Author Topic: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates  (Read 3881 times)

Offline xo18thfa

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"Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« on: March 27, 2017, 05:38:38 PM »
Many years ago I built a Gauge 1 version of Ernest Glaser's "Cracker".  Cracker, originally Gauge 0, is a single cylinder, gear driven, single acting oscillating engine with a gas fired boiler.  Here are a few examples of Cracker.





The plans for Cracker are available at:

http://home.iae.nl/users/summer/16mmngm/Articles_htms/Cracker.htm

My version of Cracker, named "Chip", is a scale up, convert to inch and round off of Mr. Glaser's plan.  The bore is 7/16" with a stroke of 5/8".  Gear reduction is 3.25 to 1.  Chip has no lubricator, throttle, water gauge or safety valve (the oscillating motor is the safety).  The burner is Mr. Glaser's original, converted from metric to inch.  A separate car carries the fuel tank.  Here is Chip as finished:



I like the Cracker design a lot and have since built several variants.  They are surprisingly powerful and long running little engines.  This version, named "Regal", follows the general Glaser plan, but is fired by  alcohol with the fuel tank between the frames. 

Start the construction with the gear train.  The Regal gears are 48 Diametral Pitch.  The pinion on the crank shaft is 18 tooth, with gears of 52 teeth.  This train provides a gear ratio of 3.25 to 1.  I made my own gears for Regal, however, stock gears are available.



It's best to test the gears for fit prior to making the frames.  Ensure the gears turn without any bind, but are not too loose.  Carefully measure the distance between pinion and gears and use this dimension for the frames.



The frames are 16 gauge (approx. 0.059") hot rolled plate.  Sheet brass will work as well.  Do not use aluminum or stainless steel.  Here is the drawing:



Saw two pieces about 1/8" oversize and clamp together with 0 x 80 machine screws.  Place the screws in the lower corners of the frames where they later waste out.



Clamp the frame slabs to the table of the mill.  Place a 3/4" thick MDF spacer under the frames to prevent drilling or milling into the table.



Mill the ends to 6" overall length.  Mill one long edge cleanly.  This long end is the top of the frame for the next operations.



Set up dial indicators on the X and Y axis of the mill table.  Or use the DRO if have one. 



Locate and drill a total of eight #51 holes for 0 x 80 machine screw clearance.



Reposition the milling table clamps, without disturbing the frames to drill and ream holes for axle and crank bearings.  These locations are based on the gear train test result.  Drill two #42 holes for the engine standard.  Holes for the axles and crank bearing must be accurately located.  The dial indicators on the mill table makes easy work of the frames.



Remove the frames from the mill and finish the bottom edge.  Finish the bottom edge either on the mill or by hand.  Even though Regal is a single cylinder engine, both frames are drilled for the engine.  This way the engine can be placed on either side.



Next time, we'll work on the end beams, assemble the frame, make and install the bearings.
« Last Edit: March 27, 2017, 05:42:09 PM by xo18thfa »
Bob Sorenson
Las Vegas, NV, USA

Offline 90LX_Notch

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #1 on: March 27, 2017, 07:36:48 PM »
Nice.  I really like the variation.

A "Cracker" has always been on my to do list.  If my 13 year old son ever shows any interest in this hobby; I will steer him towards building one. 

-Bob
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My Engine Videos on YouTube-
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Online MJM460

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #2 on: March 28, 2017, 10:03:21 AM »
A fascinating looking project.  I am keenly awaiting the next update.  Great work so far.  Any details and photos of your gear making?

MJM460
The more I learn, the more I find that I still have to learn!

Offline zeeprogrammer

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #3 on: March 28, 2017, 11:11:47 AM »
Very nice project. I'll be following along.  :popcorn:

Why do you mention not to use aluminum or stainless steel for the frames?
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
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Offline Flyboy Jim

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #4 on: March 28, 2017, 02:08:17 PM »
What a neat little engine. I'll be following along for sure!  :popcorn:

Jim
Sherline 4400 Lathe
Sherline 5400 Mill
"You can do small things on big machines, but you can do small things on small machines".

Offline DTR

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #5 on: March 28, 2017, 03:39:34 PM »
That's an interesting little engine, thanks for posting :)
Dave

Offline xo18thfa

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #6 on: March 29, 2017, 04:35:00 AM »
Thanks for all the kind words.  This is the 6th Cracker (variant) I've made.  They are great little machines for sure.

All the bearing get soft soldered to the frame (next installment), so aluminum or stainless won't work for frames.

I posted a thread of the gear making process on another forum.  I'll post it here shortly.

Today, I got started on the boiler, so it's moving along very well.

Thanks again, Bob
Bob Sorenson
Las Vegas, NV, USA

Offline Zephyrin

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #7 on: March 29, 2017, 08:01:58 AM »
They are great little locos ; I did 3 of them in the past, a great fun to build, and they run fiercely and cope with sharp curves !
Nice thread, it's good to see another variant, alcohol fired !
« Last Edit: March 29, 2017, 08:05:18 AM by Zephyrin »

Offline zeeprogrammer

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #8 on: March 29, 2017, 11:11:37 AM »
All the bearing get soft soldered to the frame (next installment), so aluminum or stainless won't work for frames.

Thanks Bob.  :ThumbsUp:
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
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Zee-Another Thread Trasher.

Offline xo18thfa

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #9 on: March 31, 2017, 05:15:21 AM »
Make the end beams from the same material as the frames.  Here is the drawing for the end beam and other parts used in this section.



Use the same general method to make the end beams.  Regal uses a brass screw in eye hooks as couplers.  Drill the end beam exactly in the center for a tight fit screw hook and soft solder in place.  Shape the end beam as desired, but maintain overall dimension and spacing of holes.



Next are the bearings.  There are 8 bearings total.  Seven are for axles, gear counter shaft and the flywheel end of the crank.  One extra length bearing is on the cylinder end of the crank.  Make the bearing from 3/8" diameter round brass.  Use a squared end parting tool work for all the machining steps.



Use the parting tool to turn the shoulder portion of the bearing.  Turn the shoulder slightly under 5/16" so they fit easily in the frames.  Center drill and drill with #21.



#21 drill is 0.159" diameter.  The axles are from 5/32" ground and polished stock.  The fit is very slightly loose, but not sloppy.  Next part the bearing off the stock.



The frames and end beam assemble with brass angle gussets in the corners.  Make four gussets as shown in the drawing.  Brass angle is ideal, however, aluminum angle available from Lowe's or Home Depot works fine.  Here are the frame parts ready to assemble.



The hot rolled steel plate used for the frames and end beams has a blackened scale coating from the rolling process.  Prior to assembly, remove the scale by soaking the parts in swimming pool acid.  Assemble the frame using 0 x 80 machine screws and model hex nuts.  Cut some lengths of 5/32" diameter ground and polished steel, either cold rolled or stainless.  Slip the bearings into position using the axles for alignment.



The frames are drilled to allow the engine to be on either side.  Ensure the longer crank bearing is on the side of choice.  Flux and soft solder the bearings in place using the axle stock for alignment.

Clean up the frame assembly and test fit the gears.  Everything turns smoothly.



Next time is wheel turning.
Bob Sorenson
Las Vegas, NV, USA

Offline zeeprogrammer

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #10 on: March 31, 2017, 11:39:56 AM »
Great post and detail.

What exactly is swimming pool acid? Can it be obtained from the pool store or is it meant for industrial use?
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
"To work. To work."
Zee-Another Thread Trasher.

Offline Flyboy Jim

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #11 on: March 31, 2017, 02:04:32 PM »
Nice progress. I'm enjoying following along on your build Bob.  :popcorn:

Jim
Sherline 4400 Lathe
Sherline 5400 Mill
"You can do small things on big machines, but you can do small things on small machines".

Offline xo18thfa

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #12 on: March 31, 2017, 04:49:18 PM »
Thank you. 

Carl, yes it's hydrochloric acid from the swimming pool store.  It works great to remove rust and the scale from hot rolled steel.

This project is moving along.  Hopefully finish the boiler today, if the wind stops blowing.
Bob Sorenson
Las Vegas, NV, USA

Offline Dan Rowe

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #13 on: March 31, 2017, 07:39:25 PM »
Bob,
Nice to some more of your machine work in this forum. I am still slowly working on a few Shays still.

Cheers Dan
ShaylocoDan

Offline xo18thfa

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Re: "Regal" 0-4-0 Oscillator in Gauge 1, Progress and Updates
« Reply #14 on: April 01, 2017, 03:29:23 AM »
Hi Dan.  Been staying busy here, that's for sure.  Just got lazy writing and taking pictures.

thanks, Bob
Bob Sorenson
Las Vegas, NV, USA