG's version of the PM -3A engine  (Read 8471 times)

Offline AOG

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Re: AOG's version of the PM -3A engine
« Reply #15 on: December 13, 2016, 01:48:58 AM »
I got a lot done this weekend so let's get caught up. The next part to be made was the piston valve. I started by turning the blank to size.



Next I drilled out one end and parted off the valve.



Then the spools and valleys were cut.



The other end was drilled and tapped then the valve was placed in a collet block on the mill and the cross hole drilled.



Next up was the little fitting that pivots on the end of the  piston valve
A piece of hex stock was turned to dimension.



Then the cross hole was drilled on the mill



Then it went back to the lathe where it was parted off, drilled and tapped.



Next up was the gland nut. A piece of hex stock was drilled and turned round.



Then the end was threaded and the piece parted off.



Next up was the crosshead guides. I started by leveling them and skimming the bottom surface to make them flat.



Then I spot faced the mounting pads and oiler pad.



Then the various holes were drilled, completing the parts.



Next I made the crosshead. After squaring up the blank I drilled the hole for the pivot pin.



Then I drilled and threaded the hole for the piston rod.



Next the center slot was milled.



Then the edges were milled out.



With the crosshead complete I made the four supports and some 5-40 nuts none of which I took pictures of. Here is a family shot.



I'm actually further ahead than this but that will have to wait until I recharge my camera.

Tony


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Offline b.lindsey

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Re: AOG's version of the PM -3A engine
« Reply #16 on: December 13, 2016, 01:58:30 AM »
Not too much left to do Tony. She's looking great. We should have a runner in no time at all!!   :cartwheel:

Bill


Offline AOG

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Re: AOG's version of the PM -3A engine
« Reply #17 on: December 13, 2016, 04:51:59 AM »
If all goes well I'll have it running tomorrow

Tony

Offline crueby

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Re: AOG's version of the PM -3A engine
« Reply #18 on: December 13, 2016, 03:00:11 AM »
Great progress! Looking forward to seeing it go.

 :cheers:

Offline b.lindsey

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Re: AOG's version of the PM -3A engine
« Reply #19 on: December 13, 2016, 05:02:09 AM »
Yes, looking forward to the maiden run already Tony!!

Bill

Offline Flyboy Jim

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Re: AOG's version of the PM -3A engine
« Reply #20 on: December 13, 2016, 05:07:17 AM »
Won't be long now Tony. When you have this engine finished, I'll be interested to get a comparison of how this build went, compared to your PMR #2.

Are those ER32 collet blocks you have there?

Jim
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Sherline 5400 Mill
"You can do small things on big machines, but you can do small things on small machines".

Offline AOG

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Re: AOG's version of the PM -3A engine
« Reply #21 on: December 13, 2016, 05:28:43 AM »
They are indeed ER32 blocks. I have a square and a hex block both of which are in one of the pics. I picked them up on a trip to the U.K. A couple of years ago.

Tony

Offline Flyboy Jim

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Re: AOG's version of the PM -3A engine
« Reply #22 on: December 13, 2016, 05:39:14 AM »
They are indeed ER32 blocks. I have a square and a hex block both of which are in one of the pics. I picked them up on a trip to the U.K. A couple of years ago.

Tony

And in Post #15, 4th picture: They're not only collet blocks........they're a "machinist jack" as well!  ;)

I have a set of ER16 collets. Maybe someday I can figure out how to make a pair of collet blocks that use that size for my Sherlines.

Jim
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Sherline 5400 Mill
"You can do small things on big machines, but you can do small things on small machines".

Offline Don1966

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Re: AOG's version of the PM -3A engine
« Reply #23 on: December 13, 2016, 04:05:56 AM »
Nice work Tony and also waiting to see it running.


Don

Offline Kim

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Re: AOG's version of the PM -3A engine
« Reply #24 on: December 13, 2016, 08:03:11 AM »
Looking great Tony!  Can't wait to see it go!

I have a set of ER16 collets. Maybe someday I can figure out how to make a pair of collet blocks that use that size for my Sherlines.

Jim, that little Taig ER-16 adapter you have for your lathe actually makes a great hex collet block.  And you can use it for a square block if you use the flats against the sides of the vice, then use the same sides against the base (clamping on the pointy edges).  Not quite as secure as a true square block, but I've used it, and its serviceable.  The sides on the Sherline vice are tall enough to make it work.  Give it a try!
Kim

Offline AOG

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Re: AOG's version of the PM -3A engine
« Reply #25 on: December 14, 2016, 12:39:05 AM »
Ok let's finish this build out. Time to build the crank. I started by milling one side flat.



Then it was flipped around and placed against my chuck stop and the other face cleaned up.



Then it was flipped again and and held by the boss. The face was trued up and the center drilled and reamed.



Next up was some mill work. The spindle was centered on the boss and the hole for the crank pin was drilled and tapped.



The part was finished by drilling and tapping a hole for the set screw.



Next up is the flywheel. I mounted it in the three jaw and cleaned up one face.



Then I flipped it and cleaned up the other side. I also drilled and reamed the center hole.



Next I did an initial cleanup on the outer rim.



Over to the mill while I drilled and tapped the set screw hole.



Then I mounted the flywheel onto the shaft and did a final true up.



Next up is the connecting rod. I spot faced both sides of the bosses.



Then the required holes were drilled.



The eccentric sheath was next. It was placed in the collet chuck and bored out.



Then the mounting hole was spot faced, drilled and tapped.



Now for the last part, the eccentric it self. I setup the four jaw and turned the offset.



Then the center was drilled and reamed.



The four jaw was recentered and the groove was cut.



Then the eccentric was parted off and the set screw hole drilled and tapped.



That completes the machining on the the engine (or so I thought). I tried to assemble it and I couldn't get the crosshead in. It turns out that I had misread the plans and hadn't widened out the crosshead area enough on the base casting. I took care of that it want together ok. After getting everything adjusted I applied the air and it took right off. It was running on 15 psi with no gaskets or rings. Here is a picture after the first run.



Now I have to tear it down and paint it. The next posting will be in the showcase.

Tony


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Offline Tennessee Whiskey

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Re: AOG's version of the PM -3A engine
« Reply #26 on: December 14, 2016, 01:23:45 AM »
Tony,  I joke and tell one of my managers she's so slow that it takes her an hour and a half to watch 60 Minutes  :lolb:  You on the other hand can get it done in 45  :ThumbsUp: :ThumbsUp: :NotWorthy:  Nice job.

Cletus

Offline b.lindsey

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Re: AOG's version of the PM -3A engine
« Reply #27 on: December 14, 2016, 02:14:36 AM »
No video yet Tony??  I'm crushed. It looks great though and will take your word that it's a runner :)

Bill

Offline AOG

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Re: AOG's version of the PM -3A engine
« Reply #28 on: December 14, 2016, 02:29:22 AM »
I thought about doing a video but decided against it. If I took a video i knew that I would have put it on the shelf and never looked at it again. Since there is no video the project isn't over so I can try to stay motivated for the part that I hate (painting).

Tony

Offline b.lindsey

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Re: AOG's version of the PM -3A engine
« Reply #29 on: December 14, 2016, 02:32:35 AM »
Works for me then Tony. I will  stay tuned till the very end!!

Bill

 

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