Author Topic: S. Charlesworth slide valve mill engine  (Read 3328 times)

Offline scc

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S. Charlesworth slide valve mill engine
« on: January 21, 2019, 10:32:40 AM »
Hi All,     Having abandoned my "New project mill engine"  thread, I have decided to do the job properly!  I've  been lurking in my dark but dry cellar with a nice traditional drawing board. ( I can hear the groans from all the CADers).  I have enough detail now to make a start on obtaining materials rather than adapting the parts to suit scrap bin contents :ShakeHead:   Although a start has been made progress will be slow. As much as I love this hobby there are many demands on my time..........family, wife's business, three days a week at work on full size road steam, caravan, etc....Often when there is time I'm too knackered to use it :old:      so be patient friends.

Regards to all               Terry

Online Jasonb

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Re: S. Charlesworth slide valve mill engine
« Reply #1 on: January 21, 2019, 12:19:10 PM »
Will you be able to salvage any of the parts already made or are you going to start again from scratch?

Offline b.lindsey

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Re: S. Charlesworth slide valve mill engine
« Reply #2 on: January 21, 2019, 02:55:31 PM »
That certainly fits the description of a "man cave" Terry, but I must say it looks to be a cozy space to think and draw. Doesn't look too dark from the picture and as long as its dry and warm, it looks quite inviting  :D

Bill

Offline Ye-Ole Steam Dude

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Re: S. Charlesworth slide valve mill engine
« Reply #3 on: January 21, 2019, 05:00:48 PM »
Hello Terry,

That looks like a neat place and setup to do all the design and drawings. I will be on board.

Have a great day,
Thomas

Online Kim

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Re: S. Charlesworth slide valve mill engine
« Reply #4 on: January 21, 2019, 05:07:31 PM »
... I've  been lurking in my dark but dry cellar with a nice traditional drawing board. ( I can hear the groans from all the CADers).  ...

Hey Terry, let the CADers groan :) When you're doing something for fun, you might as well do it in a way you enjoy!

Looks like a nice cozy space you have there!
Kim

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #5 on: January 21, 2019, 07:11:09 PM »
Thanks for the comments guys. Yes it is a cosy space but a little short on headroom. Our heating boiler lives there so quite warm at the moment.   Jason I have scrapped all the  previous bits apart from the flywheel.       Terry

Offline kvom

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Re: S. Charlesworth slide valve mill engine
« Reply #6 on: January 21, 2019, 11:14:56 PM »
Pencil & paper?  Nah, it'll never work,   :ROFL:

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #7 on: January 25, 2019, 01:17:17 PM »
Drawing system contempary to the subject matter and suitable for my abilities :) :atcomputer: :shrug:

Postman arrived today with some goodies.   A couple of just- in -case items for the Burrell AND some metal to start my mill engine. Hope to make a start as soon as time permits.            Terry

Offline Art K

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Re: S. Charlesworth slide valve mill engine
« Reply #8 on: January 25, 2019, 04:07:45 PM »
Terry,
If you can do it on a drafting board all the more power to you, it's probably becoming a lost art as well. I cant do on paper what I can in cad. Knowing my abilities... :)
Art
"The beautiful thing about learning is that no one can take it away from you" B.B. King

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #9 on: February 06, 2019, 08:02:22 PM »
Having checked my drawings a few times I discovered some glaring errors :embarassed:  Redrawn and treble checked the moment came to start on metal. There  was not much  spare time available so I made the split brasses for the crankshaft main bearings.   Soldered two rectangular lumps of brass together, squared up in the mill, then set up in the four jaw. I machined the outside profiles of both, then drilled a midges undersize for the shaft, then parted off. They are now  in the pickle.  All easy stuff for most of you, but I'm chuffed to be back in the shed.....even for short periods.          "One small step..etc"                 Terry

Online crueby

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Re: S. Charlesworth slide valve mill engine
« Reply #10 on: February 06, 2019, 08:04:54 PM »
Very  nicely done!  Keep on 'steppin'!

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #11 on: March 24, 2019, 09:29:09 PM »
Am I ever going to make progress on this engine?   Having had to dismantle my mill and remake feedscrew nuts etc, I decided today to start on the fabricated power take off pulley.  Got some bar stock set up with the rotary table set on edge at 90 degrees. It was clamped to the mill table by three tee bolts and straps. In spite of very gentle feed (1/8" endmill) the set up insisted on slowly moving off centre. :cussing:
There is insufficient room to do much so I have decided to fit a key to the base of the rotary table so that it cannot turn. All my kit worked OK building the big Burrell..................trying not to get annoyed........
Terry

Offline Admiral_dk

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Re: S. Charlesworth slide valve mill engine
« Reply #12 on: March 25, 2019, 05:35:43 PM »
It's bad enough when one self makes mistakes - but it is really annoying when the tools are playing up  :censored:

I hope that you get everything back on track - if only one bit at a time  :cheers:

Best wishes

Per

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #13 on: March 25, 2019, 08:49:36 PM »
Cheers Per,    All sorted now I hope. I have made and fitted a key to the rotary table base that is a snug fit in the mill table tee slots.  While I was at it I put one one my big milling vice. Should have done it years ago. Every thing stays square now. :) Managed a bit of gardening as well. ..so a good day......off to the real job tomorrow :(         Terry

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #14 on: July 15, 2019, 09:29:41 PM »
I cannot believe that it is several months ago that I last posted on this build :o  Things got really busy on the full size Burrell at "work" and I have been getting home worn out :old: I have also had a spell in hospital to remove a nasty tumour. All is well now and I am venturing back to the shed. Made parts for the belt pulley which  as yet is not soldered, progressed the fabricated base and started the con rod with it's bearings. As usual all basic stuff so just a few pics.      Terry

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #15 on: July 15, 2019, 09:31:11 PM »
one more pic

Offline Johnmcc69

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Re: S. Charlesworth slide valve mill engine
« Reply #16 on: July 16, 2019, 12:12:35 AM »
 :ThumbsUp: :popcorn:
 I like that flywheel. Nice work!

 John

Online crueby

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Re: S. Charlesworth slide valve mill engine
« Reply #17 on: July 16, 2019, 12:23:15 AM »
Great job on the flywheel hub and that con rod bearing, looking terrific!
 :popcorn: :popcorn:

Online bjo

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Re: S. Charlesworth slide valve mill engine
« Reply #18 on: July 22, 2019, 07:44:54 PM »
I LOVE that last photo of it assembled!  ;D

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #19 on: July 28, 2019, 11:14:56 AM »
Thanks gents,    When I looked closer at the real engine I realised that the con rod bearings are not retained by the usual gib and cotter arrangement :ShakeHead: The joint is retained by two gibs and a central cotter with a threaded end. This thread worked out at 6ba, the cotter end was not much bigger so it was  a bit of an education for me to be on such a scale.....OK, I realise that 6ba is HUGE for a lot of you but come on, I have just finished a 4" scale lump!      Terry

Offline Ye-Ole Steam Dude

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Re: S. Charlesworth slide valve mill engine
« Reply #20 on: July 28, 2019, 11:51:11 AM »
Hello Terry,

That makes for a nice arrangement.

Have a great day,
Thomas

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #21 on: October 14, 2019, 09:16:04 PM »
After yet another long interuption of "shed" time I have managed a little bit of progress.  Not being happy with the first set of slidebars I have made a new set, progressed the bed and started on the cylinder.  I cut out the bed for the cylinder and forgot to allow for the flanges :facepalm2:
in spite of having made a set of drawings :old: Had to cut the correct size aperture AFTER I had put some primer on. I will be following Jason's excellent system for the cylinder. It's good to be back making swarf again.   
Something that I have noticed is that when using small cutters on my mill with the knee raised, it is hard to see the work. Visibility is so much better on the "quill" type mills that so many of you use.

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #22 on: November 02, 2019, 10:23:49 PM »
I have been looking at my part made belt pulley, as yet still in component form. I was going to ask for ideas to hold it all concentric when I silver solder it.   Recent posts by Mike makes me think third hands will be worth making. :thinking:  The rim will be split in line with the hub to enable it to be fitted inboard of the flywheel.             All suggestions welcome :help:      Terry

Online Jasonb

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Re: S. Charlesworth slide valve mill engine
« Reply #23 on: November 03, 2019, 07:15:58 AM »
Bit late now but the trick is to leave the hole in the hub undersize and then you can mount the completed wheel/pulley in the lathe and bore out the hub to get a nice true fabrication.

As it is I would mount a post onto a flat plate that the hub can be clamped to and then clamp the rim concentrically around that and build up the wheel then solder. You need to watch out for the rim expanding as it heats up.

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #24 on: November 03, 2019, 11:22:14 AM »
Thank you Jason,    The hole is actually undersize by about 50thou.   Probably not enough...I suppose I could possibly sleeve it.  I'd not considered rim expansion,   cheers for that.                 Terry

Online Jasonb

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Re: S. Charlesworth slide valve mill engine
« Reply #25 on: November 03, 2019, 01:38:05 PM »
Are your spokes threaded into the hub or just loose? If loose work round the rim first and allow to cool then do the hub, this will allow the rim to expand and then shrink back into place.

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #26 on: November 04, 2019, 09:48:03 AM »
spokes loose in hub,  planned to silver solder them.      Cheers Jason.            Terry

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #27 on: December 13, 2019, 11:59:37 AM »
Earlier this week I had some spare time so got to the workshop. In spite of Jason's lovely fabricated bronze cylinder design ( and my lack of adequate heat source) I have changed my mind again and following prototype with a cast iron one. Set some CI bar in the 3jaw, faced one end and took a light skim along the length to ensure no hard spots that would catch me later. Into the saw to cut almost to length then back in the 3jaw to drill and bore to 0.005" below finished size. My next move is to mount on a mandrel with tailstock support and machine the outside profile. My photos always seem a bit blurred so I took extra care this time and got in close and steady. After three failed attempts to upload :Mad: I contacted admin.  Our ever helpful Jo pointed out correctly that my pic sizes may be too big :facepalm2:   So no pics with this post I'm afraid and some camera sorting on the agenda

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #28 on: December 17, 2019, 09:12:02 PM »
Camera sorted :whoohoo:(I hope)           A bit more progress, I set the cylinder onto a mandrel and machined the outside profile. Next onto the Raglan to machine the flat for the port block. This will be screwed together similar to Chris's winding engine.
I've added a pic of my scheme to build the drive pulley. The intention is to cut a shallow groove in an old faceplate in which to clamp the rim. The hub will be on a mandrel fitted to an M3 arbor in the lathe spindle. I hope this will enable a concentric wheel. :thinking:         Terry

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #29 on: December 19, 2019, 09:35:28 PM »
Back to the cylinder and time to make the end covers. On this engine both ends have similar castings but only one has a hole in!  A simple turning job although I struggled a bit with a lack of  suitable cutters, most being too big.....investment reqd. I shall machine both before I set up for the stud holes, etc.       Terry

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #30 on: December 20, 2019, 09:30:29 PM »
I am enjoying my unexpected free time to progress my engine :)   The back cover tonight. Note the tool changes to get the shape...just got away with it. The 3jaw on the little Clarke is surprisingly accurate so did the cover spigots on that.   I think the mounting feet will be next..or maybe the cover studs :thinking:    I always used to be concerned about parting off. My Atlas has a rear toolpost and with a Chronos tool I now part off  using power feed usually trouble free :ThumbsUp:                Terry

Offline Ye-Ole Steam Dude

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Re: S. Charlesworth slide valve mill engine
« Reply #31 on: December 20, 2019, 09:35:42 PM »
Hello SCC,

This is some mighty nice machine work and the project is looking good.

Happy holidays to you,
Thomas

Offline Johnmcc69

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Re: S. Charlesworth slide valve mill engine
« Reply #32 on: December 21, 2019, 12:24:53 AM »
 :ThumbsUp:
Looking great Terry! Glad you're getting things worked out.
 Parting is a little scary isn't it? But once you get a nice curl coming off, it's pretty slick.

 John

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #33 on: December 21, 2019, 10:36:09 AM »
Thank you Thomas  and John :cheers:   Best Wishes for Christmas.............and to everyone else of course!         Terry

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #34 on: January 02, 2020, 10:20:24 PM »
A bit more time so I decided to make the studs for the cylinder covers. Luckily I looked at pics  of the prototype :happyreader: it uses square headed bolts.....made that way or repair for stripped threads?   I decided to make some...machined some round bar to size and threaded 6ba leaving an oversize head. Having no collets I ended up holding my bolts in a small drill vice and JUST cleared the mill head to mill the square.
Next up the slidebars were checked for parallel on the mill and at the same time machined the "run-out " pockets/ oil reservoirs.
Made the cylinder base next. A jig to position the cylinder at the correct height then a quick welded fabrication. Drilled and tapped the cylinder 6ba to fix. There is much work to do on the base yet.         Best Wishes to All.              Terry

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #35 on: January 26, 2020, 10:01:32 PM »
A bit further into the journey!  I finished the cylinder covers today. Did the pcd on the rotary table then cocked it up by drilling the gland holes out of sync :cussing:    had to plug them and redrill /tap. All turned out well in the end. With all the cover fixings done I can move on to the valve block  and position the passages accordingly. My square head bolts seem ok too.       Terry

Offline zeeprogrammer

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Re: S. Charlesworth slide valve mill engine
« Reply #36 on: January 28, 2020, 11:22:00 AM »
Looking good.

I hadn't seen a part (don't know what it's called) with 3 bolts. I've seen 5,6, or more. Is there a reason?
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Offline gbritnell

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Re: S. Charlesworth slide valve mill engine
« Reply #37 on: January 28, 2020, 11:56:24 AM »
Very nice work!
gbritnell
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Online Jo

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Re: S. Charlesworth slide valve mill engine
« Reply #38 on: January 28, 2020, 12:01:06 PM »
I hadn't seen a part (don't know what it's called) with 3 bolts. I've seen 5,6, or more. Is there a reason?

I assume you are referring to the packing gland Zee. Oval packing glands normally use 2 STUDS and nuts, round packing glands 3 STUDS and nuts, to keep the packing in place to provide the seal on the piston/valve rod through their centre. I am sure Terry is only using the bolts as a temporary measure  ::)

Jo
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Offline zeeprogrammer

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Re: S. Charlesworth slide valve mill engine
« Reply #39 on: January 28, 2020, 12:04:41 PM »
Thanks!
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Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #40 on: January 29, 2020, 09:31:01 PM »
Round 3 stud packing gland as per prototype, Blank on the back cover.   The bolts are just there for the "family" shot.   I had made a start on the cylinder in bronze, but decided to follow prototype and do it in cast iron.   I know most of your well equipped shops will have bandsaws, etc but my basic home built hacksaw saved me a lot of sweat when chopping a lump of cast iron for the valve block :)
Thanks for the interest folks :ThumbsUp:   I was thinking no one was looking.        Terry

Online crueby

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Re: S. Charlesworth slide valve mill engine
« Reply #41 on: January 29, 2020, 09:47:09 PM »
Wow - that hacksaw rig sure saved you a LOT of greasy elbows!

Online Kim

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Re: S. Charlesworth slide valve mill engine
« Reply #42 on: January 30, 2020, 05:53:12 AM »
Wow!  That does look like a good-sized hunk of CI.  How long did it take your power hacksaw to hack its way through?
Kim

Offline scc

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Re: S. Charlesworth slide valve mill engine
« Reply #43 on: January 30, 2020, 05:11:35 PM »
I didn't time it Kim,  I just switch it on and do something else ::)   I guess 5 to 10 minutes.      Terry