Author Topic: GDB Inline 4 Cylinder OHV I.C.  (Read 3166 times)

Offline 90LX_Notch

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GDB Inline 4 Cylinder OHV I.C.
« on: August 19, 2018, 07:28:54 PM »
My next build has begun.  It is George Britnell's Inline Four Cylinder Over Head Valve Internal combustion engine. 

This will be a long term build due to work and kid related activities.  If updates are sparse please inquire with a post.  It helps me to find shop time knowing that someone is following along.

Engine Block:

The block is 6061 Aluminum and was first squared.

Somehow the pictures of the more difficult side are not on the camera.  I was stumped for awhile as how to get the .062 radius that is called for at the bottom corners and transitions.  My .125 ball endmill did not have the required length of cut.  I finally realized that if I angled the mill's head at 45 degrees I could machine and blend the required radii. 

Fortunately, I do have the pictures for the easier side.  I scribed the necessary lines and began to whittle away at the block.  Once the required angle was roughed, the engine block was transfered to a fixture plate that allows it to be set for angles in the mill's vice.  This particular angle fixture design came from one of the contributors of the "Shop Made Tools" thread at  Home Shop Machinist.  Once the angle was set the the block was indicated and clamped to the fixture with c-clamps. 

Once both sides were machined I started to do some hand blending with sandpaper and stones.  I still to do more blending but will hold off until the engine block is completed.

-Bob
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #1 on: August 19, 2018, 07:31:21 PM »
More pics
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Online b.lindsey

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #2 on: August 19, 2018, 08:28:25 PM »
Good start on the block Bob. I will be here for the duration, no matter how long it takes :)

Bill

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #3 on: August 19, 2018, 10:51:37 PM »
Thanks Bill for jumping onboard. 

I'm excited for this build.  This is such a cool little engine.  I was blown away by George's video of it when I started in this hobby nine years ago.  We all marvel at George's work; but, to actually build one of his engines to print, really opens one's eyes to just how skilled he is.  To say it's humbling is an understatement.  My skills are going to get pushed beyond their limit.  But, that is the only real way to build skills.

-Bob
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Offline Tennessee Whiskey

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #4 on: August 20, 2018, 12:22:46 AM »
 :popcorn: and  :DrinkPint: in hand: Iíll ride along too Bob.

Eric

Online gbritnell

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #5 on: August 20, 2018, 01:19:19 AM »
Bob,
Needless to say but if you have any questions please don't hesitate to ask.
I'll be following every step of the way.
P.S. You will want to put the cam hole in before opening up the crank pockets.
gbritnell
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Online 10KPete

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #6 on: August 20, 2018, 01:20:56 AM »
I think it's safe to say that many of us have a seat for this show!

 :ThumbsUp: :popcorn: :DrinkPint: :ThumbsUp:

Pete
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #7 on: August 20, 2018, 01:30:58 AM »
Glad to have you along again Eric.

Thanks George I appreciate it.  I've been able to figure out everything so far.

Thanks so much Pete.  I am happy that you coming along again for this one.

-Bob
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Offline zeeprogrammer

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #8 on: August 20, 2018, 01:53:36 AM »
As I said in another thread...I'm watching.  :popcorn:
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Offline Roger B

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #9 on: August 20, 2018, 07:53:15 AM »
I will be following along as well  :ThumbsUp:  :ThumbsUp:  :wine1:
Best regards

Roger

Offline crankshafter

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #10 on: August 20, 2018, 08:31:19 AM »
Bob
I'm in for the ride ;)

CS




"I cut it twice, and it's still to short"!!??">#%

Offline deltatango

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #11 on: August 20, 2018, 08:48:19 AM »
Hi Bob,
I'm following this one as well. It doesn't matter how long it takes!
David

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #12 on: August 20, 2018, 08:23:35 PM »
Zee, Roger, crankshafter and David thank you for signing on for this journey.  Your support, as in the past, is greatly appreciated.  I'm hoping to make some progress this week and post it over the coming weekend.

-Bob
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Offline fumopuc

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #13 on: August 20, 2018, 08:25:06 PM »
Hi Bob, me too, will wait for each new step of this build.
Kind Regards
Achim

Offline Sleddog

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #14 on: August 21, 2018, 12:22:48 AM »
I've got my chair slid into position too. Right next to the popcorn :popcorn:
Looking forward to following along.

Jack

Offline Dave Otto

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #15 on: August 21, 2018, 12:27:16 AM »
Hey Bob,
Looking forward to following along with your new project.


Dave

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #16 on: August 21, 2018, 11:39:40 AM »
Achim, Jack and Dave, thank you for joining in.  It's going to be a long ride.

-Bob
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #17 on: August 26, 2018, 04:16:19 PM »
Engine Block continued:

Unfortunately, I didn't get any shop time this past week.  Yesterday, I was able to get a little time in and did some layout work for the next machining operation.  I am hoping to get some time in this afternoon to actually do some machining.

As far as the layout goes, I thought I'd post a picture of my Brown and Sharpe 570 vernier caliper in action.  It is an old vernier that I picked up that has two holes in it that are for setting dividers.  It provides an easy way to set an accurate radius for layout work.  I usually don't do layout work and just machine off of the dials from datums.  For this particular venture, I have the layout lines to serve as a check and balance to hopefully prevent a machining blunder.
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Online gbritnell

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #18 on: August 26, 2018, 06:05:35 PM »
HI Bob,
Even though I have digitals on my machine I always give myself layout lines for reference.
gbritnell
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #19 on: August 28, 2018, 08:53:44 PM »
George they are a big help with the intricacies of this part.

I literally got called into work Sunday right when I was about to go into my shop.  I was able to get in the shop a little Sunday night and installed a toolmaker's button.  The button will allow me to indicate accurately on the rotary table to mill the pocket for the timing gears.

-Bob
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #20 on: September 03, 2018, 10:11:36 PM »
Engine Block continued-

After the layout, the block was tapped 5-40 and a Toolmaker's Button was installed.  The Button was then carefully moved into position.  The Engine Block was then setup on an angle plate and mounted to the Rotary Table.  The Button was then indicated true to the Rotary Table; finally, the RT was indicated to the spindle.  Then it has just been a lot of cranking of the handles and whittling away at the aluminum.  This feature is probably about 90% finished.

-Bob
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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #21 on: September 03, 2018, 10:28:36 PM »
Looking great Bob. Glad you are finding some shop time.

Bill

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #22 on: September 03, 2018, 10:32:52 PM »
Thanks Bill.  Thank goodness for this long weekend.  We had a wedding on Long Island that chewed up most of it.  Luckily I was able to get in the shop this morning and machine what I posted above.  Now I need to get off of this computer and get back at it.

-Bob
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Offline zeeprogrammer

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #23 on: September 03, 2018, 10:54:12 PM »
I got really confused by the photo of engine block.
I don't recall your posting a picture of the project and my googling left me even more confused.

Can you point me to a picture of what you are building?
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #24 on: September 04, 2018, 12:54:17 AM »
Carl a video is worth a million words.  It is George's four cylinder.  I am currently machining the front of the block.  The pocket is where the timing gears will reside.


-Bob
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Offline zeeprogrammer

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #25 on: September 04, 2018, 12:56:54 AM »
Fantastic!
And thanks. That's going to be a fun engine!  :ThumbsUp:
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #26 on: September 04, 2018, 08:50:33 PM »
Block continued-

Once all of the pocket was milled with the 3/16 endmill that I was using, I moved onto the od of the pocket that protrudes beyond the block.   I calculated the wall thickness and used my Starrett 220 Multi-Anvil Micrometer to verify the dimension.  Next, the bottom edge of the block was indicated square to the table.  This allowed me to position x and y in order to cut a .355 radius inside the pocket.  The radius is required for the crank timing gear.  I used my boring head to cut the radius.  The process was repeated, and a .434 radius was cut for clearance for the water pump.

-Bob
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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #27 on: September 04, 2018, 10:08:21 PM »
You are on a roll Bob!! Always like following your builds.

Bill

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #28 on: September 05, 2018, 01:19:56 AM »
You are on a roll Bob!! Always like following your builds.

Bill



Thanks Bill!  You made my day!  I was able to even get a little shop time in this evening.  I'll post the pictures tomorrow.

-Bob
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Offline Tennessee Whiskey

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #29 on: September 05, 2018, 07:44:05 PM »
Iím here also Bob. Looks like you are moving right along. ĎFraid youíre going to have to find something larger than a pill bottle to take this one to shows in though 8)

Eric


Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #30 on: September 06, 2018, 11:34:40 PM »
Thanks Eric.  Maybe a shoe box to transport this one.

-Bob
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #31 on: September 06, 2018, 11:41:37 PM »
Block continued-

The tangent points of the two internal radii needed to be milled in a straight line along with the outside of the wall. In order to align the radii, two ball bearings and tool blank were used.  This worked well and the tangents were sucessfully blended.  Next the outside of the wall was milled. 

-Bob
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Offline zeeprogrammer

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #32 on: September 07, 2018, 12:13:21 AM »
Neat!
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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #33 on: September 07, 2018, 12:57:26 AM »
Yeah, neat trick Bob. Have to file that one away.

Bill

Offline Dave Otto

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #34 on: September 07, 2018, 01:13:50 AM »
Nicely done Bob!

Dave

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #35 on: September 07, 2018, 02:07:28 AM »
As always, thank you gentlemen for your support. 

I posted the bearing trick in "Tip and Tricks" with a writeup.

-Bob
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Offline Roger B

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #36 on: September 07, 2018, 08:45:48 AM »
Off to a great start  :ThumbsUp:  :ThumbsUp:  :wine1:
Best regards

Roger

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #37 on: September 09, 2018, 04:27:52 PM »
Block continued-

The timing case feature is now complete, sans the threaded holes for the cover and some additional handwork.  The .062 radius on the outside back edge was done with a lathe tool that was mounted in a fly cutter.  The spindle was locked in position and the Rotary Table was cranked and acted like a Planar with the tool being fed in small increments.  This allowed the cutter to cut right up to the corners without trailing away as would happen if the tool was turning in the spindle. 

The outside of the small radius for the wall, which was machined in the above post were the tangent was milled, was done in a similar fashion.  The boring bar was mounted 180 degrees out from normal as if to cut an od with the boring head.  The boring head was carefully turned back and forth by hand.  After each cut, Z was increased .010 and the motion was repeated until the depth of the wall was fully cut.

-Bob
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #38 on: September 09, 2018, 04:28:52 PM »
Thanks Roger for your support.

-Bob
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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #39 on: September 09, 2018, 06:57:52 PM »
Good to see you getting some shop time Bob. The block is coming along well.

Bill

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #40 on: September 17, 2018, 03:18:12 AM »
As always Bill, thank you for following along.

For a couple of different reasons I put the block on hold.  My allergies have been bad and the block requires more concentration than I am able to muster at this point.  Secondly, I have the Rivett 608 up on blocks incase the basement floods as Florence moves this way.  I was planning on boring the cam tunnel next and was going to set it up on the Rivett with an angle plate bolted to the faceplate. 



Crankcase breather-

In order to keep this build moving, I picked off a part that I could get through with my allergy situation.  I started the crankcase breather assembly by making the flange.  I started with a piece of .750 diameter aluminum and roughed out a blank.   The blank was then mounted to the .187 dia. expanding collet that I used for the flywheels in the "Tiny I.C." build.  The collet was used to face the back of the blank and was then transfered to a Vee Block, which was setup on the Rotary table.  The bolt holes were drilled along with one hole into the collet that allowed the blank to be pinned to help prevent it from moving during milling. The basic profile for the flange was then milled.  The smaller radii were filed by hand.

-Bob
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Offline Art K

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #41 on: September 17, 2018, 04:03:44 AM »
Bob,
Just in case I haven't chimed in yet I wanted to let you know that I'm following along. I have a great respect for George and it is great to start to see people building his designs. Great work so far.
Art








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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #42 on: September 17, 2018, 05:48:29 AM »
Nice little part there, Bob.
Sorry about the allergy situation.  That's no fun at all. Hope it gets better soon!
Kim

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #43 on: September 17, 2018, 10:49:42 PM »
Thanks Art for following along as well as your kind compliment.

Thanks Kim.  Yeah, allergies are not fun at all.  I try very hard not to take anything for them and usually they clear up within a day or two on their own.  The fall is a particularly bad time for me. 

-Bob
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Offline zeeprogrammer

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #44 on: September 17, 2018, 11:41:16 PM »
 :popcorn: Following along.

Try not to sneeze in the shop. Those small parts will fly.
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Offline Art K

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #45 on: September 18, 2018, 12:12:14 AM »
Bob,
I started taking Wal-itin by my doctors recomendation it's Walgreen's generic version. Other wise I'd be blowing my nose all summer, oh yeah and sneezing to.
Art
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #46 on: September 24, 2018, 12:16:11 AM »

Block continued-

The cam tunnel calls for a .312 diameter hole, 4.523 deep.  In order to get good geometry, the engine block was setup on an angle plate on the faceplate of the Rivett.  A toolmaker's button was used to locate the center point of the block.  As of right now, I am about halfway through the block with a .250 pilot hole.  It is taking an extremely long time to drill the pilot because the lathe is in backgear and the surface speed is far below what a .250 drill requires.

-Bob
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Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #47 on: September 24, 2018, 12:17:17 AM »
Thanks Art for the tip.  Unfortunatly, there aren't any Walgreen's near me.

-Bob
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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #48 on: September 24, 2018, 12:56:31 AM »
That's quite a set up Bob!! Hope the allergies are better now.

Bill

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #49 on: September 25, 2018, 12:16:28 AM »
Thanks Bill.  My allergies were bad Friday and Saturday.  They were good yesterday.  I should have quit while I was ahead though.  I had a little mishap with the block. The boring bar rubbed and the block shifted on the angle plate.  I believe it is recoverable.  I just have to add an extra step to the plan that I had in mind.

-Bob
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Offline gldavison

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #50 on: September 28, 2018, 04:20:12 PM »
Hi Bob

 Just caught up on this build. Excellent work so far. I'll be following along. Did George have a build thread on this engine? I need a project for this winter, and this looks like a good one. So I need plans.

Gary

Online gbritnell

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #51 on: September 28, 2018, 07:03:37 PM »
HI Garry,
There is no build thread as it was made long before I had a computer or digital camera. I do have the drawings. Send me a personal email and I'll give you the particulars.
gbritnell
Talent unshared is talent wasted.

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #52 on: September 30, 2018, 11:42:29 PM »
Thanks for following along Gary.

It will be nice if you pursue this engine also.  If we can get a third person (come on Bill), it will be the "Tiny" builds of a couple of years ago all over again.

-Bob
Proud Member of MEM

My Engine Videos on YouTube-
http://www.youtube.com/user/Notch90usa/videos

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #53 on: September 30, 2018, 11:43:50 PM »
Unfortunately, I couldn't squeeze in any shop time this weekend.

-Bob
Proud Member of MEM

My Engine Videos on YouTube-
http://www.youtube.com/user/Notch90usa/videos

Offline 90LX_Notch

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #54 on: November 26, 2018, 03:06:17 AM »
Well, it has been close to two months since I last posted in this thread.  Life has gotten in the way of any shop time.  However, I was able to get in the shop today and made a .250 diameter by six inch long boring bar.  The bar uses #44 (.086) drill rod as an insert tool bit.  I proofed it on a piece of 7075 aluminum using the above setup (faceplate and angle plate) and successfully bored a .300 dia, 1.5 inches deep.  Unfortunately, when I went to take a picture, the camera batteries were dead.

Hopefully, I can get more shop time in and start to move forward with this build.  Unfortunately, this winter is already stacking up to be bad.  We had a 10" storm hit us last Thursday and I have been called out several times since, for icey road conditions.

-Bob
Proud Member of MEM

My Engine Videos on YouTube-
http://www.youtube.com/user/Notch90usa/videos

Online steamer

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Re: GDB Inline 4 Cylinder OHV I.C.
« Reply #55 on: November 26, 2018, 11:18:08 AM »
I hear ya buddy!   Stick with it, it'll come back and winter wont last for ever....... 8)

Dave
"Mister M'Andrew, don't you think steam spoils romance at sea?"
Damned ijjit!