Author Topic: AOG’s version of the Elmer’s number 33 mill engine  (Read 2202 times)

Offline AOG

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AOG’s version of the Elmer’s number 33 mill engine
« on: July 04, 2018, 06:44:44 PM »
It’s been a while since I posted my last build. I got a little burnt out on model engineering so I decided to take a break for a while. Now I’m back and ready to build my next engine. I haven’t built an Elmer’s engine in a while so I decided to take a stab at his number 33 mill engine.



I started with the base plate. It was squared up and coordinate drilled.



Then the sub base was squared up and drilled. I decided to omit the fake mounting feet because I didn’t think they added anything to the model.



Then I used a 7 degree angled endmill to cut in the draft angles.



Next up was the base. The part was squared up and drilled. I ended up misreading the prints and putting some holes in the wrong place but i plugged them and redrilled. Thankfully the plugs will be hidden under the cylinder.



Next up was to cut the slot for the crank. I didn’t have the right tools to put in the angles called out in the plans so I ended up using a ball endmill to make the slot.



I finished the piece by putting in the draft angles.



That’s all for now

Tony


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Offline crueby

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #1 on: July 04, 2018, 06:48:04 PM »
Excellent start!
 :popcorn: :popcorn: :popcorn:

Offline zeeprogrammer

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #2 on: July 04, 2018, 07:11:34 PM »
That will be a bit of fun.  :popcorn:
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Offline b.lindsey

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #3 on: July 04, 2018, 07:51:51 PM »
Good to see you starting on another build Tony.

Bill

Offline cfellows

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #4 on: July 05, 2018, 04:08:26 PM »
That was one of my favorites of Elmer's engines.

Chuck
So many projects, so little time...

Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #5 on: July 11, 2018, 06:05:18 PM »
Thanks everyone, and now for the next update. The bearing supports. First the small one. A blank was squared up and the mounting holes drilled.



Next the hole for the bearing was drilled for a 10-32 clearance hole. The blank was mounted on the rotary table and the end rounded over.



Then it was back into the vise to square the shoulders.



The mounting holes were tapped and the piece test fit to the base. That’s when I ran into a problem. When I angled the edges of the base I forget to leave an area at full width to support the bearing.



I ended up milling down the support down to fit the available space.



I have some 3/8 bronze on order for the bearings so I step drilled and reamed the hole to size.



Next up was the larger bearing support. I squared up a blank and marked out the general shape.



Then I drilled out the bearing hole and a decorative hole in the blank.



The mounting holes were drilled and tapped. Next the part was mounted on the rotary table and rounded over.



The shoulders were squared off and the bearing hole taken out to 3/8.



Then the sides were milled to the lines.



I’ll end this updated with a family shot.



Till next time

Tony


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Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #6 on: July 22, 2018, 10:06:49 PM »
I got a little more work done this weekend. I made the cross slide guide. I started by squaring up two blanks. Then I drilled the mounting holes.



Next the tops were cut from the parent stock and milled to size.



Then I cut the relief in the bottom guides.



The blanks were flipped and the waste stock removed.



I turned up a set of spacers on the lathe.



That leads us to this family shot. (Please excuse it for being slightly out of focus)



Till next time.

Tony


Offline zeeprogrammer

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #7 on: July 22, 2018, 10:19:10 PM »
 :ThumbsUp:

Somehow I missed the previous post. The bearing supports look great.
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
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Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #8 on: August 01, 2018, 05:54:55 PM »
This week I worked on the cylinder. I squared up the blank and offset it in the four jaw chuck. The bore was drilled and reamed.



Then I turned the end to size.



The part was removed from the four jaw, flipped and placed on a mandril. That allowed me to turn the other end concentric with the cylinder bore.



Then it was over to the mill to drill the mounting holes and exhaust passage.



The part was rotated and the exhaust port drilled. The valve ports were milled and drilled. Finally the mounting holes for the valve chest were drilled.




The cylinder was placed on end and the mounting holes for the heads were drilled and tapped.




This next part always makes me nervous. It was time to drill the passages from the valve ports to the ends of the cylinders. For once it went without a hitch.



With that done I milled down the sides to final dimension and cut the round over.



A little work with the files and we end up with this.



Till next time.

Tony



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Offline b.lindsey

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #9 on: August 01, 2018, 08:13:33 PM »
I missed a few posts too Tony. You have made some nice progress in the meantime. Looking good!!

Bill

Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #10 on: August 13, 2018, 12:06:51 AM »
The project for this weekend was cylinder heads. I started with the easy one, the outboard head. The stock was turned down to match the cylinder OD and a register was turned.



Then it was over to the mill where I drilled the mounting holes while the head was still on the parent stock. Did I mention that I love the PCD function on my DRO?.



The head was parted off and faced. Next I turned the inboard head to dimension.



Then it was drilled and tapped to take the gland nut.



The mounting holes were put in on the mill



The head was parted off and the register was turned.



The bronze for the bearings came in and I had some additional time so I decided to make the crankshaft bearings. The bearings were turned to size and parted off with just a center pop in each end.



Then they were pressed into the supports with loctite 638 to hold them in.



The supports were reinstalled onto the base. Then they were drilled and reamed in situ to preserve alignment.



That’s it for this update. Till next time.

Tony


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Offline b.lindsey

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #11 on: August 13, 2018, 12:52:21 AM »
Great update Tony. Nice pictures too!!

Bill

Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #12 on: August 13, 2018, 01:20:22 AM »
Thanks Bill

Tony

Offline toolznthings

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #13 on: August 15, 2018, 01:49:38 PM »
Nice looking work and moving along towards the finish line.  :ThumbsUp:
Thanks for the visit !
Brian

Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #14 on: August 19, 2018, 08:24:55 PM »
I got a lot done this week so let’s get started. First up was the steam chest. After squaring up the blank, I put the part in the four jaw and turned one end round.



Then the part was flipped, turned and the other end rounded over using a round over end mill as a form tool.



The part was then drilled halfway tapping size for the gland nut.



Then it was over to the mill where I drilled the four mounting holes.  I tried to chain drill the interior but I stuffed it up. The holes were to close together and the drill wandered.



Thankful I was able to clean it up with an end mill.



The part was rotated and the intake was drilled and tapped.



At that point I realized that I forgot to drill the valve spindle hole into the far side of the valve chest. I took care of my omission and tapped the valve chest for the gland nut.



Next up were the valve cover and valve plate. They were made together. I superglued the two blanks together and squared them up. Next I drill the four mounting holes.



I separated the parts with my butane torch and drilled the holes in the valve plate.



The last piece I made this weekend was the valve itself. The part was made on the parent stock. I took the end to width and milled the pocket.



Then the stock was flipped and I milled in the channels for the valve rod and nut.



The part was then cut from the parent stock and brought to length.



That’s it for this week. Till next time.

Tony


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Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #15 on: August 26, 2018, 09:04:48 PM »
This week the piston and crankshaft were completed. Let’s start with the piston. The blank was turned down slightly oversized and grooved for a silicon o-ring.



Then the end was drilled and tapped. A shoulder was put in using an end mill.



The piston was parted off and put aside. The piston rod was cut to length and threaded on both sides.



Then the piston was screwed on to the rod. Next the assembly was trued up and turned to size.



Next up is the crankshaft. The blank for the crank was turned on the lathe. Then it was drilled and reamed to take the shaft.



Over to the mill where the shape was milled out (please excuse the dark picture)



The crank was parted off and the shaft was stepped to take the crank.



The shaft was pressed into the crank and the assembly trued up in the lathe.



At that point I realized that I had forgotten to drill and tap the hole for the crank pin. That was handled in the mill.



Next I turned up and hardened a set of filing buttons and rounded over the end of the crank.



I’ll end this update with a family shot.



Till next time

Tony




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Offline zeeprogrammer

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #16 on: August 26, 2018, 11:26:12 PM »
The family shot is great! I'm always glad to see those.

Looking good!  :ThumbsUp:
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Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #17 on: August 26, 2018, 11:28:56 PM »
Thanks Z, a couple more weekends of work and we should have it running.

Tony

Offline b.lindsey

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #18 on: August 26, 2018, 11:30:54 PM »
Yep, I love the family shots too. Looking forward to a nice runner!!

Bill

Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #19 on: September 02, 2018, 07:56:10 PM »
This is a four day weekend for me so I had plenty of time to make some serious progress.  I started by making some hardware. I turned up the crank pin and gland nuts for the cylinder and valve chests.



Next I fabricated the eccentric rod. I turned and reamed a piece of brass to fit over the eccentric.



Then it was parted off and a slot was cut to take the rod.



The rod was drilled for the pin and soldered to the ring.



Then the part was pickled and the end rounded over.



Next was the eccentric itself. The initial shape was turned in the four jaw and the center drilled and reamed.



Then the offset was put in and the eccentric was turned to a slip fit on the eccentric rod.



The next part was the valve rod. I don’t have a center small enough to turn this part with support. It was shaped by turning small segments and then extending the part. Then the segments were blended with some emory cloth.



The part was threaded and then taken to the mill where the flats were milled and the hole drilled.



Then the end was slotted with a slitting saw.



With the valve rod done it was time to make the connecting rod.
This was turned to shape with tailstock support.



Then the flats and holes were put in on the mill.



After parting off the connecting rod I started on the flywheel. It was fettled to clean it up and mounted in the three jaw and the hub cleaned up.



The part was flipped and the inner rim cleaned up.



The part was flipped again and grabbed by the inner rim to reduce chatter. The side, rim and hub were taken to dimension.



There are a couple of blowholes in the rim so I am going to fill them and paint the whole thing. Next the center was drilled and reamed. The flywheel was superglued on to an off cut of the drill rod used to make the crankshaft and trued up.



The last thing done on the flywheel was to drill and tap it for the grub screw.



The last piece to make is the crosshead. The blank was squared up then drilled and tapped to screw onto the piston rod.



Then it was drilled for the cross pin and slotted.



Lastly the two relief cuts were made.



Here is the final family shot.



I’ll end with the engine temporarily assembled for a test run.



 Now I have to take it all apart for paint and lag the cylinder. Till next time

Tony


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Offline Ye-Ole Steam Dude

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #20 on: September 02, 2018, 08:00:35 PM »
Looking really good Tony.

Have a great day,
Thomas

Online Kim

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #21 on: September 02, 2018, 10:47:38 PM »
Wow, Tony, that's a lot of progress!
Can't wait to see the video of it running :)
Kim

Offline zeeprogrammer

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #22 on: September 02, 2018, 11:07:56 PM »
Nice progress! Nice work! Almost there.  :ThumbsUp:
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Offline b.lindsey

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #23 on: September 03, 2018, 12:30:56 AM »
Sweet Tony, and you still have a day to go in the long weekend  :D

Bill

Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #24 on: September 03, 2018, 12:37:53 AM »
Thanks guys, it’s a runner but no vids until I get it painted. Otherwise I’d procrastinate on the final paint and finishing which I hate. I’ve got it all torn down and ready for primer tomorrow.

Tony

Offline AOG

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Re: AOG’s version of the Elmer’s number 33 mill engine
« Reply #25 on: September 09, 2018, 09:48:04 PM »
It’s done and she’s a runner. Pics and video are in the showcase.

http://www.modelenginemaker.com/index.php?topic=8426.msg182899#msg182899

Tony