Author Topic: Bond's "Simplex" Petrol Engine  (Read 26754 times)

Offline ScroungerLee

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Re: Bond's "Simplex" Petrol Engine
« Reply #30 on: November 20, 2012, 12:35:43 PM »
Nice method for the rocker arms.  I keep learning things from your work.

Thank you

Lee
Mmmmm.... Shiny!

Online Jasonb

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Re: Bond's "Simplex" Petrol Engine
« Reply #31 on: November 25, 2012, 05:59:31 PM »
Just a heads up for anyone who has taken a fancy to this engine, while thumbing through my Engineers Emporium cataloge I see that they supply castings for this engine though they are not listed on their web site. Infact they have several engines that are not on the web.

http://www.theengineersemporium.co.uk/

J

Offline Don1966

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Re: Bond's "Simplex" Petrol Engine
« Reply #32 on: November 25, 2012, 06:37:54 PM »
Love the rockers, excellent work. Love the machinery.

Don

Offline pgp001

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Re: Bond's "Simplex" Petrol Engine
« Reply #33 on: November 25, 2012, 08:27:18 PM »
Jason is quite correct, they are doing this engine again.

My engine is an original and has slightly different casting to the ones on offer now.

The chap from Engineers Emporium saw my part finished engine at Harrogate and "expressed an interest" in having a copy of my original drawing for it, so I am not sure what drawings they are issuing with the castings.

Phil

Offline pgp001

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Re: Bond's "Simplex" Petrol Engine
« Reply #34 on: January 12, 2013, 05:37:04 PM »
OK Its been a while since I uploaded some photo's, so here are few more.

This is my attachment for making studs on the Myford using a Coventry die head (Jo take note)





I have been busy making cams, or I should say making a lot of tooling to make cams.

This is the turning fixture to produce the radiused flanks on the cam blanks, Graham Meek gave me the information on how this should be done.









Here it is in the lathe loaded up with my blanks ready to go.



And here showing the result of the first pass before turning the blanks over.



Phil

Online Jo

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Re: Bond's "Simplex" Petrol Engine
« Reply #35 on: January 12, 2013, 05:42:40 PM »
This is my attachment for making studs on the Myford using a Coventry die head (Jo take note) ;D
.......
Phil

I am looking forward to acquiring a 1/4" coventry die head with some good sized threading inserts (16BA to 8BA) but in the mean time I am using wirlwind dies for stud making ;) So it is not the thread cutting that is the problem, it is just the tedium of the pure volume :ShakeHead:

Jo
Enjoyment is more important than achievement.

Offline pgp001

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Re: Bond's "Simplex" Petrol Engine
« Reply #36 on: January 12, 2013, 05:46:47 PM »
I actually skipped a step, we needed to make the cam blanks first.

Here they are having a 3/32 keyway broached in them so they can be both located on the fixtures and on the engine camshaft.





I made two from Silver Steel so they can be heat treated, and a couple of spares in Mild Steel just to test the machining fixtures.



I then had to make the fixture for milling the two radii on each cam, bearing in mind the inlet and exhaust are both different.





Phil
« Last Edit: January 12, 2013, 05:53:03 PM by pgp001 »

Offline pgp001

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Re: Bond's "Simplex" Petrol Engine
« Reply #37 on: January 12, 2013, 05:51:51 PM »
Jo

The good thing about using a Coventry die head is that it has a triggered release at the correct thread length, and then you simply slide it back and reset it ready for the next one, you do not have to reverse it back off the thread so it is "much" faster to use.
The quality of the thread produced is also far superior to using normal dies.

Go on you know you want to  :)

Phil

This is my attachment for making studs on the Myford using a Coventry die head (Jo take note) ;D
.......
Phil

I am looking forward to acquiring a 1/4" coventry die head with some good sized threading inserts (16BA to 8BA) but in the mean time I am using wirlwind dies for stud making ;) So it is not the thread cutting that is the problem, it is just the tedium of the pure volume :ShakeHead:

Jo

Online Jo

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Re: Bond's "Simplex" Petrol Engine
« Reply #38 on: January 12, 2013, 05:54:57 PM »
Another gentleman encouraging me in my tool addiction ;D.

Jo
Enjoyment is more important than achievement.

Offline pgp001

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Re: Bond's "Simplex" Petrol Engine
« Reply #39 on: January 12, 2013, 06:04:36 PM »
Once the cam radius fixture was made I could actually finish the cams by using it on the rotary table.

First the table is clocked true to the spindle.



Then having clocked the table tee slot square to the Z axis of the mill, the fixture is fitted and its centre post is also clocked concentric to the rotary table.
An end stop is fitted, and using slip gauges the fixture can then be easily set in either of the two positions needed for the different tip radii.



Here is one of the base circle radii just being milled.



And as usual I was so engrossed in machining I forgot to take photo's of milling the tip radii, but it was just a matter of sliding the jig along using the slip gauges and table stop, it took days to make the jigs and set it all up, and minutes to machine the cams.

Phil


Offline pgp001

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Re: Bond's "Simplex" Petrol Engine
« Reply #40 on: January 12, 2013, 06:11:51 PM »
Next job was the cam shaft itself, this is simply a piece of 1/4" diameter bar with some holes for the cam locating pins to be pressed in.
So it was a simple indexing and drilling job once set up on the mill.





Here is the shaft during a trial assembly with the skew gear and cams.



And here we are setting the cam timing so the skew gear can be finally pinned in position on the shaft.



Nearly there now  :ThumbsUp:

Phil

Offline John S

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Re: Bond's "Simplex" Petrol Engine
« Reply #41 on: January 12, 2013, 06:20:36 PM »
I really like those typical classic air cooled motor cycle engines, something pleasing about the simple lines.

John S.
John Stevenson, Nottingham , England

Offline pgp001

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Re: Bond's "Simplex" Petrol Engine
« Reply #42 on: January 17, 2013, 10:55:30 PM »
Well here is the "last but one" part to be made, the carburettor retaining clamp.

Loctite an aluminium blank onto a short stub of round bar, this acts a chucking post for milling the radius etc.



Cut the bulk of the corners with a hacksaw.



Stick it in the Marlco collet indexer and mill the radius.





A bit more slitting, drilling & tapping and we have a split clamp.



Finally the last part to be made is the crankcase breather, based on Westbury's Kiwi design.



One last tapped hole in the crankcase for the breather.



Then a total strip down and final clean of all the parts.



Before final assembly begins with the crank and con rod.



All the bits for the carb go together.



And hey presto we have a finished engine with five hours to spare on new years eve.
Last years resolution was to finish it that year and I just did it  :ThumbsUp:

















The end for now
I might see how it runs when the weather improves and I can set it up outside.

Phil 

Offline tvoght

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Re: Bond's "Simplex" Petrol Engine
« Reply #43 on: January 18, 2013, 12:06:56 AM »
Really a fine looking engine. Thanks for sharing.

--Tim

Offline zeeprogrammer

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Re: Bond's "Simplex" Petrol Engine
« Reply #44 on: January 18, 2013, 12:25:40 AM »
I might see how it runs when the weather improves and I can set it up outside.

Might? What do you mean 'might'?  ;D
Carl (aka Zee) Will sometimes respond to 'hey' but never 'hey you'.
"To work. To work."
Zee-Another Thread Trasher.

 

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