Author Topic: CHUK2 - Alyn Foundry Flame Gulper  (Read 3836 times)

Offline Chipmaster

  • Full Member
  • ****
  • Posts: 671
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #45 on: January 26, 2020, 02:14:20 PM »
Hi Graham, yes I attached the paper pattern to check that I would be machining the authentic cam shape as indeed it did without any further work on the cam face.
Andy

Offline Twizseven

  • Full Member
  • ****
  • Posts: 408
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #46 on: January 26, 2020, 04:16:30 PM »
Just checked my Lenz boring/facing head and do have suitable tooling to run in normal direction. This will be another Ďfirstí as I have never used it before.
Colin

Offline Twizseven

  • Full Member
  • ****
  • Posts: 408
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #47 on: January 26, 2020, 04:18:59 PM »
Jason, 
My other boring head would certainly unscrew if I used that backwards.
Colin

Offline Alyn Foundry

  • Full Member
  • ****
  • Posts: 975
  • North Wales, Great Britain.
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #48 on: January 27, 2020, 12:05:09 PM »


Graham,
Yes the fiddly bits.  am waiting for some material to arrive but don't think this will be till wednesday.

Colin

I too have some bits ordered Colin, also expected this Wednesday....   ;)

Offline Twizseven

  • Full Member
  • ****
  • Posts: 408
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #49 on: January 27, 2020, 02:47:13 PM »
Graham,  Just turned camshaft casting to it diameter. Bl...y H..l itís hard. Well chilled on 50% of perimeter. Most tools just slide off it. Could not touch it on the Myford. Put it in Colchester with big tipped cutter and took lot of it off. About to attempt milling the profile.
Colin

Offline Alyn Foundry

  • Full Member
  • ****
  • Posts: 975
  • North Wales, Great Britain.
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #50 on: January 27, 2020, 03:07:45 PM »
Hi Colin.

The only consolation is that we won't be using their services again....

Try annealing the casting before the next operation, heat up towards bright Orange then immediately bury it in dry sand. Hopefully you'll have a softer Iron to work with.

Cheers Graham.

Offline Jo

  • Administrator
  • Full Member
  • *****
  • Posts: 13172
  • Hampshire, england.
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #51 on: January 27, 2020, 03:09:00 PM »
Or put it in your log burner over night  ;)

Jo
Enjoyment is more important than achievement.

Offline Twizseven

  • Full Member
  • ****
  • Posts: 408
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #52 on: January 27, 2020, 07:25:59 PM »
Jo,
Unfortunately do not have a log burner, not even an open fire now.

Graham/Jo,
If its is annealed how does that effect the operations already carried out, e.g. its is already reamed out to 10mm for the crankshaft.

There is an outside possibility might have a kiln by end of day.  If that does occur I assume I could heat in kiln and then leave the kiln to cool down slowly (overnight) with the casting in it.

Colin

Offline Alyn Foundry

  • Full Member
  • ****
  • Posts: 975
  • North Wales, Great Britain.
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #53 on: January 27, 2020, 07:58:32 PM »
Hi Colin.

If you've got access to a kiln, all the better. Just take the parts up to around 800 degrees C, make sure of the colour and then just switch it off. Don't open the door until cold.

I say parts I'd do the crank web at the same time.

You might have to " squeak " the reamer through the 10 mm hole again, that's about all.

Cheers Graham.

Offline Twizseven

  • Full Member
  • ****
  • Posts: 408
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #54 on: January 27, 2020, 08:32:14 PM »
Graham,

Funny you should mention the crank web, that also was a tad hard.

Missed out on kiln.  Must try harder (spend more  :ThumbsDown:

Good to know that is all that would be affected.

Colin

Offline Twizseven

  • Full Member
  • ****
  • Posts: 408
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #55 on: January 28, 2020, 06:07:04 PM »
It was a bit of a struggle but eventually managed to find a cam.  As I had not sourced a kiln, I decided the only other way to get through the hard stuff was to remove it by brute force.

Cut out a paper pattern from Grahams plans, laid it on the cam disk and drew round the outline of the part which needed to be removed.  Used the 4" linisher to remove to within a couple of millimetres of the line.

Back on to the mill and used the boring head to bring to the correct shape/size.  For reasons best kept to myself this took an inordinate amount of time.   Decided to put a few holes in as per Jo's cam, did this using diving head and just indexing in 10 degeee steps.  Then drilled and tapped for 2BA fixing grub screw.

Colin

Offline Jo

  • Administrator
  • Full Member
  • *****
  • Posts: 13172
  • Hampshire, england.
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #56 on: January 28, 2020, 06:11:07 PM »
A tipped tool will go through the hard stuff  :ThumbsUp:

Imitation is the greatest form of flattery  ;) I wonder which form of mechanism you are going to use to operate the shutter

Jo
Enjoyment is more important than achievement.

Offline Alyn Foundry

  • Full Member
  • ****
  • Posts: 975
  • North Wales, Great Britain.
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #57 on: January 28, 2020, 06:39:57 PM »

I wonder which form of mechanism you are going to use to operate the shutter

Jo

I'm waiting to see a " springless " design appear....   ;) 

Offline Jasonb

  • Full Member
  • *****
  • Posts: 7020
  • Surrey, UK
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #58 on: January 28, 2020, 06:49:27 PM »

I'm waiting to see a " springless " design appear....   ;)

Should be easy enough to machine a suitably shaped groove into the face of a disc for a follower to run in, couple of clicks and the CNC would have that done in no time :)

I suppose one advantage of these pre hardened cams is that you don't have to make them from silver steel and then heat treat to save wear :LittleDevil:

Offline Twizseven

  • Full Member
  • ****
  • Posts: 408
Re: CHUK2 - Alyn Foundry Flame Gulper
« Reply #59 on: January 28, 2020, 07:15:24 PM »
Jo,
I did like the way you had done your cam and the holes,  I just put mine a bit smaller and a couple more off them, so not quite plagiarism.

I also prefer the idea of positive lift of the cam follower and let weight help to close/shut the inlet port.  I think you commented that you had to fit a spring.  Would a heavier mechanism overcome that need.

Jason,
Pre-hardened  :lolb:

Not having CNC that option is out for me.  If I bought a CNC machine home I would be hung, drawn and quartered.

Perhaps you will have to modify your CHUKY and tried for grooved cam face and follower.

Graham,
Desmodronic valve timing on a flame licker  :Lol:

All,
Jo commented about using tipped tool to cut through the hard past of the casting,  I was able to do this on the Colchester with tipped tools but struggled on the Myford with tipped tools.  How would you fit a tipped tool to the boring head below:

Thanks all,

Colin
« Last Edit: January 28, 2020, 07:18:38 PM by Twizseven »