Author Topic: 1909 Mercedes Aero Engine  (Read 45778 times)

Offline Jasonb

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Re: 1909 Mercedes Aero Engine
« Reply #90 on: January 15, 2019, 03:13:15 PM »
That seems to tie in with the 0.7kg given on the merc drawings

Offline Old Bill

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Re: 1909 Mercedes Aero Engine
« Reply #91 on: January 25, 2019, 10:39:06 AM »
Time has been short recently although I have managed to snatch an hour or two in the shed. Better still, I have a day off today! I have turned up the spring retainers and a few spares as I predict that a few will be hidden by the Gremlin when I try to fit them.





Then it was on to the rocker shaft mounting pillars. First job was to turn up the pillars.



Then to make a start on the cross pieces. Holes first!



A couple of plugs in the end to give me a filing datum and then I radiused the edge with the file. Right or wrong, at least they will all be the same!





Cut them off and face to length.





More buttons and filing.



A trial fit!



The tricky bit was to silver solder them together with the tops pointing the right way so that they do up tight in the right position. I scribed the top of each pillar before fluxing and assembling. Then I rotated the top according to the line and soldered them up. They seem to be OK.



Clean up and onto the next.



The rocker shafts seemed like a good place to continue so, as they are only grooved bits of silver steel, I have just done them. I have datumned each groove from the last in order to keep the tool close to the chuck. This does give me tolerance stacking but I don't think it will be an issue that I can't get around with the rockers.









It is beginning to look quite pretty. Timing gears next.

Steve   :) 


Offline scc

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Re: 1909 Mercedes Aero Engine
« Reply #92 on: January 25, 2019, 10:43:04 AM »
Extremely impressive :ThumbsUp:             Terry

Offline Vixen

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Re: 1909 Mercedes Aero Engine
« Reply #93 on: January 25, 2019, 10:48:19 AM »
Looking Good  :ThumbsUp: :ThumbsUp: :ThumbsUp:

Mike
It is the journey that matters, not the destination

Sometimes, it can be a long and winding road

Offline Old Bill

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Re: 1909 Mercedes Aero Engine
« Reply #94 on: January 25, 2019, 10:52:19 AM »
You are very kind, Terry. Thanks.

Steve.

Offline gbritnell

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Re: 1909 Mercedes Aero Engine
« Reply #95 on: January 25, 2019, 12:18:00 PM »
That's going to be a unique engine. Very nice work!
gbritnell
Talent unshared is talent wasted.

Offline Ye-Ole Steam Dude

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Re: 1909 Mercedes Aero Engine
« Reply #96 on: January 25, 2019, 12:36:46 PM »
Hello Steve,

Beautiful workmanship and a beautiful engine.

Have a great day,
Thomas
Thomas

Offline Old Bill

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Re: 1909 Mercedes Aero Engine
« Reply #97 on: January 26, 2019, 08:52:19 PM »
You are all too kind. I am sure that anyone could do this really. They just have to want to enough!

I thought I would move onto the timing gears. These are supplied as pre-cut blanks and just need finishing off.



First job was to make a collet for the pinion. As cutting four slots is a lot easier that three, I elected to use my four-jaw self-centring chuck.







Some years ago, I made the George Thomas keyway cutting attachment and this made short work of the slot in the pinion. Actually, I can highly recommend making such a device as key slots are so easy that they become the preferred method of securing wheels to shafts and are infinitely better than locking screws.







The big wheel was held the same way before setting up in the mill to drill the pilot holes for the spokes..



Must get a taller mill. This is as high as it goes!





A few minutes with the sawing wires.





And then a couple hours with the needle files and some emery cloth.



I drilled and tapped it 5BA for a grub screw. This was a mistake as I have only found 4BA and 6BA for sale! Will have to make one or make do with a slotted screw.





I thought I had better see how they mesh and drilled and reamed some holes in a piece of steel at the coordinates specifed in the drawing. They do mesh but are a bit tight so I shall add a couple of thou in each direction just to give them some slack.



I am planning to take a look at the camshaft next but sooner or later, I am going to have to grit my teeth drill the holes through the crank case. The crank hole is big enough to line bore but despite the good advice offered to me here, I am still not confident about the camshaft bearings. I expect it will be ok in the end. I just need to have a go!

Steve    :) 


Online sco

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Re: 1909 Mercedes Aero Engine
« Reply #98 on: January 26, 2019, 09:09:31 PM »
Great work Steve - keep it up!

Simon.
Ars longa, vita brevis.

Offline 10KPete

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Re: 1909 Mercedes Aero Engine
« Reply #99 on: January 26, 2019, 10:24:42 PM »
 :ThumbsUp: :ThumbsUp:

 :popcorn: :popcorn:

 :cheers:

Pete
Craftsman, Tinkerer, Curious Person.
Retired, finally!
SB 10K lathe, Benchmaster mill. And stuff.

Offline Vixen

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Re: 1909 Mercedes Aero Engine
« Reply #100 on: January 26, 2019, 10:50:21 PM »
looking good :ThumbsUp: :ThumbsUp:

Mike
It is the journey that matters, not the destination

Sometimes, it can be a long and winding road

Offline steamer

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Re: 1909 Mercedes Aero Engine
« Reply #101 on: January 27, 2019, 01:49:10 AM »
Cranking out some work there Steve!   I like the valve lifter brackets a lot!

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

Offline Old Bill

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Re: 1909 Mercedes Aero Engine
« Reply #102 on: January 27, 2019, 08:29:04 PM »
Thanks Chaps. It is amazing what you can do when you don't have to go to work!

Thinking about the camshaft now. Roger B. very kindly sent me an Excel spreadsheet to calculate the cam lift at various positions to enable me to mill the profile. However, when I entered the cam details, I was getting some very odd answers so I took the old fashioned approach and drew the cam out at twenty times full size.



With a 120° working angle, 6mm base circle and 10mm flank radii, it doesn't quite make the full lift and there is no tip radius. This doesn't feel right to me but I don't have the experience to suggest what it should be. If I increase the working angle to 130°, I get a tip radius of 0.95mm or if I make it 125°, I get 0.38mm. I could increase the flank radii to 12mm which would also give me 0.38mm radius. I would value some advice please!

In the mean time, I decided to turn up the camshaft blank.







Then the other half of the centre main bearing. This is a very simple shape!





A couple of 5BA studs and that is another tick in the box.





I am beginning to think about drilling the main bearings so I have bought some long-series drills. Looks like I should have asked for 'extra long'......



I have made an extended centre drill by Loctiting one in the end of a piece of silver steel.



And I finally took Jo's advice and fitted a digital read out to the quill on my mill. It has been sitting on the bench for several years waiting for the feeling to come upon me to do it!



I think I shall do the oil tray in the sump next whilst I ponder the cams.

Back to work tomorrow so it will slow down!

Steve    :)


Offline stevehuckss396

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Re: 1909 Mercedes Aero Engine
« Reply #103 on: January 27, 2019, 11:24:18 PM »
If you plan to start the engine with a drill or RC starter go to 140 (280 crankshaft) degrees with a 110 degree lobe seperation

From the comp cams catalog

HYDRAULIC-Great for street machines.   2000 to 6000RPM        280 280  110°
Do not be like the cat who wanted a fish but was afraid to get his paws wet.

Offline steamer

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Re: 1909 Mercedes Aero Engine
« Reply #104 on: January 27, 2019, 11:35:06 PM »
If you plan to start the engine with a drill or RC starter go to 140 (280 crankshaft) degrees with a 110 degree lobe seperation

From the comp cams catalog

HYDRAULIC-Great for street machines.   2000 to 6000RPM        280 280  110°

Ill keep that in mind on my engine Steve!

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

 

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