Author Topic: Travis Steam Engine 2 X Size  (Read 1328 times)

Offline toolznthings

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Travis Steam Engine 2 X Size
« on: March 01, 2019, 06:47:38 PM »
Starting a new build thanks to Thomas ( Ye-Ole Steam Dude ) for sharing his nice set of plans for the engine he designed. A couple of private messages back and forth with Thomas and he agreed a double size build
would work out. This will be posted as I progress through the build.

Going to start with the crankshaft which will be probably the most difficult part to make. Leaving the output ends long, the crank will be 16.5 inches long. In keeping with the style of the engine I decided on a metric
size ball bearing for the crank to run on. It's overall size is compact compared to a inch size bearing. I'm using a 6003-2Z bearing. McMaster Carr # 6661K16.

Fastener sizes will be chosen as I go forward.

The for throws for the crank are 1.000" thick x 1.500" wide and 2.000" in diameter on the rounded end. The main shafts are .750 diameter at the throws and .625 diameter at the output ends. The connecting rod journals are .500" diameter. A diameter is turned for a slip fit for 17 mm bearing I.D.


Extra attention to sizing the throws was done by surfacing grinding the thickness and width after rough milling from a finish turned 2.000 diameter making four blanks. The extra effort will be apparent as I begin addition machining.

The blanks with the CAD layout of the crankshaft.
Setup in the mill for drilling, spot drill first opp.

 
Thanks for the visit !
Brian

Offline Johnmcc69

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Re: Travis Steam Engine 2 X Size
« Reply #1 on: March 01, 2019, 07:33:24 PM »
Wow! That's going to be a big model! Great work so far!

 Sign me up for the ride....
 :popcorn:

 John

Offline Ye-Ole Steam Dude

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Re: Travis Steam Engine 2 X Size
« Reply #2 on: March 01, 2019, 10:53:53 PM »
Hello Brian,

I am so pleased to see the first parts being machined, it goes without saying that I will be following this build all the way. Sure hope that you document each step along the way and share plenty of photos with all of us. Let me know if I can help in any way, either PM or direct email.

I am excited to see this project underway :cartwheel:

Have a great day,
Thomas

Offline yogi

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Re: Travis Steam Engine 2 X Size
« Reply #3 on: March 01, 2019, 11:15:04 PM »
Very cool Brian!
Im looking forward to see the progress.  :popcorn: :popcorn: :popcorn:

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #4 on: March 02, 2019, 02:43:44 AM »
Hello Brian,

I am so pleased to see the first parts being machined, it goes without saying that I will be following this build all the way. Sure hope that you document each step along the way and share plenty of photos with all of us. Let me know if I can help in any way, either PM or direct email.

I am excited to see this project underway :cartwheel:

Have a great day,
Thomas

Thanks Thomas !  And others !  :)
Thanks for the visit !
Brian

Offline crueby

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Re: Travis Steam Engine 2 X Size
« Reply #5 on: March 02, 2019, 02:57:46 AM »
Those are impressive specs!  Do you have a pic or drawing of what it will look like?


 :popcorn: :popcorn: :popcorn:

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #6 on: March 02, 2019, 05:03:45 AM »
Search for " Travis Steam Engine " Thomas has a build on his YouTube channel. Just think twice the size.  :)
Thanks for the visit !
Brian

Online b.lindsey

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Re: Travis Steam Engine 2 X Size
« Reply #7 on: March 02, 2019, 02:21:56 PM »
This one will be quite a beast at 2x scale. Should be a great project though.

Bill

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #8 on: March 04, 2019, 05:48:41 PM »
More work on the crankshaft ...........

A note on the initial setup for the crank throws. I used a dial indicator in the mill spindle and swept the width of the blanks to find dead center. All the blocks are exactly the same width, 1.500 "

After spot drilling all the blanks I rough drilled for the crank pin bores and the output ends. I like to chamfer the the bores after drilling to plus size of the finished bore before the boring operation. This prevents a burr from being rolled into the finished hole if chamfered last.

Setup the boring head and bored the .750" and .500" bores to close slip fit for the shafts. The rod journals will be ground 12L14 rod .500 in diameter and one piece .750" in diameter for the center link.

The crank ends will be turned from 7/8" diameter 12L14 stock. Three diameters in one setup, .750", 17mm for the bearing and .625" at the ends.

First attempt at the lathe starting with .750" ground stock in the collet did not produce a shaft true enough and I went with the 7/8" stock to turn all the diameters.

Last picture showing a dry fit assembly of the parts.
 
Thanks for the visit !
Brian

Offline bent

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Re: Travis Steam Engine 2 X Size
« Reply #9 on: March 04, 2019, 06:45:49 PM »
Cool!  Will be following with interest  :popcorn:

Offline Ye-Ole Steam Dude

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Re: Travis Steam Engine 2 X Size
« Reply #10 on: March 04, 2019, 08:03:19 PM »
Hello Brian,

Beautiful work on the crank, are you going to make it 180 degree or a 90 degree?

Have a great day,
Thomas

Online b.lindsey

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Re: Travis Steam Engine 2 X Size
« Reply #11 on: March 04, 2019, 10:03:10 PM »
Nice progress already Brian.  :ThumbsUp:

Bill

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #12 on: March 05, 2019, 02:22:19 AM »
Hello Brian,

Beautiful work on the crank, are you going to make it 180 degree or a 90 degree?

Have a great day,
Thomas

Hi Thomas,
Keeping the crank like the drawing, 180 degrees. Trying to stay true to the design as possible.
Thanks for the visit !
Brian

Offline Jim Abood

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Re: Travis Steam Engine 2 X Size
« Reply #13 on: March 07, 2019, 12:19:55 AM »
Hi Brian
You always do incredible work.   I am looking forward to seeing more  pics of the build.
Jim

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #14 on: March 07, 2019, 01:06:41 AM »
Thanks Jim ! Welcome to the forum  :hi:
Thanks for the visit !
Brian

Offline gbritnell

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Re: Travis Steam Engine 2 X Size
« Reply #15 on: March 07, 2019, 01:10:33 PM »
Hi Brian,
With the flat crank the engine won't be self starting? I went to Youtube to look up the engine but there's so many on the channel with the same name I didn't know which one to look at.
gbritnell
Talent unshared is talent wasted.

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #16 on: March 07, 2019, 03:26:26 PM »
H i George !

Try this link to his YouTube channel :      https://www.youtube.com/channel/UCNWSrK1_cKLTO3gGfzbGvZw

I realize it won't self start, but the crank is a project in its self as designed.
Thanks for the visit !
Brian

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #17 on: March 07, 2019, 03:52:25 PM »
More crankshaft build ..........

Assembling the crank parts using 609 Loctite with 427 primer. Output shafts assembled first with the center throws and .750 shaft as a separate assembly. ( no picture )

Set up each output assembly in Starrett V-blocks and established gauge block stack that supports the throws parallel to the surface plate. Two additional gauge block stacks will be used in the next
setup to support the remaining parts.

Aligning the V-blocks with a Starrett straight edge on a mill fixture plate. The rest of the parts are assembled and very lightly clamped. I will be using #2 and #3 taper pins to pin all parts after giving
a day or so for the Loctite to cure.

More to come ..........
Thanks for the visit !
Brian

Offline dpaulson

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Re: Travis Steam Engine 2 X Size
« Reply #18 on: March 07, 2019, 04:46:59 PM »
Brian
I built the Travis# 4 steam engine you are building only to Thomas drawings , Looks great
Dave

Offline Ye-Ole Steam Dude

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Re: Travis Steam Engine 2 X Size
« Reply #19 on: March 07, 2019, 05:08:47 PM »
Hi Brian,
With the flat crank the engine won't be self starting? I went to Youtube to look up the engine but there's so many on the channel with the same name I didn't know which one to look at.
gbritnell


Hello George,

It is Steam Engine No. 4 (see attached drawing) and believe it or not it does self start most of the time even with low air pressure.

Brian, that crank looks great and I like your hold down technique.

Have a great day,
Thomas

Offline yogi

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Re: Travis Steam Engine 2 X Size
« Reply #20 on: March 07, 2019, 06:02:39 PM »
Hi Brian, quite a bit of fixturing you got going on there...  :ThumbsUp: :ThumbsUp: :ThumbsUp:

 :popcorn: :popcorn: :popcorn:
 

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #21 on: March 11, 2019, 12:57:36 PM »
More crankshaft work ..........

Setting up the crank to drill and ream for taper pins. Doing the connecting rod journals first with a #2 size pin. Edge find to center position and spot drill four places, drill and ream.
Using a left hand spiral-right hand cut reamer under power. Not a good idea for success to try this with a straight flute style reamer as they tend to grab and will often break.  :o

Same type of setup to do the larger .750" shafts with a # 3 reamer.

A note about installing the taper pins. Be sure the reamed holes are clean and oil free and the same for the taper pin, too. The pins will not seat firmly with oil left over from reaming, etc.

I had long pins on hand and used them for the assembly since I wanted pin stick out on both sides of the hole for the next operation.
Thanks for the visit !
Brian

Online b.lindsey

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Re: Travis Steam Engine 2 X Size
« Reply #22 on: March 11, 2019, 02:01:08 PM »
Coming along well Brian and with those taper pins the crankshaft should be  good and solid as well.

Bill

Offline yogi

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Re: Travis Steam Engine 2 X Size
« Reply #23 on: March 12, 2019, 01:38:41 PM »
That's one beefy crankshaft! Looking good.  :popcorn: :popcorn: :popcorn:


Offline Ye-Ole Steam Dude

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Re: Travis Steam Engine 2 X Size
« Reply #24 on: March 12, 2019, 07:52:25 PM »
Hello Brian,

Great looking crank and quite beefy. :ThumbsUp: :ThumbsUp:

Have a great day,
Thomas

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #25 on: March 13, 2019, 12:52:55 PM »
Finish operations on the crankshaft .......

Sawed off the taper pins staying away from the throws as not to mark them. Won't take long to grind off the remaining part even though there looks to be a lot to remove.

Blocked up on the surface grinder for the first side with 1-2-3 blocks. will grind off the pins and take about .001" dust off on the throws to finish. Ran this side dry because I'm to lazy to cleanup
the coolant from the tooling.    ::)

The last side gets the same operation down on the magnet this time with coolant.   :cartwheel:



More parts to come .........



« Last Edit: March 13, 2019, 02:47:40 PM by toolznthings »
Thanks for the visit !
Brian

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #26 on: March 13, 2019, 02:47:19 PM »
The end results .........


The final check for run out with the crank running on its bearings. Happy !

Thanks for the visit !
Brian

Online b.lindsey

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Re: Travis Steam Engine 2 X Size
« Reply #27 on: March 13, 2019, 03:00:09 PM »
 :ThumbsUp: :ThumbsUp:

Bill

Offline Admiral_dk

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Re: Travis Steam Engine 2 X Size
« Reply #28 on: March 13, 2019, 09:52:33 PM »
That is a great result with the crank  :ThumbsUp:  :cheers:

Offline jeff l

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Re: Travis Steam Engine 2 X Size
« Reply #29 on: March 14, 2019, 12:56:11 AM »
Great Job !

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #30 on: March 19, 2019, 09:03:54 PM »
Machining the overall size of the base plate and bottom plate ......

Rough sawed from .750" plate. The base plate and bottom plate. I made the bottom plate thicker than 2X scale of the original that would have worked out to 1/2" thick. Overall finished size will be .750" x  9.750" x 6.000".
The bottom plate ( supports the cylinders ) will be .750" thick x 4.000" wide x 7.750" long.

Milled the width on both plates, first operation.

Using a angle plate in the mill vise I machined the ends and overall length to size. This setup will give a perfect 90 degree edge to the plate face, important since these two parts produce the engines main frame.
Thanks for the visit !
Brian

Online b.lindsey

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Re: Travis Steam Engine 2 X Size
« Reply #31 on: March 19, 2019, 09:59:32 PM »
Looks good Brian. This is going to be a hefty engine when done.  Still watching along.

Bill

Offline yogi

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Re: Travis Steam Engine 2 X Size
« Reply #32 on: March 19, 2019, 10:03:46 PM »
Looking good Brian!  :popcorn: :popcorn: :popcorn:

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #33 on: March 20, 2019, 01:24:04 AM »
Thanks, guys.   :)
Thanks for the visit !
Brian

Offline toolznthings

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Re: Travis Steam Engine 2 X Size
« Reply #34 on: March 22, 2019, 05:12:01 PM »
Machining the frame end plates and bearing bores .........

End plates for the engine frame are made from .375" thick plate and finished to overall size of 6.000" wide x 5.250" high. Overall size will be machined with the plates clamped in pairs.





I put a center mark on each side of the plates to scribe a layout circle for the bearing bores as a roughing guide.

Bored thru 13/16" clearance for the crank shaft and as a reference bore to locate when doing the opposite side.




Finish boring for slip fit to the ball bearing using a flat bottom ground boring bar. ( layout line visible ) The bore is half the thickness of the bearing in depth. Added a counter bore .010" deep to clear the inner race of the bearing.




Used a 45 degree chamfer bar to to break the bores edges. Flip to the opposite side and pick up bore and repeat the operations.




Next operation will be to cut the angled features on the plates to a 4.000 width at the top to match the bottom plate width. Used a height gage to scribe accurate layout lines where the cut runs out.
Set up with sine bar for the correct angle and used mill stop to locate the position of the sine bar so opposite side cut would be the same.





This finishes the plates for now.

If you like the posting of pictures this way, thank my friend Yogi for helping me out.  :ThumbsUp:


Thanks for the visit !
Brian

Offline Ye-Ole Steam Dude

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Re: Travis Steam Engine 2 X Size
« Reply #35 on: March 22, 2019, 07:22:34 PM »
Hello Brian,

Yes the photo layout is great with wording in between just works better. I have tried that a couple of times and for whatever reason I wind up deleting something.

Your work is beautiful. Like all involved projects I get anxious to see the completed engine, but hate to see it end because I enjoy following along.

Have a great day,
Thomas

Offline Johnmcc69

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Re: Travis Steam Engine 2 X Size
« Reply #36 on: March 22, 2019, 08:56:26 PM »
Very nice work Brian (& Yogi, great pics...)
 & a shout out to Thomas for his design.

 John

Offline yogi

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Re: Travis Steam Engine 2 X Size
« Reply #37 on: March 23, 2019, 01:37:15 AM »
Looking good Brian!  :ThumbsUp: :ThumbsUp: :ThumbsUp: