Elmer's # 13 2X Larger than original ......

[yogi]

 

Coming along nicely.
Keep the pictures coming. 

[toolznthings]

More machining on the engine feet and crankshaft bearing blocks .....

Clearance holes for 1/4" bolts were drilled in the feet where they will mount to the base plate. The top side of the feet has 1/4-28 tapped holes for the columns and 10-32
holes for the crankshaft bearing blocks. This finishes the feet.

The bearing blocks had 13/64 clearance holes drill in the tabs. Then set up in the mill for rough drilling and boring for the bronze bearings to be made later. A ground block balances the vise at the far left.

At the CNC mill the blocks are held in position on a small setup plate and the bore swept for part zero. A small clamp was then added to the setup through the bore.
This operation finished the contour shape on the top of the blocks.


 

[toolznthings]

Machining the base plate that mounts to the engine feet and the 660 bronze bushings for the crankshaft bearing blocks.

The base is machine from cast aluminum tooling plate and the overall size is .750" thick x 4.000" wide and 6.750" long.
At the cnc mill  the interior cut out was milled thru the plate. Mounting holes were drilled thru and reamed to .257" diameter.
Notches for connecting rod clearance will be milled later.

At the lathe 660 bronze bar stock was machined with the o.d. turned for a slip fit to the bearing blocks. The i.d. was bored to allow for .001" + fit to the crankshaft journals.
Parted off and chucked for a 45 degree chamfer at the bores.
Loctite with primer was used to assemble the bearings to the blocks.

[toolznthings]

Alignment and dowel pins .......

Aligning the crankshaft bearing blocks to the base and adding .062" dowel pin reamed holes. The hole spacing will be different on each end so the parts are not interchangeable.

After this setup .125 dowel pin holes are placed thru the base into the feet and later before final assembly the feet will be doweled to the steel base plate.

Next step and modification is to add flat bottom counter bores to the base where the columns will mount. This will provide alignment for the columns.

[toolznthings]

A couple more pictures ....

The crankshaft with the assembly for a trial fit.
Flat bottom counter bores with a end mill ground for this operation.

[b.lindsey]

More nice progress and you are getting a very nice finish on all the parts. Looks better that the picture in Elmer's book!!  Still following along.

Bill

[toolznthings]

Thanks, Bill !
Appreciate your interest . 

[toolznthings]

Machining the six engine columns ..........

Made from 1/2" diameter 12L14 stock.

 Four columns pass thru the base and hold it to the engine feet. The center columns pass thru and are held to the base with a nut on the far side. The overall length was modified to allow for the depth of the flat bottom bores in the base.

Set up in the lathe using 5C collet and a spindle stop the overall length was finished on all the columns first. The following setups turned the .250 diameter for the 1/4"-28 threads.
Ends were chamfered for the thread and all the ends were single point chased.

At the mill with a 5C indexer and stop I added wrench flats to the columns. This was an additional modification to the build.

A trial assembly checking the results.

[toolznthings]

One additional picture .......

[b.lindsey]

Those turned out beautifully toolz. 12L14 is nice to work with, just keep them oiled as it tends to rust easily.

Bill

[toolznthings]

Machining the bottom plate that supports the cylinders.

Made from .250" thick tooling plate the overall size was machined to 4.000" wide x 6.750" long.

Using dividers a layout of the 1.875" thru holes in the plate was made and after locating the centers at the mill. Roughing out with a end mill close to the layout was done first.
The boring head was used to finish the thru holes first. The boring bar was ground to achieve a flat bottom bore needed on the next operation after the thru bores.

A counter bore of 2.000" x .062" deep was finished next. The cylinders will set in this counter bore.
A boring tool ground at 45 degrees was used to add a small chamfer to each bore edge.

The last operation added the thru holes for the columns.
The last picture showing a test fit.

[b.lindsey]

Things are starting to come together very nicely!!

Bill

[yogi]

Laying out the holes and roughing them out with an end mill: Old school and very effective! I like it! 
Very detailed build. Thanks for sharing. 

[toolznthings]

Laying out the holes and roughing them out with an end mill: Old school and very effective! I like it! 
Very detailed build. Thanks for sharing. 

When you're old you tend to " old school " ! 
Thanks for the reply ! 

[toolznthings]

Machining the bronze cylinders.

Using cored 660 bronze stock I rough bored the 1.750" I.D. and turned the 2.000" O.D. leaving stock to finish.
After the material cooled down to room temperature the O.D. was finished first. Again, waiting for any temperature in the part to cool before finishing the I.D.
I wrapped the part O.D. with a strip of rubber and secured with tape. This prevented any chance of chatter when boring to size.

Parted off leaving stock for finishing the cylinder to 3.250" long. The opposite end faced to the proper length to finish.
Did some polishing to the bore and broke any sharp edges inside and out.