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As a thought now you have thinned down both sides & exposed that internal corner, could you set it up & with the correct sized end mill take out the square corner?
That will bring me to cylinder #3.Wish me luck.A 3rd failure typically makes me question why I bother.
Quote from: zeeprogrammer on August 24, 2018, 03:23:04 PMThat will bring me to cylinder #3.Wish me luck.A 3rd failure typically makes me question why I bother. But are you enjoying yourself ? Yep Just think how much experience you are getting, you couldn't have tackled something this difficult only a few years ago. TrueAnd what would life be like if we didn't find ourselves new challenges to try to over come? Bored Its the journey that matters Okay. Okay. I'll come out of my hole. It didn't hurt to have done that crosshead guide just before.
A 3rd failure typically makes me question why I bother.
The inlet port is supposed to be drilled parallel to the cylinder bore. From Stew's original metric drawings the cylinder end cover at radius 28mm is supposed to be larger than the rounded part of the cylinder, which is radius 24mm, and so will cover the port. On my model the edge of the cover is level with the flat base of the cylinder block. It would appear from your picture that your cylinder end cover is too small enough and if you made that part bigger it may save you making a new cylinder block.