Author Topic: 1st I.C. build "Tiny"  (Read 51825 times)

Offline zeeprogrammer

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Re: 1st I.C. build "Tiny"
« Reply #15 on: March 12, 2017, 01:05:44 PM »
Catching up. Nice stuff Bob.

I've not used a faceplate before so I'm always interested in seeing how people use them.
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Offline 90LX_Notch

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Re: 1st I.C. build "Tiny"
« Reply #16 on: March 12, 2017, 01:48:15 PM »
Thanks Jim and Carl.  A faceplate can really allow you to do some interesting stuff.  It's is a very versatile accessory that is often over looked.

Next up was the radius at the back of the frame.  Just prior to this point I discovered a major mistake.  When I milled the slots for the bearing caps I somehow forgot to offset .100 for the edge finder  So, the crank bores are off by .100.  (I think I can shorten  the connecting rod as a fix.  If not I will have to remake the frame.)  The radius was the only thing left to complete the frame so I forged on.

The center point for the radius was lightly scribed on the frame.  I had left the pallet on the lathe because it was set for the centerline of the crank bore. I just had to shim the frame up and move it over to align with the scribe mark.  With the frame aligned, a Dremel flexshaft was setup in the tool post.  Light cuts were made and the faceplate was rotated by hand in small increments until the radius was complete.  This is a link from years ago that includes a video link on using this technique:  http://www.modelenginemaker.com/index.php/topic,319.msg1916.html#msg1916

When set up right, this technique yields great results.


-Bob
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My Engine Videos on YouTube-
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Offline 90LX_Notch

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Re: 1st I.C. build "Tiny"
« Reply #17 on: March 12, 2017, 04:16:51 PM »
Onto the head.

It is simple turning for the basic shape of the head.  Things get fun locating the pockets, guides and spark plug hole on the .375 dia.

First up was to mount the head on the mini pallet and spot the valve guides/pockets and spark plug hole.  The pallet was then setup on the faceplate and the first spot was indicated.  I drilled the pocket undersize and close to depth.  This was about two weeks before Christmas and life got busy.  Around 10 weeks later I picked back up.  Here's where I learned that I should leave notes if something is going to sit or at least review everything.  I fired up the lathe and drilled through.  This was with a .106 bit.  The guides are supposed to be .094. 

No problem just make one larger diameter valve.  Wrong!  I placed a .106 pin in the hole and ran the lathe to check if the guide hole was straight.  To say the drill wandered is understatement.  The whole reason for drilling the pocket undersize was so that I could bore the pocket to .136.  I wound up boring the .136 through the head as part a plan to save the head.  I then moved on to the other pocket and successfuly bored the pocket and drilled/reamed the guide.  The .094 pin ran true for that guide.

The save.... I turned up and pressed a piece of bronze into the .136 through hole of the messed up guide.  I then made a transfer punch that fit the valve pocket and used it to make a spot on the bronze.  The head was remounted and the pocket was indicated.  The guide was then drilled/reamed and luckily ran true.

-Bob
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My Engine Videos on YouTube-
http://www.youtube.com/user/Notch90usa/videos

Offline Kim

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Re: 1st I.C. build "Tiny"
« Reply #18 on: March 12, 2017, 09:20:31 PM »
Sounds like a great save there, Bob.
When I look at that last photo, I can't see the pressed in piece at all! :)
Kim

Offline steamer

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Re: 1st I.C. build "Tiny"
« Reply #19 on: March 13, 2017, 12:11:43 AM »
Lovely tool porn....keep the pictures going!
Dave
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Offline steamer

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Re: 1st I.C. build "Tiny"
« Reply #20 on: March 13, 2017, 12:14:08 AM »
Hey Bob! Who's boring bars are those?

NICE!

Dave
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Offline 90LX_Notch

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Re: 1st I.C. build "Tiny"
« Reply #21 on: March 13, 2017, 12:21:52 AM »
Thanks Kim.  You can see the saved guide in the picture below.

Will do Dave.  They are real old carbide bars that I got in a trade.  If you watch Adam Booth's YouTube channel, his friend Gil picked up an old Gerstner a couple of years ago and these were in it.  He posted on Practical Machinist that he was looking to do a trade for them.  They were right up my alley so I traded some endmills that were to large for what I do.


The Head continued:

 Next up was the spark plug hole.  It is a compound angle of ten degrees in two planes.  The first angle was set using a protractor and the small toolmaker's vice that I picked up at Cabin Fever this year.  Years ago when I first got into all of this I made a 2.5" sine bar based on a thread Tel did.  I made it from aluminum because that was all that I could buy locally at the time. It gets the job done.  Anyhow, I used an adjustable parallel to set it. (Great tip from Tom Lipton's YouTube channel.)

The toolmaker's vice and sine bar were then set up in the mill and the spot was picked up for the spark plug hole.  The .125 hole was drilled and reamed.  The head was then turned over in the toolmaker's vice and the compound angle was reset.  The hole was then indicated and the spark plug threads were done along with the counter bore.

-Bob
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My Engine Videos on YouTube-
http://www.youtube.com/user/Notch90usa/videos

Offline Dave Otto

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Re: 1st I.C. build "Tiny"
« Reply #22 on: March 13, 2017, 12:37:15 AM »
Looks great Bob, I really enjoy seeing your setups.


Dave

Offline 90LX_Notch

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Re: 1st I.C. build "Tiny"
« Reply #23 on: March 14, 2017, 12:02:35 AM »
Thanks Dave.  The setups are little much but it's the only way that I can get good geometry.


Head continued:

With the spark plug hole done I moved on to the valve seats.  Having never been down this road, I was nervous.  I made a seat cutter the way that George does except that I made it as a D-bit.  The tool did it's job and the seats were cut.

-Bob
Proud Member of MEM

My Engine Videos on YouTube-
http://www.youtube.com/user/Notch90usa/videos

Offline steamer

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Re: 1st I.C. build "Tiny"
« Reply #24 on: March 14, 2017, 12:10:53 AM »
Thanks Dave.  The setups are little much but it's the only way that I can get good geometry.

-Bob

If that what it took to get good geometry...then the set up was right!.....   Looking good!

I like that tool!    I've left my valve seats dead sharp for now, and I'll lap the valves in with rubbing compound later....

Dave
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Damned ijjit!

Offline b.lindsey

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Re: 1st I.C. build "Tiny"
« Reply #25 on: March 14, 2017, 12:33:56 AM »
Nicely done Bob, I am watching you guys for pointers :)

Bill

Offline steamer

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Re: 1st I.C. build "Tiny"
« Reply #26 on: March 14, 2017, 12:36:31 AM »
Follow bob!    I'll be the poster child for how not to do it.

LMAO! :lolb:

Dave
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Damned ijjit!

Offline 90LX_Notch

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Re: 1st I.C. build "Tiny"
« Reply #27 on: March 14, 2017, 12:48:06 AM »
Whoa! Don't follow me.  This is my first IC rodeo.  I think I did alright with the valves, but.....  It has to run inorder to prove them.  That's a long, long ways off.

-Bob
Proud Member of MEM

My Engine Videos on YouTube-
http://www.youtube.com/user/Notch90usa/videos

Offline rudydubya

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Re: 1st I.C. build "Tiny"
« Reply #28 on: March 14, 2017, 06:15:09 AM »
Hey, I'm following along with all you guys.  In bystander mode.  This is great fun!

Regards,
Rudy

Offline zeeprogrammer

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Re: 1st I.C. build "Tiny"
« Reply #29 on: March 14, 2017, 12:53:38 PM »
Nicely done.  :ThumbsUp:

Great pic of the D-bit. That was interesting.
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
"To work. To work."
Zee-Another Thread Trasher.