I made it through Irene without any issues and thanks to the mandatory evacuations I had a few days off of work which I used to good effect. While waiting to work on the boiler leaks I made the door assembly. The door and door frame were filed until they latched together. Then I drilled the hinges in the frame.
The door was slotted in and drilled via the frame.
Next the mounting holes in the frame were drilled.
The frame was used to transfer the hole locations onto the boiler shell. The boiler shell was then drilled and tapped.
Back to the boiler. A friend of mine recommended a boiler leak treatment that is used on low pressure industrial heating boilers (less then 75 psi) to seal seeps. I filled the boiler with a 100 to 1 mixture of water and leak stop, connected an extension pipe with a pressure gauge and relief valve. (The extension pipe was to give some steam space to the completely full boiler) and fired it up on esbit tablets. That stuff worked like a charm. All of my seeps were sealed. After it cooled down I spent the next two hours cleaning up the esbit residue. I'll never use that stuff again.
Here is a pic of the boiler ready for paint.
I'm going to hold off on painting it until my gas burner comes in incase I have to make some modifications to fit it in the boiler. So with the boiler out of the way, I started on the generator. The first part is the base casting. I milled the base flat.
I put the base in the four jaw and faced the end.
My original plan was to bore the casting on the lathe but I wasn't happy with the security of the part in the jaws. I decided to do the work in the mill. First I spot faced and drilled the top hole.
Then I milled the sides level.
Then with the previously faced side on parallels I milled the other end flat and bored out the casting. It was the first time I had used the quill power feed and it left an amazing finish to the bore.
Then the holes for the end caps were drilled and tapped.
At that point I realized that I had forgotten to drill the mounting holes in the base so that was taken care of.
That completes the base casting. Next up is the back end cap. Both ends of the casting were faced in the lathe.
Then the center hole was drilled and reamed.
The part was Locktited onto a mandril, trued up and turned to fit the bore.
Next the end cap was put in the mill and the mounting holes drilled.
I'll end this segment with a generator family shot.
Till next time.
Tony
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