Author Topic: Elmer's # 13 2X Larger than original ......  (Read 5810 times)

Offline crueby

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Re: Elmer's # 13 2X Larger than original ......
« Reply #30 on: February 18, 2018, 10:23:16 PM »
Interesting, never seen that wrapping trick, keeps the part from "ringing" as you bore it out to thin wall?

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #31 on: February 18, 2018, 11:52:56 PM »
Hi,
Exactly. Use to be common place operation when cars had brake drums and they were re-cut. They actually had a special band just for the operation.

Offline b.lindsey

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Re: Elmer's # 13 2X Larger than original ......
« Reply #32 on: February 19, 2018, 12:58:35 AM »
Nice! One more part in the finished pile  :)

Bill

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #33 on: February 21, 2018, 01:47:21 PM »
Machining the connecting rods ...........

I changed the design of the connecting rods and they will also have split bronze bearing inserts with shoulders.

Started with making the blanks for the rods. The blanks are made to final thickness, width and overall length.
The end caps were made next and drilled for the mounting holes.
Doing both rods at once, tapped holes were added and the end caps mounted. Each assembly was then drilled and reamed for 1/16" dowel pins.
More machining to follow in the next posts.

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #34 on: February 22, 2018, 10:37:11 PM »
Connecting rods next step .........

Both the crank end and piston ends of the rods were bore to accept the bronze bearings.
Layout lines showing the piston end of the rods were laid out for reference the ends were milled to size.
Addition layout for the rod profile were done next and the rods were set up on a sine bar for the milling operation. Stops were set so the operations could be duplicated on each rod. A end mill with a hand ground radius on the corners was used to cut out the material to the layout line.
Stacked together the finished rod was used to scribe a visual reference on the second rod and it was completed.

The two rods finished milled ready for bench work later on in the build. Bearing machining will be next.

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #35 on: February 24, 2018, 04:53:58 PM »
Machining the lower split bearings for the connecting rod.

Making four bearings from 660 bronze at the lathe with flanges. The bores were rough finished in this operation.
At the mill the turned blanks were milled in half and test fitted to the connecting rods.
Assembled with the rod caps the final size of each bearing was bored.

The finished bearings and the rods.

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #36 on: February 27, 2018, 01:20:53 PM »
Connecting rod wrist pin bushings and the start of the engine pistons.

Set up to turn and bore the wrist pin bushings from bronze stock. The I.D. is sized for 1/4" dowel pins that will be used for the wrist pins. Turned for a slip fit in the connecting rod and held in place with Loctite.

The pistons will be made from 303 stainless steel. Turned, bored and finish faced to length in a separate operation.
First operation at the mill does the reamed hole for the wrist pin. Setting up in next operation to add set screw holes to secure the wrist pins.

More to follow in next post......

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #37 on: February 28, 2018, 01:39:15 PM »
Finishing the pistons with tapped holes for set screws to hold the wrist pins in place. Indicating to align and find center,the operation is completed.

Dowel pins are modified for the wrist pins. The overall length was ground to make the pins fit within the piston diameter. Next set up was made to grind two flats for the set screws.


Offline b.lindsey

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Re: Elmer's # 13 2X Larger than original ......
« Reply #38 on: February 28, 2018, 02:04:14 PM »
The pistons look great, but have to say that set up for grinding the grub screw flats on the writs pins look very tenuous. Glad you got it  done without mishap.

Bill

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #39 on: February 28, 2018, 03:36:33 PM »
Hi Bill,
You are right, slow and careful on the grinding. The fine pole magnet helps for sure.

Thanks for the comment !
Brian

Offline yogi

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Re: Elmer's # 13 2X Larger than original ......
« Reply #40 on: March 01, 2018, 12:52:12 AM »
I like what you did with the wrist pins there Brian.  :ThumbsUp: :ThumbsUp: :ThumbsUp:
A grinder is sure a useful tool to have...

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #41 on: March 01, 2018, 04:37:07 PM »
Connecting rod clearance and the engine cams.

A trial assembly of the connecting rods to determine the location and depth of the notches to be cut in the base for rod clearance.
Set up on tilt table to cut the notches.

The cams are a variance of the design Julius made in his drawings and completely different than the original design.
The blanks machined at the lathe and set up at the cnc mill to machine the contour then at the manual mill to add the set screw hole.

A trial assembly with the cams, rods and some customs made brass spacers. 


Offline b.lindsey

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Re: Elmer's # 13 2X Larger than original ......
« Reply #42 on: March 01, 2018, 05:19:22 PM »
Still following along....the finish on all these parts is just incredible.....well done!!!

Bill

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #43 on: March 01, 2018, 06:32:10 PM »
Still following along....the finish on all these parts is just incredible.....well done!!!

Bill

Thanks so much ! Appreciate you following and commenting !
Brian

Offline toolznthings

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Re: Elmer's # 13 2X Larger than original ......
« Reply #44 on: March 02, 2018, 02:10:44 PM »
Machining the valve guide bracket.

I redesigned this part so the it will have a split type clamping feature to fit the columns with out set screws. This part needs to be adjusted on the columns and set screw marks into the columns would not be good. Final location is determined at assembly and during trial fits this part was removed numerious times.

Started with a long piece of 1/4" tooling plate. Setup the fly cutter to the correct radius and cut the arc for the bracket on each end of the blank.

Next operation was to bore the holes for the columns and a small bore in the center for a valve guide bushing that I added to the design.

Setup for a slitting saw, a cut was made to each bore to allow for clamping with a socket head cap screw.

Tap drilling, counter boring and tapping each location.

At the band saw the parts were cut from the longer piece leaving stock to finish the width. After the width was machined a 45 degree chamfer was cut on the outside corners.

Another trial assembly shows the parts mounted to the end columns. Easily adjustable and removable.