Model Engine Maker

Engines => Restoration of Model Engines => Topic started by: Stilldrillin on September 29, 2016, 01:22:40 PM

Title: Bodging with Boris........
Post by: Stilldrillin on September 29, 2016, 01:22:40 PM
Hello, everyone..... I'm still around!  ;D

After another painful year, I'm managing to get into my workshop, once more.  :whoohoo:

The Doc put me on statins, three years ago. I've finally realised, just what has been causing me such grief, for so long. (http://smileys.on-my-web.com/repository/Unhappy/brick-wall-017.gif)

I stopped taking them, a month ago, and now feel a new man! And, the walking stick has gone back into the cupboard......  :cartwheel:


Another needy orphan/ doorstop, arrived in July. I call him, Boris.........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/SAM_1639_zpsi7cwvpy4.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/SAM_1639_zpsi7cwvpy4.jpg.html)


Does anyone recognise the build?  Are there any plans out there?

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/SAM_1647_zpsupouxtpl.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/SAM_1647_zpsupouxtpl.jpg.html)


The usual problem. Power cyl volume too large. Both cylinders, almost the same swept volume.

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/SAM_1649_zpszhnbx70y.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/SAM_1649_zpszhnbx70y.jpg.html)


I turned up a better/ temporary crank assembly.........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20160718_150137883_zpsymqwlp4w.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20160718_150137883_zpsymqwlp4w.jpg.html)


No joy.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20160721_110050508_zpsmtl0bqok.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20160721_110050508_zpsmtl0bqok.jpg.html)


So....... He's all in pieces, on my bench. Awaiting rebuilding materials.

It's nice to be back at it, once again!  (http://smileys.on-my-web.com/repository/Respect/respect-048.gif)

David.
Title: Re: Bodging with Boris........
Post by: Jo on September 29, 2016, 01:42:12 PM
Hi David,

Please to hear you are feeling better  :cartwheel:

and now feel a new man!

Sometimes I think that I too would like to feel a new man  :mischief: but so far I have come to the conclusion that machine tools and castings sets are more reliable  :embarassed:

Jo
Title: Re: Bodging with Boris........
Post by: Ian S C on September 29, 2016, 02:35:51 PM
David, I don't see how the displacer can operate connected to the crank the way it is. Does the vertical bolt with the acorn nut on top slide up and down in the L shaped  block on the crank, if so I would have thought there would be a lot of friction there.  I would be trying to loose a good bit of weight on the displacer linkage.  Also the displacer rod seems to be on the large side, but as long as the seal at the gland is OK, this should not cause any problem.
     The ratio between the displacer, and the power piston should be some where about 1.5 : 1, plus or minus a bit, a larger ratio will allow lower temperature.
     Minimum friction, no leaks, including the hollow displacer., and if it wont start remember that the displacer leads the power piston by 90*.
Ian S C
Title: Re: Bodging with Boris........
Post by: sbwhart on September 29, 2016, 03:20:14 PM
Hi Dave

Good to see you back at it, been on those Statin things myself for about the same time I seem to so far .
Not posted much myself as I'm on a loco build and things  happen at a slower pace on that sort of project but I recon I'm long over due updating you Guys

Cheers
Stew
Title: Re: Bodging with Boris........
Post by: b.lindsey on September 29, 2016, 04:07:47 PM
Welcome back to the shop Dave. Happy to hear you are doing better!

Bill
Title: Re: Bodging with Boris........
Post by: Stilldrillin on September 29, 2016, 10:18:24 PM
Hi David,

Please to hear you are feeling better  :cartwheel:

and now feel a new man!

Sometimes I think that I too would like to feel a new man  :mischief: but so far I have come to the conclusion that machine tools and castings sets are more reliable  :embarassed:

Jo

Hello Jo.
 You keep an eye open, for that new feelable man.  :naughty:
I've been told, reliable is overrated. Just, not exciting enough.......  :(
Title: Re: Bodging with Boris........
Post by: Stilldrillin on September 29, 2016, 10:30:00 PM
David, I don't see how the displacer can operate connected to the crank the way it is. Does the vertical bolt with the acorn nut on top slide up and down in the L shaped  block on the crank, if so I would have thought there would be a lot of friction there.  I would be trying to loose a good bit of weight on the displacer linkage.  Also the displacer rod seems to be on the large side, but as long as the seal at the gland is OK, this should not cause any problem.
     The ratio between the displacer, and the power piston should be some where about 1.5 : 1, plus or minus a bit, a larger ratio will allow lower temperature.
     Minimum friction, no leaks, including the hollow displacer., and if it wont start remember that the displacer leads the power piston by 90*.
Ian S C

Ian.
 The displacer linkage is a scotch yoke, Giving slight dwell at, both ends of travel. Not much friction.
The displacer shaft is 6mm dia. About right, for the length of the assembly.
 The ratio, is 1.2/1. I have some 30mm dia graphite. Should make a 29mm dia piston. Also reducing stroke should give 1.9/1.

Awaiting tubing, bearings, 6" flywheel casting, inspiration etc.......
Title: Re: Bodging with Boris........
Post by: Stilldrillin on September 29, 2016, 10:33:41 PM
Stew, Bill.
 Thanks for your replies.  (http://smileys.on-my-web.com/repository/Respect/respect-048.gif)

Updates and pics, as n when.  ;)

It's good to be back!  :)

David.
Title: Re: Bodging with Boris........
Post by: kev on September 29, 2016, 11:20:42 PM
good news indeed, and you have me thinking about those statins myself now !
Title: Re: Bodging with Boris........
Post by: tvoght on September 30, 2016, 12:02:01 AM
Good to see you back. I've  heard a lot of bad things about those statins, including significant short-term memory loss. Did you experience that?

That's an interesting way to implement a Scotch yoke. If you had not described it as such, I wouldn't have thought of it that way.

If you got the swept volume ratio to 1.9, I bet the engine would have a very sweet disposition!

--Tim
Title: Re: Bodging with Boris........
Post by: Stilldrillin on September 30, 2016, 10:40:41 PM
Thanks Kevin.
 I won't go back on them again! I never had a need for cholesterol reduction, in the first place!

Tim.
 Mrs Drillin thought I had early dementia signs. I was "vague", and didn't remember, what she swore she told me. Read that, whichever way you wish.  ;)

Though, I was making plans, how to dispose of the workshop and contents........  :(



Anyway! Enough!

I did attend a few shows. Here's a member's random video. My table, after 30secs.......

http://www.youtube.com/watch?v=pW_fZnx0aRA



Also..... I came away from STL, with "Best in Show". For the second year running........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/Sandman%20Cup%202016_zpsakhqqnnu.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/Sandman%20Cup%202016_zpsakhqqnnu.jpg.html)


Happy!  :whoohoo:

David.
 
Title: Re: Bodging with Boris........
Post by: Oldboy on October 01, 2016, 12:22:10 AM
Welcome back David.  Great to hear you are feeling better and back in the workshop.

Barry.
Title: Re: Bodging with Boris........
Post by: b.lindsey on October 01, 2016, 12:32:06 AM
Congrats David. Great picture and video.

Bill
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 16, 2016, 01:54:35 PM
Barry, Bill.
 Thanks Chaps!  (http://smileys.on-my-web.com/repository/Respect/respect-048.gif)

So.... The initial rebuild begins. With the displacer.  :thinking:

I really, don't like copper pipe for this purpose. Too heavy. Too much heat absorbtion/ conduction.  :ShakeHead:

Lots of handy diameters and lenghths, of s/s exhaust available on Ebay. This is 42mm......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161004_112832728_zpsjgnt23iw.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161004_112832728_zpsjgnt23iw.jpg.html)


Bored out, to lighten. Now, around 20 thou' wall thickness.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161004_144937850_HDR_zpsw1xv0pug.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161004_144937850_HDR_zpsw1xv0pug.jpg.html)


8mm thick, s/s offcut, friction turned, to slide in the displacer's bore.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161012_132416255_zpsgzpzkayj.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161012_132416255_zpsgzpzkayj.jpg.html)


Chopped the inside away, to give 1mm wall thickness......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161013_113747333_zpsd0zci2k1.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161013_113747333_zpsd0zci2k1.jpg.html)


Drilled through boss. Silver soldered in, a 12mm long extension. Then drilled to spigot depth, and tapped M5.

Rough cut end cap, in background Awaiting friction turning........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161014_114309770_zpsvdzqmnzw.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161014_114309770_zpsvdzqmnzw.jpg.html)


Silver soldered in, both end caps. Cleaned up.

That looks better! Even though, it will not be seen........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161014_145939438_HDR_zpsk2ytcitg.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161014_145939438_HDR_zpsk2ytcitg.jpg.html)


Next up.... Reducing the power cylinder bore. From 35mm to 29.5mm.  :headscratch:

I used two more lengths of s/s exhaust pipe. They have very accurate and consistant, bores and o/d's.
 A couple of thou' removed, allowed two to be sleevelocked together.
Topped to just below original bore size. Then bore opened out to 29.5mm.

Lots of time spent oscillating, to achieve a decent finish, and remove the 1 thou' taper.......  ::)


(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161010_132521889_zpslxu8u8eu.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161010_132521889_zpslxu8u8eu.jpg.html)


Looks ok, I think! The joint can just be seen, at 10 and 4 o'clock positions. close to the bore's chamfer.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161011_132855594_HDR_zpskre5fwlv.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161011_132855594_HDR_zpskre5fwlv.jpg.html)


Frankly..... I'm not impressed by the little end's arrangement.......  :o

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161011_132731320_HDR_zps8xhv4wvm.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161011_132731320_HDR_zps8xhv4wvm.jpg.html)


And, there's only poverty, holding the big end in place........  :facepalm2:

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161016_084520175_zps83vaunls.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161016_084520175_zps83vaunls.jpg.html)


Guess, we now need a new conrod!  :shrug:

Thanks for looking in.....  :cheers:

David.



Title: Re: Bodging with Boris........
Post by: Roger B on October 16, 2016, 06:18:34 PM
Looks like another rescue well under way  :ThumbsUp:  :ThumbsUp:  :wine1:
Title: Re: Bodging with Boris........
Post by: b.lindsey on October 16, 2016, 06:27:17 PM
Nice progress David. Looking good!!

Bill
Title: Re: Bodging with Boris........
Post by: Bluechip on October 16, 2016, 07:40:39 PM
Hi Dave

Glad to see you're back on front line service ..  :ThumbsUp:

No doubt it will be a nice engine after you've sorted all it's little foibles. It appears to be water-cooled ??

Some rather interesting Stirling engines at Midlands MEX last Friday, including a Van der Graaff generator running off one.

Good crack of a spark about every 20-30 seconds ...  :zap:

Dave   .....  ( :headscratch: Ruddy Daves, snided out with 'em. Never had this problem when we had proper Flit guns .... )



Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 23, 2016, 10:48:34 PM
Roger, Bill.
 Thanks Chaps!  :)

Thanks Dave.
 Yes, it is water cooled, though said to be leaking.....  :ShakeHead:

Electrickery. Going crack, every few seconds?? Not for me, or mine!  :paranoia:

I blame Royalty, for the excess of us, around our age. One of 'em gave up the throne for love, sometime before we were born......  ^-^



Managed to get some Boris work done, over the past week.

I'm used to catching up on household, gonna do's. But, after all this, "almost crocked" time, I'm having trouble with, whatabout's, whenyergonna's, and havyerforgotten's.......  :facepalm2:

A piece of 1/4" brass, spigoted/ screwed to the end of 8mm dia bar.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161018_125042184_zpsnemsvhu1.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161018_125042184_zpsnemsvhu1.jpg.html)


6mm, far end. 4mm, this end. 110mm apart.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161018_133833958_HDR_zpschv1ehg5.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161018_133833958_HDR_zpschv1ehg5.jpg.html)


Taper turn. Mill little end flats........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161019_114350223_HDR_zpsxk3ggm6z.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161019_114350223_HDR_zpsxk3ggm6z.jpg.html)


That looks better, to me........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161019_115005133_zpsn0nskm8w.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161019_115005133_zpsn0nskm8w.jpg.html)


Graphite piston. Roughed out, and parted off. (Most of the mucky work done)......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161020_145955647_HDR_zps7czfub4l.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161020_145955647_HDR_zps7czfub4l.jpg.html)


Thanks for looking in! (http://smileys.on-my-web.com/repository/Respect/respect-048.gif)

David.

Title: Re: Bodging with Boris........
Post by: Art K on October 23, 2016, 11:26:23 PM
David,
My wife just recently started statin but she does need it to reduce cholesterol, exercise & diet didn't do the trick. I must admit I don't know much about Sterling engines but I decided I wanted to build one for my uncle that would run on the top of his wood heater as a fan. Phil lent me a book called Steam and Sterling. In it is Moriya that drives a 10" fan. It suggests using asbestos as a gasket. Any suggestions as to a replacement? Would this run on a stove top without the alcohol burner.
Art
Title: Re: Bodging with Boris........
Post by: b.lindsey on October 23, 2016, 11:39:36 PM
Art, depending on thickness, check your local auto parts house for head gasket material. Jerry Howell specifies and supplies something called fiberfrax for his Sterling's, and may sell it as well. His family runs his website now. For thicker applications, consider something like phenolic.

Bill
Title: Re: Bodging with Boris........
Post by: Stilldrillin on November 06, 2016, 02:52:05 PM
I've got a bit behind, with the write up...... :Doh:


Delrin mandrel, to mount piston.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161031_130738665_HDR_zpsfc4vwqng.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161031_130738665_HDR_zpsfc4vwqng.jpg.html)


Held on, with M6 caphead. Finish turned, until it almost enters the bore. Mucky stuff!

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161031_133640255_zpszrfoj8gh.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161031_133640255_zpszrfoj8gh.jpg.html)


Six inch rule. Supporting reversed emery cloth.

Polish the outer end o/d, until the piston enters the cylinder. Then, polish the centre section. allowing it to enter some more.

Then finally, polish the skirt area. Allowing full length entry to cylinder.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161031_134115156_zpsvp4ousnv.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161031_134115156_zpsvp4ousnv.jpg.html)


Obviously, both hands needed for polishing control. I needed my left hand for the camera!

Reversed emery cloth is used for polishing graphite.
Fine emery cloth. Correct way around, for brass etc.

The steel rule backing, gives much better control, than fingers....

Thanks for looking in!

David. (http://smileys.on-my-web.com/repository/Respect/respect-048.gif)
Title: Re: Bodging with Boris........
Post by: Stilldrillin on November 06, 2016, 02:57:32 PM

I slotted and cross drilled/ reamed. The clevis.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161102_132336745_zpstegdby6c.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161102_132336745_zpstegdby6c.jpg.html)


Drill/ tapped M4 through. Reducing shank to 6mm dia, to locate in piston......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161102_135955864_HDR_zps8mdjzhqe.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161102_135955864_HDR_zps8mdjzhqe.jpg.html)


That looks better, than original........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161102_150837182_zpskqdc5twx.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161102_150837182_zpskqdc5twx.jpg.html)


This afternoon, I finished the piston/ cylinder fit to each other. Then sleevelocked the cylinder liner in place, in the original cylinder.

Assembly, tomorrow. Wonder if we'll have a runner, soon?   :thinking:

Thanks for looking in!  (http://smileys.on-my-web.com/repository/Respect/respect-048.gif)

David.
Title: Re: Bodging with Boris........
Post by: Bluechip on November 06, 2016, 03:50:33 PM
Hi Dave

Of course we'll have a runner soon. Alternatives are not an option.   :ThumbsUp:

Bit heroic doing this today?  Too flamin' parky here. Abandoned my shop antics after about 15 mins. and indulged in a bit of radiator cuddling.

Dave
Title: Re: Bodging with Boris........
Post by: Jo on November 06, 2016, 04:20:59 PM
Reversed emery cloth is used for polishing graphite.
Fine emery cloth. Correct way around, for brass etc.

The steel rule backing, gives much better control, than fingers....

I hold it round a 10" smooth file. Steel rules have a nasty habit of getting a sharp edge from running scribers up and down their edges.

I would have said typical Yorkshire man but then realised that you can't be from Yorkshire as you didn't mention about only buying one grade and as it wears out using it instead of wasting money buying the finer grades  ::)

Jo
Title: Re: Bodging with Boris........
Post by: Stilldrillin on November 06, 2016, 04:47:06 PM
Hi Dave

Of course we'll have a runner soon. Alternatives are not an option.   :ThumbsUp:

Bit heroic doing this today?  Too flamin' parky here. Abandoned my shop antics after about 15 mins. and indulged in a bit of radiator cuddling.

Dave

Hello Dave.
 Progress should take it's usual course.  ;)

My first line was. "I've got a bit behind, with the write up...... :Doh:"
I'm copy/ pasting from another forum. So.....  I've still, not caught up with all posts, as yet. That particular "today", was last week, sometime.......  :shrug:

Though, I have drilled/ tapped the flywheel, in record time, this afternoon. Cold out there!  :-\
Title: Re: Bodging with Boris........
Post by: Stilldrillin on November 06, 2016, 05:01:30 PM
Reversed emery cloth is used for polishing graphite.
Fine emery cloth. Correct way around, for brass etc.

The steel rule backing, gives much better control, than fingers....

I hold it round a 10" smooth file. Steel rules have a nasty habit of getting a sharp edge from running scribers up and down their edges.

I would have said typical Yorkshire man but then realised that you can't be from Yorkshire as you didn't mention about only buying one grade and as it wears out using it instead of wasting money buying the finer grades  ::)

Jo

Scriber, Jo?  :o
  D'yer know, I can't remember the last time I used such a weapon! Though, I do have a couple of nice, carbide pointed ones, on the bench. Ready to leap into action, should they ever be needed.......  ;)

Emery cloth? I never mentioned my preferred method, as I thought, everyone works that way...... Don't they?  :headscratch:

I had a thrifty Yorkshire upbringing, including apprenticeship.
 Moving back to Derbyshire, almost 50yrs ago, really opened my eyes as to how the other half live.....  :Lol:
Title: Re: Bodging with Boris........
Post by: Stilldrillin on November 06, 2016, 05:19:33 PM
Here is some progress, from last Friday. Dave.

Finished piston/ rod assembly........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161104_122939435_zps8rd0qwir.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161104_122939435_zps8rd0qwir.jpg.html)


Commence assembly.........

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161104_130453782_HDR_zpse5j1b97i.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161104_130453782_HDR_zpse5j1b97i.jpg.html)


Not happy with the offset scotch yoke, link. It wants to bend the  unsupported displacer shaft.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161104_130510370_HDR_zpspesii02x.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161104_130510370_HDR_zpspesii02x.jpg.html)


Now, we just need a flywheel.......

(http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161104_154302636_HDR_zpsaclsoxnx.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161104_154302636_HDR_zpsaclsoxnx.jpg.html)


I have a suitable casting. Though, it is made of unknown bronze. Rather tough stuff!  :hellno:

That is a 4" dia chuck. I like to make my machinery work hard, when necessary.........

 (http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161104_151245939_HDR_zpssiy90iiw.jpg) (http://s110.photobucket.com/user/Dayjo/media/2015%20Onward/IMG_20161104_151245939_HDR_zpssiy90iiw.jpg.html)


The belt had done 3 years, since I modded the lathe to lower the gearing. Can't grumble!  :shrug:

All good Engineers have a spare! It was up and running, after 20 mins fumbling. But, I'd had enough, for one day........   ::)

Thanks for looking in!

David.
Title: Re: Bodging with Boris........
Post by: Stilldrillin on November 06, 2016, 10:30:10 PM
Finally got the flywheel, proof turned. Sufficient to be in balance.......

Put a small light under. And, after a few seconds.........

http://www.youtube.com/watch?v=fUDvX5kEnQw


It's a great feeling!  :whoohoo:

David.
Title: Re: Bodging with Boris........
Post by: 10KPete on November 06, 2016, 10:56:38 PM
Very nice, David. Very nice. Congratulations on a job well done.

Pete
Title: Re: Bodging with Boris........
Post by: Stilldrillin on November 07, 2016, 06:21:09 PM
Thank you, Pete.....  :ThumbsUp:
Title: Re: Bodging with Boris........
Post by: Admiral_dk on November 07, 2016, 08:15:16 PM
Very worth the effort - a nice runner  :praise2:
Title: Re: Bodging with Boris........
Post by: b.lindsey on November 07, 2016, 09:25:55 PM
OH excellent....quite a fine runner too!!  Well done.  :ThumbsUp:

Bill
Title: Re: Bodging with Boris........
Post by: steamer on November 08, 2016, 01:31:05 AM
It's a runnah!!!!

Dave
Title: Re: Bodging with Boris........
Post by: Dave Otto on November 08, 2016, 01:47:59 AM
Nicely done David!


Dave
Title: Re: Bodging with Boris........
Post by: Roger B on November 16, 2016, 11:22:52 AM
Nicely done  :praise2:  :wine1:
Title: Re: Bodging with Boris........
Post by: sbwhart on November 16, 2016, 08:56:01 PM
Wot a butey Dave

A real nice runner

 :whoohoo: :whoohoo: :whoohoo: :whoohoo:

Stew
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 15, 2017, 08:31:37 PM
Yikes! It has been almost 11 months, since I posted anything about this, shambles!   :embarassed:


As we can now, all, see the previous Pbucket pics, using the appropriate add ons.......

Firefox.....  https://addons.mozilla.org/en-US/firefox/addon/photobucket-fixer/

Chrome..... https://chrome.google.com/webstore/search/photobucket_hotlink_fix?hl=en


I'll continue with, Blundering with Boris.... Hope, there's still some interest!  :facepalm:


After some 10mins running, at Earl Shilton show. The crank assembly began rocking from side to side, on it's single, 5mm wide upright!

Reminded me of stepping into a rowing boat/ dinghy........

(https://s25.postimg.org/lbnio6pgv/IMG_20161218_102959429.jpg) (https://postimages.org/)


Secured with M3 countersunk screws.......

(https://s25.postimg.org/d6a23d5wv/Boris.jpg) (https://postimages.org/)


Up close. "You could stick yer cap neb, under there!".......

(https://s25.postimg.org/vlpxnezwv/IMG_20161217_135151771_HDR_2.jpg) (https://postimages.org/)


It's almost stood on tiptoe! The column base isn't flat!  (http://www.4smileys.com/smileys/angry-smileys/wallsmiley.gif) (http://www.4smileys.com)  (http://www.4smileys.com/smileys/angry-smileys/wallsmiley.gif) (http://www.4smileys.com)

You can see the rub mark, of the "keel". Inboard of the outer two screw holes.......

(https://s25.postimg.org/vyhbtlpwf/IMG_20161219_125030060_2.jpg) (https://postimages.org/)


It's needing a new crankshaft assembly. With bearings at each end. I'm on it.......   (http://smileys.on-my-web.com/repository/Respect/respect-048.gif)



I wondered, why the new displacer insisted on catching the inside of the hot cap.

The shaft guide was at an angle, having been hammered into the bulkhead......   (http://www.4smileys.com/smileys/angry-smileys/wallsmiley.gif) (http://www.4smileys.com)

(https://s25.postimg.org/jz8oje9lb/IMG_20170630_134857074_HDR.jpg) (https://postimages.org/)


Time to strip, completely. And, totally rebuild, to my spec......

(https://s25.postimg.org/y6yd81ma7/IMG_20170630_152419616_HDR.jpg) (https://postimages.org/)


I've taken the pics, as I've gone along. Not always, in sequence.....

First job, was to get rid of the unnecessary/ leaking, water jacket.

Four inch dia. Made  from tough stainless steel. Not easy to machine, with a mini lathe's lack of power.....

(https://s25.postimg.org/sfac56ydr/IMG_20170616_105909521_HDR.jpg) (https://postimages.org/)


What a mess, in there!

(https://s25.postimg.org/8r1zm5sb3/IMG_20170616_111854643_HDR.jpg) (https://postimages.org/)


I intended incorporating the end flange, into the cooling fins.......

(https://s25.postimg.org/itk765s1b/IMG_20170616_115144722_HDR.jpg) (https://postimages.org/)


But. The darned thing fell off. After I'd drilled the new screw holes.....

(https://s25.postimg.org/tzh3d8y33/IMG_20170815_130226844_HDR.jpg) (https://postimages.org/)


Yet another "interesting situation", needing a solution........   :facepalm2:



So..... While thinking what to do, about the detached flange. I set to, making the cooling fins.

Around 4"/100mm diameter.

Started with, square, 5mm thick blanks. And, one off at 8mm thick, to screw to the bulkhead.

Using 3 stops, on the mill table. Means I can locate/ relocate all blanks, accurately. Every time......

(https://s25.postimg.org/t632az0r3/IMG_20170816_150407471_HDR.jpg) (https://postimages.org/)


Making it easy, to mill off the corners. Instead of sawing......

(https://s25.postimg.org/kcc5tvdsf/IMG_20170816_145031097_HDR.jpg) (https://postimages.org/)


Also, to drill a central, 6mm hole.......

(https://s25.postimg.org/f3h4vzvdb/IMG_20170818_111632785_HDR.jpg) (https://postimages.org/)


A piece of 4" dia steel, in the chuck. Faced with wide insulation tape. Plus a lump of spare nylon......

(https://s25.postimg.org/n01m486tr/IMG_20170817_134318729_HDR.jpg) (https://postimages.org/)


Friction turned the remaining corners away........

(https://s25.postimg.org/jx5helh8v/IMG_20170818_113951489_HDR.jpg) (https://postimages.org/)


Giving, a handful of discs, all the same diameter.


Moved onto the mill.......

(https://s25.postimg.org/8jiy3e6q7/IMG_20170818_144330187_HDR.jpg) (https://postimages.org/)


Removed the centre areas. Just undersize, to the hot cap o/d of 47mm......

(https://s25.postimg.org/yqfjllzm7/IMG_20170818_150950207_HDR.jpg) (https://postimages.org/)


Parted off, five, 63mm dia blanks. From bar stock, and removed the centres, too.......

(https://s25.postimg.org/g2bsaf6a7/IMG_20170918_150621827_HDR.jpg) (https://postimages.org/)


After finish boring, on the lathe. A quick mock up......

(https://s25.postimg.org/a045jxhu7/IMG_20170918_150246112_HDR.jpg) (https://postimages.org/)


I think that looks ok. So far....   (http://www.cheesebuerger.de/images/midi/froehlich/a040.gif)

Thanks for looking in.....  :ThumbsUp:
Title: Re: Bodging with Boris........
Post by: Jon Cameron on October 15, 2017, 08:48:50 PM
Keep on Bodging David  ;)

Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 15, 2017, 10:47:19 PM
Keep on Bodging David  ;)

Thanks John!

It's nice to see you over here, too.....  ;)
Title: Re: Bodging with Boris........
Post by: Jon Cameron on October 15, 2017, 10:57:14 PM
Seemed only right since I want to build steam engines now, instead of just repainting, polishing, and soldering existing ones.
Title: Re: Bodging with Boris........
Post by: b.lindsey on October 15, 2017, 11:09:38 PM
Time flies as they say David. Good to see an update on this one.

Bill
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 16, 2017, 01:01:36 PM
Thanks Bill!  :ThumbsUp:


I eventually, got my head around the hot cap, sealing/ retaining problem.

Finding a piece of correct diameter, tube. (It just happened to be bronze). I silver soldered a ring, to replace the original flange.....

(https://s25.postimg.org/4535t3pn3/IMG_20170923_093950785_HDR.jpg) (https://postimg.org/image/7op3iwscr/)


Recessed, the new holding flange.......

(https://s25.postimg.org/j4v1xkplb/IMG_20170920_133055395_HDR.jpg) (https://postimages.org/)


The cylinder/ spigot, protrudes through, by "a couple of thou'". To make a positive location/ seal, against the bulkhead.......

(https://s25.postimg.org/b2rorrmov/IMG_20170923_111840211_HDR.jpg) (https://postimages.org/)


Held on, by three, neater than original, screws........

(https://s25.postimg.org/5bo5oqsnj/IMG_20170918_150700139_HDR.jpg) (https://postimages.org/)


Secure......

(https://s25.postimg.org/px2xgna8f/IMG_20170918_150647137_HDR.jpg) (https://postimages.org/)


Thanks for looking in!   :)
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 16, 2017, 01:40:10 PM
I hate to see engines, held onto their wooden bases using, obvious, wood screws. I prefer engineering screws. Button heads, look ok.

Or, in this case. Countersink.......

(https://s25.postimg.org/r78q339en/IMG_20170923_094158391_HDR.jpg) (https://postimages.org/)


The two rear fixing holes are now, under the bearing pedestals.

Had to drill a central hole.......

(https://s25.postimg.org/h9xpa0u33/IMG_20170923_094127137.jpg) (https://postimages.org/)


I drill, clearance holes, for the screws.
Underneath. I counter bore 15mm deep. The same diameter, as the nut's a/f measurement.

I can then pull the nuts, captive, into the recess......

(https://s25.postimg.org/nave738zj/IMG_20170923_094323694_HDR.jpg) (https://postimages.org/)


Thanks for looking in!
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 16, 2017, 07:27:12 PM
New, improved, crankshaft location.....

The two uprights, are made from 6mm thick angle iron. Cleaned up, square, on the mill. Dowelled and screwed in place, from underneath the base plate. Allowing removal, and accurate replacement, when necessary.....

The two, outer bearing housings, are a sliding fit, in the uprights. Held in place with slidelock........

(https://s25.postimg.org/6qevin6pb/IMG_20171010_130911409_HDR.jpg) (https://postimages.org/)


The inner bearing housings, slide over the smaller diameter.......

(https://s25.postimg.org/3wbq56wtb/IMG_20171010_130904371_HDR.jpg) (https://postimages.org/)


Butting against the upright. Also, held with sleevelock.......

(https://s25.postimg.org/ams7emc9b/IMG_20171010_152759156_HDR.jpg) (https://postimages.org/)


Should be much more effective than the wobbly, original assembly.

Thanks for looking in!
Title: Re: Bodging with Boris........
Post by: Roger B on October 16, 2017, 09:18:32 PM
Looks to be a good 'redesign' of this engine  :ThumbsUp:  :ThumbsUp: I await the first trials  :wine1:
Title: Re: Bodging with Boris........
Post by: Ian S C on October 17, 2017, 10:18:34 AM
Just wondering, how many ball races have you got on the main bearings, it looks like two on each side.  It's often suggested that the shields on the bearings are removed, the grease washed out and replaced with a low viscosity oil, although I'll admit that I leave the bearings intact.
Things look as though they are getting back together.
Ian S C
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 17, 2017, 06:55:10 PM
Looks to be a good 'redesign' of this engine  :ThumbsUp:  :ThumbsUp: I await the first trials  :wine1:

Thanks Roger! I have a show, on Saturday. Hoping I can give it a good, first run.

Just wondering, how many ball races have you got on the main bearings, it looks like two on each side.  It's often suggested that the shields on the bearings are removed, the grease washed out and replaced with a low viscosity oil, although I'll admit that I leave the bearings intact.
Things look as though they are getting back together.
Ian S C

I'm not after a high speed/ powerful engine, Ian. Just a, "show speed", runner. A total of eight bearings. All shielded.
They are now turning more freely, than they were.....


The crank assembly, is finished....

(https://s25.postimg.org/6zvaaprbz/IMG_20171017_142951934_HDR.jpg) (https://postimages.org/)


It cycles nicely. No tight spots.......

(https://s25.postimg.org/kgs8tl9db/IMG_20171017_143048098.jpg) (https://postimages.org/)



The flywheel, is next. At 7" dia. It's a little on the large side, for a mini lathe......

(https://s25.postimg.org/ddkddyoi7/IMG_20171017_150530290_HDR.jpg) (https://postimages.org/)


The original bore was unsuitable. So, I drilled out, oversize, and plugged with a piece of m/s. Held in with the ever faithful sleevelock.

The rear boss, held in the chuck jaws, has been machined nicely true to the rim. Allowing me to set the rim running, within a thou'.

Now, I'm starting to open up to a 10mm dia bore. Hopefully. Perfectly true to the rim......

Does anyone have any tips, for producing, such a bore?
Title: Re: Bodging with Boris........
Post by: Roger B on October 17, 2017, 09:45:57 PM
A small boring bar if you have one. If not a 2 flute endmill (6 or 8mm) in a suitable holder used as a boring bar. Drills or reamers will follow the existing bore.
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 17, 2017, 11:11:18 PM
A small boring bar if you have one. If not a 2 flute endmill (6 or 8mm) in a suitable holder used as a boring bar. Drills or reamers will follow the existing bore.

Thanks for that Roger!  :ThumbsUp:  Sometimes, this old brain needs a little help!  :facepalm:

I have a toolpost chuck......

(https://s25.postimg.org/ze5b8dekf/Toolpost_Chuck.jpg) (https://postimages.org/)


Also, some 6mm dia, shanked, carbide boring bars!

I can bore a drill diameter, recess. To give a concentric start, to the incremental drills.
Then a 10mm recess, to start the reamer.....  ;)

Thanks again, for the nudge.....  :praise2:
Title: Re: Bodging with Boris........
Post by: b.lindsey on October 18, 2017, 12:35:12 AM
Wow, some impressive progress this week David. Hope the trial run at the upcoming show goes well for you.

Bill
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 19, 2017, 07:36:21 PM
Roger, Bill.
Thanks, Chaps!

The first drill through, had been 5.5mm. I thought it was pretty concentric.  :thinking:

I then bored a recess. To steady, the subsequent, 7.5mm drill.......

(https://s25.postimg.org/yf716o44f/IMG_20171019_113425994_HDR.jpg) (https://postimages.org/)


I could feel/ hear the drill, cutting. As it held true, against the eccentric pilot hole.  :ThumbsUp:

The next drills 8.5, 9, 9.5, were started off the same way. They cut very sweetly.

Same again, with the 10mm reamer. Making a perfectly sized hole. Running perfectly true!  :whoohoo:

It just goes to show... A little care, and forethought, is all that's needed. Very pleased!  ;D


After installing the flywheel, I realized, I had time for a quick test run.......

http://www.youtube.com/watch?v=dlk_io15Ez8


Only, the cosmetics left to do, now......  :hellno:

Thanks for looking in!
Title: Re: Bodging with Boris........
Post by: crueby on October 19, 2017, 10:21:01 PM
Running very well! Congratulations!
Title: Re: Bodging with Boris........
Post by: b.lindsey on October 19, 2017, 11:30:36 PM
A very unique mechanism David. And it runs very well obviously....well done!!!!

Bill
Title: Re: Bodging with Boris........
Post by: 10KPete on October 19, 2017, 11:37:28 PM
That is really an interesting valve "eccentric". I wouldn't have thought it would run so well! And it runs beautifully!!
Congratulations David!!

Pete
Title: Re: Bodging with Boris........
Post by: Ian S C on October 20, 2017, 03:38:44 AM
I quite like the displacer drive, I have used a scotch yoke on one of my engines, these straight line systems do help reduce the length of a motor quite a bit, but may not be as efficient as a conventional conrod and bearing, but it's good to try all types of action as it is pleasing to see the different motions of each. 
Ian S C
Title: Re: Bodging with Boris........
Post by: Ian S C on October 20, 2017, 09:33:46 AM
I now see why there are two bearings each side, there are virtually two crankshafts as the displacer crank pin  is it's self held in bearings and free to rotate, or more exactly stay still while the crankshaft it's self rotates.  Being a bit slow on the uptake it took a little time to work it out.
Ian S C
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 23, 2017, 07:26:58 PM
Chris, Bill, Pete.
Thank you, Gentlemen!  :ThumbsUp:

, but may not be as efficient as a conventional conrod and bearing, but it's good to try all types of action as it is pleasing to see the different motions of each. 
Ian S C

Can you tell me, why not, Ian?  :thinking:

There is a dwell, at either end of travel. Allowing more time for heating/ cooling.
 Also between those two points, the travel time is more rapid than a simple, crank oscillation......

The engine ran happily, for over 5 hours on Saturday. Stopping, only for meths top ups......  :whoohoo:

(https://s25.postimg.org/syal6sr33/IMG_20171021_114403028_HDR.jpg) (https://postimages.org/)


It has much more torque, at the crankshaft, than any of my other engines....

Thanks for looking in!  :)
Title: Re: Bodging with Boris........
Post by: scc on October 23, 2017, 07:57:27 PM
I have never really bothered much about hot air engines :thinking:   This well made example is wonderful :ThumbsUp: I may be converted!
Regards         Terry
Title: Re: Bodging with Boris........
Post by: Stilldrillin on October 23, 2017, 10:36:38 PM
I have never really bothered much about hot air engines :thinking:   This well made example is wonderful :ThumbsUp: I may be converted!
Regards         Terry

Thanks Terry!  :ThumbsUp:

Give one a try! (Pick a decent sized one). Nothing more frustrating. When they sulk.....   :rant:
 But, so satisfying, when it all comes together, as a good, reliable runner.  :cartwheel:
Title: Re: Bodging with Boris........
Post by: Ian S C on October 24, 2017, 02:08:24 AM
David, I was just a little worried that there might be a bit of extra friction with the pin moving up and down in the crank pin, but as you are getting a good power output, it could be a good way to go.
Ian S C