Model Engine Maker

Engines => From Plans => Topic started by: mikehinz on October 09, 2018, 10:03:45 PM

Title: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 09, 2018, 10:03:45 PM
I've made a start on my 3rd engine.  This one is going to be the famous Pottyengineering Horizontal Mill Engine as originally created and drawn by Mr. Stewart Hart.  Since I'm located in the US and Imperial fasteners and tooling is the most readily available, I decided to build the engine in Imperial measure and use the closest and most appropriate sized fasteners and stock.  Additionally, in my seemingly unending quest to learn 3D CAD, I created a model using Fusion 360 and will generate drawings from that model as I go along. 

I've linked a YouTube video that I just did of the animated model just showing that it all works and that there are no apparent collisions or other issues.  I've also posted a couple of renderings of how I've been thinking about the appearance of the engine.  My decisions to this point are to purchase a 4" cast flywheel from Martin Model & Pattern, some oil cups from PM Research and scale model fasteners from American Model Engineering Supply.  I've also tried to use some brass parts for accent and plan to use a brushed type of finish. 

I'm ordering the materials that I don't have on hand right now and will be starting a bit slowly as I'm in the process of making a few mods to my shop equipment including installing a DRO on my lathe.  But I'm now at least making process on engine number 3!

https://www.youtube.com/watch?v=D6mlvtss7BY

Enjoy and follow along!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on October 09, 2018, 10:16:04 PM
This will be a nice addition Mike. I will be following along.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Johnmcc69 on October 10, 2018, 12:35:41 AM
Looking good Mike.
 I'm on board.

 John
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 13, 2018, 02:00:37 AM
An exciting day, I got started on the engine! 

I decided to start with the aluminum base as there are a number of parts that have to fit on the base properly all have to align pretty closely.  As per my previous post, I'd modeled this up in Fusion 360 and have started generating working drawings from the model.  The engine worked in F360 so I'm reasonably confident things will fit, as long as I don't screw up the machining!   I thought I had some 1/4" AL for the base but it turned out I didn't when I actually looked for it, so yesterday I made a trip to The Yard here in Wichita and picked up a piece of 1/4" scrap 6061 plate they had. Prices there for drops are extremely cheap, currently $1.70/pound and they have almost any size and shape of AL that you could dream of.

Anyway, on to the machining!  First pix is after sawed a piece more or less to shape and then squared it up and brought it to the spec'd dimensions, 9" x 2.25".  This is drilling the clearance thru holes for the #10 mounting bolts
(https://lh3.googleusercontent.com/uU_3kZCKcgyTfb4WeWRcwGuaGBSmRAeRczIH6LwHAmigGBzCyzzXG1Le9uRjUNLdp1AIr7hLtimYDnvtEzRwZLxuoDMM08GyDLK78mDevvWO-2RMeZt0cXRAFzPbazkHPsDTapzuaEUYtIjRiHmswCU2C6KI9sWzm5y-MZyi65o3294NWLxvVUfwRgCG01amS7JvZT8uULU3Sx5KFqTYcWWvXMS8b31zs6gQd2NkVoy-SM3fJCVPnbRpbBqdjWoFWj8izKt4wXOoCI2QDxquSveVwwzraeEwv5-L9noO5U0brtuyTmZ2xjCVOl4cOjOE0QeewcB5uo3yv4B_vjKACbRHP8onQbiAlDkI3QR_LZe7vRMUedpvJkXx6zC0mynL6Y8taqtJ7-8VnS4nBKbrA-qlVMBJu95StEdd3BbJrc2nLUIN3kTNPKVCFlWLiGzUf2QgTtCI-k0VBdWKzKeQTDXfBSGZQEzHQLS1O3Udh0Q8PNWoZb_0KBDToVxHVuN710v4wjMc4VKyaeeRKGYiqxKy_sEce6HQIWSpv1nA7wWuuedWgLPA7dV2kPjtXTuVS29GbJox76iIt1Ep9fMHDy6EXEO7sh8K_H2bcAV9QSUniL1cyJTHxjcq_fW9NaEQ7Jr2OzrwNrqGcsL1thlBhv_Q44BmQsy931GMw-gaYuO-Ok5i_UIOdoIw=w674-h898-no)

Next pix shows what you (or at least what I did) when you don't have a proper counterbore tool on hand for 4-40 shcs.  I just put a 2 flute 3/16 end mill in the drill chuck and plunged in with the quill at each required location to .115".  It worked perfectly as far as i could tell.
(https://lh3.googleusercontent.com/k-4NnGB8tluNxNU2-ESA6scb-xg_y3X0JOHrt1Ek8rFNM8c7acUeSdCwICMLFbmJ54Y2CTZPJBT8TA-UQOOM4Hwdk2KOZGZn2CqU-4nyAGzd0muIZKSiqwJWheSnRElBVMT94cZC2ekBSnsKHdwG1e0nuUpUYoB3X3ddfLj3QlSCLt8eR_aKktPhuRltzskzklSL0l_LjB98girPs0iyvwUKCJgVvEih2gHI6qZzmtD-_823fkLxUt0sYTadUJMR6irVL2fnupJDNBst5BztrYiPzqhhQhk5-fgox3FgfEbn29uCKii2qNjP2LcTFjxQznARBOv46HmYAx28fDpUbWO-bmM5NtzX5jG2ETP5MhQ_QSf6ns4Mw6XMJ0yAp_Fet4ZEas3-Mi3DRK7iDptV4L9Clna7Ipb-bSgASSnTRCK3FlkIbNoRb7rI69J_txXWmuRSIXB4qMtKh8IzvoT0lyDz33uD9bRIkKNL0gjGfwHi1uDeYMbNc2Z6mnBDePaICk_2KXMYqcn-7croYxin2yaXrXZ3GUga01C9cznBxl-JvtCgtF70MqJPkB9FJtcukFt43MOYoPAC7cjrV0yf0JK-F5Xq_Ykp9QYJqgja0T6SqMOzCGkUH0V488ccSoeuc9ujm3ROa4vYkZMaMCi_BEG9zJ1x1BXKgSCAZYlc2ToVTSYOHtXAZ4ov=w674-h898-no)

Tapping 4-40 in 4 locations.  I kicked the mill out of gear and simply rotated the chuck by hand while putting light pressure on the quill.  I'd drilled for 75% threads and this process went smoothly.  No broken taps and a test 4-40 shcs went in each hole with a good fit.
(https://lh3.googleusercontent.com/7Lvzt1fS1jM36u13LnvqsUkT4W4rpaS7NGbsqsk17DgKbl4Yrm_1JIi9ZvHcK71Ffjb958bcBdROiaORjPTZnq07oBbQ46uxjZm6-Z3GGUhJ2NY3FdIIdR2bX9VB63yJrKyaAJoWpMghwSEeaCtbDpMUsw4-2NbO865cLakPuAs1jewjY7uJsOBH0W0prbrbMyXBjBvUxYtu0QtpR043Nuf_lQlcPq3wPkOOeSjrFCuJ0l4sAJ4ClOZICT76pYzKU2kdvqmkMAviVBT9W9c-Y_gWbXPjYgRKqU9NupBZL058zblk8kYF_OaZfG3fgZVQjMgE1BLkk7YojsXs3RxQFGeT2eGQtesYzhfqTbrow0LWVO_7KTUyq_b4I_hl6unTzeJhEyJoyfEW8OIMQK6tbDTBbuoRm4S3IJaJmTD9nuPfKCteLpoAYY-I77xRIhbTSRHJZ6dTU8Am4o-BW2iD5y_eHF4v48MHRvB4ztjcUdE7CqCZiKbDdbsJEnlmCGNa_COJsIjUvDd-LzV6spjWUJob5WhwF7yvaSyUVPRwg8QyUiQTlP70Xl4YYop3q_icZNwjj1e4rMKqWLACE10JvsiruHuN26ReA4XAzbDsJhkFGdHeftJxGtq5IpgSPV3U8PX8-pxdUq7dmhENYtrF4ao0EAefhjmMJu8s9nK5v04dUEvJNGm6rkQK=w674-h898-no)

Here's the finished AL base plate on top of the drawing.
(https://lh3.googleusercontent.com/vYjcp7Gg3M8YTXjAFxUBSALHOXxgL7zrazo6FH3xaTZ-KNJWvB3dXAcvqjknK790u3ymbIBXNA59bdURtUmud2o2mX9tdtP23PPE2CtwYusQ3myk8IT1YVFG_aHnuXUnkGsPyVmJv6EEOh-ahPaZbjeRE4mh79QJyN304OZDGZTC9J3tLcCoOfJgp_w7VnZyK84l6iXSu4nZoETAhOSInDgdZyTWbndBlvI5yd6gTLJ18u4GymMXG54YG-sv4rJbvoRgyIZMFp35_LfHHr2q-QmxeaWbKf0QNun-jRb3Ls12el5lvdeBjClG-Ku0sU3vAxmxcXcRlTKJtoPmajdDW9fsZWwXkBxfcFliIugH9jzoZoq9q0mTFMzOq4oeZHVOQerwdl6d4He2lUiNz8gvazj0tSzmqESBNSoZpyOezvUkkarP6v3aFPwYf41Gsz6D6LNliCnBORIXExb-dZPbd_snwAYCWUWMl5BOa3fWCg3T7KxShcClUafceLfEfCTMJ4UlJ5FXQPWi00UY3o0LvogOb8TV_nL2t4ePq8tjuajPvb0l9pmd35TjYRty3FmLQfHx7b-ZPvc-FKu2VIz1M4oc-7Gd6GbwNVBmuHPSXtTmWpBhy8i8tMllrw_MivOxweK_fcUY4lVjK-ihy8l6w4EMPHAmfwfmbMvMSDWmL2G0H5_6UEj0P9pn=w674-h898-no)

I also started on the crankshaft supports.  The drawing spec'd 5/16" plate and I only had some 3/8" on hand.  I cut a piece to rough shape then squared it up in the mill and brought it width.  I then used a flycutter to take the plate down to 5/16".  After getting to the required thickness, I cut that piece in half and the pix shows bringing them both to the required height fo 1.60".  I did them both at the same time to get them as equal in height as I could.  This pix just shows the final measurement.  I used a 3/4" HSS 4 flute end mill.  Worked well.
(https://lh3.googleusercontent.com/f0o126iJSAKscRcsKqHOYQXMKvzrP_0w7VUltePeAKz3QW_uZY6nlPhTD4SQFQBQzJr7L0ENO7uYlcZoQPk4EYaQKO6TJOoLGHP9K73Pgj8Zna1QXO0GLayHs974QOgBhFw34a_L_lPZCYEFgPAEWqxWqXAKdm7boflyGvTkQzNUGI-EkEG3bG3SYJGJfnJKHV-Rir6tOqhmr2e-NcWuQvd7WStekWheAoEW7shX1j7GDZTEXyAcsvUH4zh9ZxrgGrRbmo6fAhW-JCLKyDBeD7mguqne6nm6Esdra2HS5DRD0mvXRVBFjwZ8NEMSUCTlCihzqMHDEfeMiJsrsAyH7FLke6vFPXPjDOs4ZTzgLpEptMipdMJFGv0pAnRIOH-tBmPWXLcpd4tnIriAcZk10uq3ETBl6Z6-JgArkiIxbxtwlGFjTdOLvmwDv9DaC6kcClD4rCgQmlu7BkInX1WFYWxXLM0BAjsnF6mQLb51tYaJm-K8vKkc-TBlwZ3X5OHh_6cMRJRRAP9O47ta7xLKWQ6TYP5IGQBf0_YqAzHf1D4P4bLObl9K5hcM6VgG9dAhYHpZTCIf57KvuoD8TOdem9FsxdeF8yFYptQNECX4BqmLsthLhyeZcNjQBuyJ0ROqi-JehCKfy0zp24nFMmr7PdrLClMcPP6Pl441nxq-uOy5VpPP4vk7IUz-=w674-h898-no)

The last pix of machining today shows the crankshaft support pieces on top of the drawing.  The next time I work on this I'll try to complete these pieces, being careful to get the bearing holes as exactly to the same height as closely as I can and will turn the bronze bushings and get them pressed into place. 
(https://lh3.googleusercontent.com/HhpJ4LBn73WF6K9hArUqWAnPFGzImF8sxd69ivlMNS68cpv19oQF_5BaLH6qZMJX98hWFTu-efmeKDiXIaLs-RcF1LfgniK6A-0AgYNiYq1ol-KPxRhLE45ypTpaW86UUUWLeoOmW0zS2l8rQfVCFoIhtrvaInmc2e8r0s86jx3_kat2eaez8G13df86lvoQhxU-ytf75eL4-uAEfip2Y9_NXesQdhVc4XA8ZbiAcptEOtmJAgyo_WPHA6-esus8jGh8_xiFV5VY9YOEd3N8_SOIsCB-LZQxuDuBmZQ4W3kNiVsKdZeEjjvL3MX0BD_BYSKNM-Jom5RPhxFuh3tUEw9cNel0W_M63OLtjj1ebMctUC-0PVwe7ziAaqkLdK-OO3_3ei7RQA19zYtJqbi7jqW2BKmtQrXruxljEZPfVN67uEnVAaMevB4Rs7TShflt2rnbcXk9p159-Y_oMoyGTP_5cMyRl2_3h-xKdS9K-TUO_8a0eXZBwd9Ws1OleTIO_MeXnoOp-Ebb0ZrtoaFa4QHDanK9sET1csXmieZMJ7mVbNFooqRRPq22yfvIpwV6BdA1liXzk8EBocvWAAJb0NdRTiO3Nl733DkflYS3fDqSkMYYQ72bIkYJYl6pBnv3K0-OvAmwvZneRPWlLCu91jPGgGzVIK6IkrYDcfT7ST_f-dzzs-lI0vkz=w674-h898-no)

And the final pix of the day is of some parts that arrived.  I ended up getting a 4 1/2" cast flywheel from Martin Model and a small selection of scale model fasteners from American Model Engineering Supply.  Both vendors had excellent service with extremely fast shipment and the quality of everything is extremely good. 
(https://lh3.googleusercontent.com/aZUsopqDFvg5XD7idtk3XWVGfWwR8F2yij9cs90L2u0HiBK0KW0U9wyInzTR1pJ-y3qdkXTHWjTVKirIXUvk9SR1lZ9TPnRgq8y1RhCu9wEnEIyOZh4xhZ1eHgtZkHNqiVNdhncIayFzwMFB71Mi2a9rcXnHLlvPKlv1S422sBV3vFvDuUwnxixOwXBqjJgEeUCZRGkssSwHq1PjaWjDv7A9GMlMr-KDA4Y0PxYaOBcFrxGZalOI2QvZUM7Q3d0fL_TOuNgV7OeNHqtVlJtzwz2h8O-HNv285z_6d5OO7D0zgmUDMmROhbNuBbFYoHbU_Jm5A-IRFyG8VN69p-b4-n44j3xr8vEpc7HXHzY6holM4f2XZVG7jkFRiUJ4ep4QFSTVjis3VDypgNjc-MH61gMp3kP8gkoJN-NciMGhc2c9otBN0YaxbsFxQyw1XjBmqTWTseNIRc1MkK3Kc2_eOwoDJWZhDxmGhiBBn88iAII0en_x2n4vqp1pCwORwpC1tDxPPSnUeSVrN_wJo8ZMc_LgO7vQFPYVM0aHqtb-DZHNklzFDT9lcZkl99qMrbv0vsCvu859xXkxQQaxVbcuoCRRoYS7YsWXydgrIjaECac6djHh7GsAuekfRnQEE0z7mi5AeTKjPTvDmqgk8YzuCY1UnsY8svYWz4c1jbeC7ZwfyMuLJdxdx293=w674-h898-no)

All for today.  I need to place another order for some raw material.  I need a bit of drill rod and some 1/4" square stock for the crosshead slides as well as a few other small items.  I'll try to get an order in tomorrow.  I also need to work on a few more working drawings for the next parts I want to attempt.  That always takes me a bit longer than I anticipate and I end up redoing them a couple of times generally.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on October 13, 2018, 07:04:56 AM
Good Start Mike, I'll be watching with interest  :ThumbsUp:

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 13, 2018, 02:06:21 PM
Stew, the credit on this one fully goes to you!  Your drawings are excellent and more than sufficient to build the engine.  Its a very nice design and I hope when it's finished it does credit to you!

Thanks!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: JC54 on October 13, 2018, 07:27:16 PM
Looking good Mike. As a beginner I like how you say what tool you used for each operation, really helps me. Thanks. JC
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 13, 2018, 08:01:04 PM
If that's helpful info, I'll try to remember to put whatever tool info along with the speed and feed I used.  I'm afraid I won't always remember exactly what I did though!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 14, 2018, 03:29:19 PM
I managed a bit of work yesterday but didn't get to post it until now.  My wife and I ended up taking one of the grandsons out for pizza yesterday evening. 

Anyway on to yesterdays shop work!

I wasn't really ready to work on it, but I couldn't resist a bit of examination and cleanup work on the flywheel.  To my inexpert eye, the flywheels looks very good straight from the package.  There was a very modest amount of flash and there didn't seem to be any hard spots that I encountered while filing.  First pix is showing the flywheel in my vise between the soft AL jaws and using a fairly large round file to clean up the inside of the rim a bit.
(https://lh3.googleusercontent.com/x4CT2y4qu0EI4kYpDaazpTtY9AKKOgYy_kqkiyEt3BSKtReSnqJdqe-XWQIrjVTFbjFGLW3W4bYN490cjr1knlVnGSqIHHexiAomRVdCZSugdPmZKF-SlApIOa1Bu7Oz5T149NGU4aojjdcK6Syn0nHTdVbAlElhgJM3FGUDwDficDkkUMeS4epX15TCTZHOKYft0JH-PFlQlg5mp1Dt0UzIRy9QLhFcMhbSFA49n_TgjnO47pV0LMNbfjdStHNlB3DDZNvpjYaqWetkzS166KXpeJci_6H2VJ4CPAM2lFMXM3jAEUhK6a5RiiiVrxkc7U88RCoEZ9ll-tUURMJOFhmBW1GaApu7LE-LpzTRrnsTqzPlc6txpbS0aceht6loHqpDC4xIPPZ_1A-lJ9MF0V2dAdOmvW84sAxuBoLVMmwTW-j-AMbT8UpHG4SfzU6pqCSrjOd54nsOIvlyG4-4Z3L_ECqun_TEHnk7ZOgjxUcO35PW_lwmGeO2NtW46xe0Jpr_YAiwvZTFGn0UpxLZdLZfaJBBHaByuW5cA-L_2L4j6CxWQ_lfkpONqlRZyiP47KRet-FKVEgozB6RubZdsGaIrtRPmH07R65U66ENswn7TBEZtwrxwizZbWeFkTTuGEknYYaxJubEktQuSaVel4cUo-asebaefEur9G-IKeLpkqMDMyfWesT5=w711-h947-no)

This photo shows just a couple of the files I used.   There was actually a 3rd round file, a very small round file, that I used at the spoke junctions at the rim and at the hub.
(https://lh3.googleusercontent.com/O0PAEOlhooUYQqiOQ5Tz-FB9QOTotj7pVkwduxS3AGrXUBD0gpyw7LwJCNyINoZHDBaGyuN7QDzR2ZtkemrvG99Vq1O2ggimDPyGN0Lmr7ZWPoePb1gAqtnEVaL90rp9Ae1JJu4T461xYN8R3CqDovi6RRQw8HOjvPjJeeYjk93wxbA1fplyu-u7x8qZPLfiMNCy3clrr9XhELpTiy169xIgz4l-lhPA06jGY-RmQ9NwWd8bpsfr8IU2-dwU2su_57J6mFERE0BKAQFcHOb-SBIR9AMQjj4c3ySHbnLGqhyKCuGRakprs7CogWvkyzelhx1yyQ084AEVe5cmqKmeiIzKi8KDjbsypmIu2V_K6K0L-UHLK1QBIgLvgBShPPUnSDcEk7wp-eAEP_oed4B3C2uQ1I-okyXk6l1Uluv3b52vwkZ0zp6Qck7pCP9knFyoz5GjHbvvwtD9NVKcgCt-L6kSMBm4XYkJlxusu2tCR2fSvVVsur2nYUzXPL0nRVMvwex_tJTiVbOkvlgNF4jfYk6AVvHcxK9_gDEo7un61uMJUxszS6qO09SezBSHmJPyTmyo3FgKowsHIH-nmLF-Upr6uN-O2qKOnNRddvo0vL0NZKRjAsYKWy9pQGIAby4=w711-h947-no)

I'll make this a separate post as I do have a question regarding fettling on cast parts:  How far to do you go on the cleanup?  I want the flywheel to look like it's a cast piece so I don't want it too smooth.  IMO the flashing needs to be removed but what about unevenness at the parting lines?  In some areas of the flywheel the parting lines are very even and at other areas they are a bit offset.  Do most people leave them as uneven or do you level those areas out?  I know that growing up on a farm and from being around lots of old equipment, that machinery typically had quite rough castings with very little apparent cleanup done at the factory other than the machined surfaces so that's the look I'm used to.  But I really do want to know what people think.

Thanks!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: pgp001 on October 14, 2018, 03:32:16 PM
You haven't been using those files without handles fitted have you  :ThumbsDown:
Or are they just out of shot in the photo's.
Phil
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Jo on October 14, 2018, 03:45:36 PM
Fettling wise they look good.

But I am with Phil: using files without fitted handles is dangerous  :paranoia: Handles are cheap enough and make sure that they go on nice and tight so they can't come off again :ThumbsUp:.

Jo
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 14, 2018, 03:55:37 PM
The continuation of yesterday's work. 

I started on the crankshaft stands.  Since the bearings has to be quite well aligned, I decided to do the ops on the bearing locating hole on both pieces at the same time.  I started by lighty clamping the 2 pieces stacked together in the vise.  I'd milled them to the required height at the same time, so they are quite close in height, but just to be sure that both pieces are well secured, I inserted a piece of card stock between the pieces and the movable jaw on the vise.   This pix shows that prior to trimming off the card stock
(https://lh3.googleusercontent.com/GxNtQwsNIx-mW4z_e7PNptG4fIsAwKaeLtfNkfQrj-KKu2bxlFVO_sSfvA83gPYS6wpHjT_3JiEEqWkZJDCHTWODQg3Nvzsg1N_wYq68oLADwj0TJpWH8Em1qqTsHG6__eVe6otEu9iPolfBWQ0Rrb09SZwImKPwrvTK_c_8CjmYG7KjsgppwG3ulJaJVT-ImLdj6V4Jza8ixiXpGbKC5rC6vU_4rWvhD8bdJs1K2gKOq3ODgMqpfwap6BnF3D9Y9KOiwFlPXEU8yGQhEXsRSNIib14cLajmyWOsXkKLEWEkHsvO1ihJFbuJ81gCmJGbKuqMt8iFXFOGJFWIpH4NfINPCfuCFzjYpIWwNl-XBhfHI7SE1_9c4NRsaunio2mdEYRf17okgrUGYqjnL6M3AWq-yBog8Ok_eXH5-lNoDerV7NnT0jVCMWZ-Ru4t1Xa9sfbF1qfp4KFLMW86uLSDpS80sAxK29VuBORCWT2d-RIbRcSg1_sb0_44d5I4XxrxUQmuosFb6xi0hKr6RcvNw5QdB3tDo4PFZ_bgJ8RWM0IvZvXau8dttncQQelXtY41zRXV_wg-TBmxkDFX16o1gxLHgThjNuZOBQGrN9c083PEc-XHKjuF9sJ3I_OMvSqI-TTqkjQ6pB0pqxFQT-dTr_GbaVq-6cqLyX0Y8Dl35ahxaMSsXIzCjA1k=w711-h947-no)

Next I took a Kant-Twist clamp and applied it to the sides of the part to assure that they are aligned in the X direction.  Before removing the clamp, I fully tightened the milling vise.  My theory is that this process will assure alignment in X and Y as best as possible.
(https://lh3.googleusercontent.com/_IOHjQ_JTUsGps2p0m4FJlZjEtJt7IFsevDoCgtxLgemmhGKCGSuKZKO4filRe1QCQBNt0PT3ccuS4KncpKZaAL4fRXUoNbGqXh1s1ypQlXyKJnob_x2aQUw64JH43zPthcnWeKtTElZHuhD64WVA55WhgAodTOk4s-0N8-cAfQwl-BPDVXMwXtDy_hdMEBHPbFF7FjE8tTOoKRzmcLJlsz2bsYEMFdGf9JvaSkV32x-WAZHZyOmMHxEzin6pgQOqQoEBM3yIezz1GCp6DWTitvVHFQHDskjMxPUoDXgapVmgOQMBT02xXZnuVYbLYESBli10uMgANAl5KQXwrYD7TL2nT-xBbtdZzyLRG-6k3wcTEDGjWXZ5R1_AXQTcwNJHYfV6e253AIjhyd1lZK1hN02zcKYbO86rPpdXiSYdO2NzsJ_sFq8MZzrE-lXUMaE2zTCYj0QVN7P6bllNl3nA6DC519_BulhU0KvYgoaZWdUrzGo0ywcFjkwsH8pdPwSP5BbCw4ZV5vk8HS27L0oXh4Gw4yHqMDwFT7f7SPsUW6NjknJayZ0iRBAPFss5UCRIjDpEZVinfKvBDU32f5kD5ybzlSnld2dI5Uzmk2wzhl74EozunYmqFDUPSQ7A9Y=w711-h947-no)

This pix shows a tip that's helpful to me as a check.  After I use the edge finder to establish 0,0 I put a center drill in the chuck and bring the mill back to 0,0 and make sure that the drill point (or whatever I have installed) is exactly on 0,0.  The reason I do this is there have been more than one occasion where I forgot to offset 1/2 the edge finder diameter to X or Y and managed to start some ops in the wrong place.  So I do this now on a religious basis.  The 30 seconds this check takes is well worth not scrapping a part that you have a lot of time in.
(https://lh3.googleusercontent.com/mBBXziG7ClVeIOFSJomuQNKtp8VbwzzfcZmbr3woMsAmefuo30wyNTal8v6-OKderU7A3EljY4Vst9j5A8D-JuG3HrAUBwgcPuzKaYlVbnM9CR7vx5l3qJdEiRfkhkAmXqr7EQbkH4k_VOml-i8vgsSWUnNHGuvDp2MFMhWd6p8XtBVRXydbhyzYKzd_QUOFd_LIpLAWWDDop3QNmdChXvcIrK6GGJ9-ttJ9JR2t6FxX046wHpy8zaOe6UCdpaTA88NU_suSj-sHFoaGozYx30gAtsZ_Xv0mpbjPti9UtKoEFqyrqXMNY3NJO8XdYnM_dJ6o43nir8iBsVdvxhB_Fx2bzOSGZhh9N25rZTX_DZz9biN0LYAG1_oTT0IeM7oSInyOi3fl7pv8-Il3N91_hvQZsuYZUGcPSGzdIZfsBiyusBcgMpbe-EtNqDpKTRon7E5hBvPH0SHoNNExB0Cx8_fgpqNoEwrEWvK5TsLzT7SwU1Zw9Dec2_ilHzzIobrzUYnlqltWq84ofvsgaNGxok4Wy198X0p7vV3198BRUT10i4EzrUImDyzKQCLkWNCKahb4UliVupM3x0ysqCDomnWTxYNhIoS21LwkqZqfFt1YmzdAFUv9gSY30dm_QbBwFL0WdjHZusSnVhE0pCaJSL81omk-tihBcKF05YtrsSfJ0MG2cFzZgYAa=w711-h947-no)

I spotted the bearing hole location and then drilled thru with a 1/4" bit.  This shows the 31/64 bit about to enlarge the hole to 1/64" under a 1/2".  I then reamed it to .500" but didn't get a pix of that.  I tend to use good quality drills as they simply drill much closer to size and cut far better than cheap one.  There's a local supplier that sells good stuff at the same price as the much-inferior stuff from the big box stores.  Most of the drills I have are the Viking Black and Gold series.   This guy supplies most of the aircraft industry here in Wichita so the quantity he sells helps out the price to individuals.  I didn't manage to get a pix of the reaming operation.  I ran the mill at about 500 rpm for the 1/4" drill, the 1/2" drill and the reaming op. If this had been steel I'd have slowed the 1/2" drill and reaming ops down quite a lot. 
(https://lh3.googleusercontent.com/ATW488rAr8mg7jSSdrDacjEwTJ7_cuyl2EGgIhZPJ3PexJsl8uOKIR8TPeaVb0Au7ythn_Ki7P2uejvBW9Hy0YMjpzuOddU8B9kQikCAPQUt4y-r1vHQxejpnJoNS89Rb8V92_Juw7he76sr85w5HLeck0thkDBcmWAza_sU74-a8fezhzepAFyheCveFpH41_5eARLzmwferTmZYSah2oy0Rcs38D4DdcdarUbyhfTwM-45doKQhfLLopHVqxcFtBWFvtY62M2fsJnuoe8ul5ylXrn-kuMcjN4yAHzy3dF66DOUgWSh8z3CZjMSHSHWSxTAKfXG8Ro5bCc0QayJIB0_OsRMJZetXIey_baFdx4UOeGFyZeIZnnrO-790NgXBAZdWazWiPkpkW5xgAkvEw8UJ8-L66krtu6TqXFMqLX50UhYWxRGjQMQwrjX5xHeC_XJGQ4X6esV4JdNIAJwrvSZSwqZ_SoY8ZznlKIfyu-7EY_Z7WoS8k0NZ32cv4xESULdiO_yLJO4P_u3cG99_AhjPwIvD8fQnIxfHmSlIS0xwPCW8uuL3pgUIpWeYMGbXtsCEm2nfG5htxhHm1R7Isc5uXvRdGtcObHeevADu1yD1yMiYWuIMdUDcuQHU84=w711-h947-no)

And here are the 2 partially finished bearing / crankshaft supports on top of  the print.
(https://lh3.googleusercontent.com/0SYhAfkCnFrOPyXZSuaj89eI--18S9XG1aoVTaMgEL_xYP8jNzfhQ2En9p73ftGOtKi-IKx7KVj4NLM2IZgF-c1gBvbtkmC_dcUUVlhX2hEVbqhgWvs0FtMdHmf3DmbvgCKNBg-2JgCxzp6QvyeFyf6SqtzsAB96yv45ANvgOrC29_Ck3jXCovJQC4B1YvKzpms0Tx8c2GM6cgcT9iHnI1vm3ybga1fjvyqie1HrKs15Qifuw6cEthJY4jF-Z1expjS8Rd-adY3wS3kLal8CDhSJUO-vhRMwCPdbL3OkT1-iTVFNo478fLXLre_D3GgH-J--Ugu1ReePXd9OLGIzLfblXBjnnOmXAQrzV7Dd3Mz9Gqes8CDLE0P0-RVlHW61_sZHsTPTfzX0S3HxqDwce26_M73zjcZDSG5CgHTC1uyXOyXzlo3sp16NO57t7ktftVfU_bU-jpRDNk4GlsYxfgzFuwHj1wcxkJ4qQTHH1BF6QDgKDmlBc_onIJPDlsGNQ9Eejxgg7UiHudyYJwkiR9FqUbOcsAjPAltSPJX89ZoJwtW-6ySpPdcbr6HKAYEOxgCKeiDXfm1o3j__P3-8fGfA73Otl0lQoX5Qp7JuInaiTqaLZVsSfJOeh7513TM=w711-h947-no)

Today I want to finish these parts, the matching bearings and try them out on the AL base plate.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 14, 2018, 04:10:48 PM
Fettling wise they look good.

But I am with Phil: using files without fitted handles is dangerous  :paranoia: Handles are cheap enough and make sure that they go on nice and tight so they can't come off again :ThumbsUp:.

Jo

You know, I had thought to myself 'someone is going to comment about file handles'.  Those 2 pix were actually 'beauty shots' taken with a couple of new, unused files.  Here's a pix of a couple of files that have seen a LOT of use plus an extra handle! That i keep on hand.  And as a bonus, you can just see my safety glasses at the top of the pix! 
(https://lh3.googleusercontent.com/mCG66AgWDeCQ74r4Lcwj-TTu2dOBYZFymqXZB7qx1czIC6iSh5YREX0gZsLscsRkeaJ-EK7qIUrlUDvLMSB7BDepSToRRxV9vHpH9QpzGya1HvZlBSeujEW1Z1HAe5_jfTDDcZi8eU6BsQt4r4K-p3HgkOXPu8MDKshWWvtdugCIiGJNsMRnoirFVRlG-569e2R75d66DtaGb8_15s2dDkRV6zsXWJuzBwzm-3KPTP5BTqvEkxiRstx_EBj7_QIY63JqLf1GQsLCmGkO7Gi6pYbBNoTW1vCh6THbPsQ_gqQd3T9T-XkMNAPO16OJ9SXWu2q2BOBu9xlj3rWAm6BnBCjN8omOMzrFO_YkaNJa47XRsQ9ZG3WSHedce98PuWMSNTY7t4gMun7UrkE81FZEJbBCTua27aaJeW_1eT0LRWnzpNDlpQkRoYedSpnpVqOT3NQfyrXLVdFkTt7pvsXOq2vB2DeRhGuj4rivixGfxB4MR3CBncIpZtv0yINv8y0ZWk7wKtkVmhVX-H_0bkoDJS76aaCHWDXniIyr1hTED21bQspXLVLM1l2XEfBjlDH3B676PpVGDwsglj6xMOMrtmW3yF4nPcuIFCxKxXStu7dezEZdJkwSxrjSWrG-sgQ=w1238-h929-no)

I do have a question though.  I've traditionally used Nickolson wooden file handles (the ones with the ferrel as in the pix) but I really don't like them as they tend to work loose over time.  So the question is, what does everyone recommend for file handles that don't work themselves loose.

Thanks.

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on October 15, 2018, 01:20:45 AM
Today's work - finishing up the bearing / crankshaft stands, except for making and installing the bearings.  I didn't get as much time in the shop as I'd have liked but I did get these parts finished.

This pix shows my setup.  Since the parts are symmetrical and I needed to do 2 of them, I setup a workstop and held the part as shown.  I started with a 1/4" end mill, 4 flute HSS at about 1600 rpm.  I stayed about .005 inside the required dimensions so as to be able to take a finishing pass. 
(https://lh3.googleusercontent.com/0_-d87qgLCJjXg5zWm6ooYCvv1OwYLUZqoqd5ZL4BfykNv93HSc7MPU9M2Ddf6AQdxUi1JtpolZ255UoedRID5LcnFpCvkhguR3ahfvEvXHScqpH2o3u5pLxplP_VRmbuAxFDpTgUag4Lp476aVll5V1coomyp20PFl2GwWdan81z8W6fz7Erb6yYm5rddbr4aL67cbqeneoY2DbZSneuP595ZbcMMnjE2vVOBVzf_CmTgI2QbyEhdcnmdgMKUXngXVbZtbKvxt0dlNJvl12DMEUCUa1iXfKt2p6F-DCRCTvkzvKO5ZrbSh48F_Vu1BqDXlho1LU89G99XpYFKX5LEIuhf05eR3ohpLt30UP8kpmD4lWglunTZMergHc6Q9cALVXxhniUK7hIPLje_9GyRSea3-KtQiWSZg5EdqJPMYtzSlJ-e5x6UOXiF-qDaripKZIMLYVa1n8qOBwPzJEiHCS7KgtsztIz6JgJkhsBjQ9-ybLqYLuCA-Zt7rgD_76z_3jOU3PqF3i2IoFAeML6SRDDXECpyzq2IiG7m_vjpRbpGBFbCVH3o7zeztU6VlTSNdlw4mGQb1jstcIdywbwuYpInLPKgTUtXgD7IN-WWo4oNIPB_BLFOmja9DkYZWiUBPwtmnScyPchPw6iaZmT_mHp62IzYEkSgulUYqz9cJN0H-z06TFNO_H=w711-h947-no)

This shows the same setup but I installed a 1/8" end mill, 2 flute since that's what I had.  I stepped over to the full dimension and made a finishing pass climb cutting.  Also, this way I ended up with a 1/16" radius in the corner which I liked the look of. I left the mill running at 1600 rpm but should have turned the speed up to whatever the old Bridgeport could do.  Just lazy mostly.
(https://lh3.googleusercontent.com/PusKMm5wO4SFJ5ZeNq-pBC1wl8ItNtazLh_vfriddM5Zfe0-nZFMsTmilZKCVPxXISW74GsrEcvoPRl43KMZGXc1Qx0z9EoLNG8nwnUk4MHd1dUhnD-r5Cd3B05PV72QbWzRIm3wBqiUUFN4lz8s3eubCnpqi1gpyoxtt8UwnQ1_m4wTZCSzyQLmqwouBNWOS2KZS4ZveE-Rm8gmY_cY4y79CFCoktcckJ9cBG4-c-rT2RQdBTHZ6O_Vet0M5-ekjXzpnemqhfLL_XutCqs6yFfKjvqe_avF8S1V0C7uHHvyXc1XzlMrePjQxj5aL3hrcJJPw9IBdCpqDVRLZDN1A5n-wM8QngGYqVFRz2wuYint6KqpKQKWV2A_OhPl6gkUghQdY12lVuJxCSy_Y1WrKlB8cRLeXObZ12V-dolAeU3-1L2lQiyp904ngXyqRYGZjTL2wjrtLa7G0adbGqmsu1mMvazoPZKfldLoBusmt42PQYL6i_hS23Yb5NQO1HOcf14zm_5xYxBsklWmklQvAnb-IlcybbXi7yn5RLsAuEeB4-Doucu4wNR8w3e0JHQ5U5FJdlzAn2GrwGGXEw7YYJdJz6cAncmJo5LADATmcja2JaqKkD8fHRDtFIYFMyDPehQsuCJULXF2GkbWnNQK7tNcBeMwWommdwmGEPOdmYyQUTDsvVtToQuo=w711-h947-no)

In this pix, I turned the part over and you can now see why I installed the work stop in this manner.  This is starting the same op as earlier with the 1/4" end mill.  The 2nd part was done just exactly as this first part, so i didn't duplicate the pix. 
(https://lh3.googleusercontent.com/VNpG8Yv42uMsZBHnyXDCZIn8fc7KBqfA7FYtGUxS5ICijwJ_kataUHcPbn0AmL1MJbtFFgssB-Vb0B6xGFv3dQ2qhkAfpc1MUdgtmtIe7Q-FWkNP-4S-yacTTjnGGPi2LK8-GU_ZofHxwRMHu4AqXYz5Qo5UvAP89J_DufRki7xXVZSkvtV06pz7G-8fQ7g4zniRL8MpiDzsdnNenau43fQCTXNtDuDF87fL3elaQ5aLxD54vD1vBK302XiLjb1BFwIgWY3Q6HQLlcMXetWSmRyOQ9eAb0m3hss0d_sUwFK21DGdsda0CQwjMWcVGl_SC6nc0Gx3RaZbNJFM3EJENgobsHrHJmSIITluZpVufANEyPeBdvUS4SVh_8SeR2P_iFE9FSlsK104sAxT9aH3lcCe9O99rKiVbYMspjHz8GTVC20lNNbmVz19_ciOrD_8sN_et0X94mE1MD_FffXVQO8nGyVGNz2rIQbm3sbdIIwJDrYg5vtyrem7Yn-0ZBvK_X6N8XHH4ge2iICMLlMWco6j0Tlmtds6gA3c0nTzfhXyf5MvqehbVoVKfo3anCmLov26AuAt79JKNrRKqWp3Av0had6SH6lT03qNl8dXDH0Kxg2IyZa2TQBcZlW34VUzcwI5qX8GSosXTkRdSbbaJjl_1URpNkyUw02f73XQ9pKa1IHFL9ZbakJC=w711-h947-no)

There are a couple of clearance holes for the 4-40 screws.  After I used the edge finder to find 0,0 I reset the work stop as shown to be able drill the holes on the 2nd part without re-finding the part edge.  Just saves a little time.
(https://lh3.googleusercontent.com/shzaQFrZFvq5kJft2Q4NrKCzsINpUofDUAS6s8UEFAy_FgMeRf43hcBq1yoR6mZnsmX_JIXiykL8ZNIGJmgBn858XNXmDWW1QOHmsa4tl_6FiBmKCgPHLXDNiCIrZ-O5hq4xtHFKI2QmTuadk7zTn8U44YbIT1RdjzSb7zI5I8Y8CLNJ_dDwnu2Z-ySP-LsFp7idMCckQJffk-SawlO_tictbkJDZNRjgAjscxHwfoGPw59x2QhCwcyDps6VNv6mf-4wEQoqSNAR7Y7-A1VjYjHy6W5C09yMggbGkyslgrP_l_bBflMvIFFEb6VndLKMO6w4BHVj1t9bbHEh7INz-kOWHwlKvd7a5QUJohTdfPZWdUBGXZBpLlydxbASBc8iHE2AKxDA0wCEbZLlCkgKioJBumi2oAapHBKm-qYAZs6_QnkMMYfNBG1zGW8foHyyZMB_-gdSOEJHnRx2XYaF5cpLzQJ85yUmx_f7Zhk3dAj5f-8FuIHab2Olg9qpEzWelBI7pc-XaMCAjZIlufXsTaDqFu3gSFaM1KbSo8uqa6P5aCr6J-aNDj33GcqsYlEAeJl4loeb0ROmoMN7Ti5DA1hTvBGeHTaTT0E5MD8bY5xqibQrqji9z6BWwwrQS6hbNe2_Z02S4cKv-pCCIyaVGhJFv7P6DPCQ55PFPawbFDiX6KPhXsSFBHuN=w711-h947-no)

Spotting the hole locations.
(https://lh3.googleusercontent.com/nd05G_nx5ugkLo28W0Pk1QwSat_GmOMLMyY37I123eHkPWV47B3hsIR6Vlo2Gt6i7DfwHyCQ_j4_B8jU-ZzPxlsUa7obdrVlbquZH83Y51nbXFb0ztI9C2LkpjdAZUuYvlH0LCJ2O3Uko7gausblIbRPMYm3shXx8PK3mCXxD4G0UApulkXMxzOf5cR9E3eBK1Is3rjO457fpIRVLBkCDZFc45W7wev93rMGP6Jb_R8CNykiyxWMq54wKVZs7TrtQavDehnJ2OCeNKQXh8a7ojgWZkudA7oR_WNRpFr3azYwYsjtf6LkX5Fu8ADxMhBEY8Z-RV6DNYpRIvM2pjP2xKVXhGzcIPxsdvninMNUWmtLP7402qmBZqwfaOxxXwMLb8F6pOS56KdkFEGd82umOeCrZR-gQvy6z7awmfSctX3EdZxjT6SJ7NYN7B8qfbwqMJcQhZvO3-iEnHuwlm-DgCTkrAA7_PLarQutiLo_F8yDhvKLmmdrM58RxQXtnLdg8y66hAQd7nAADwoh_4aOV9PNf7r4v3DB-bqgByyFkwwVtwmKCZnFxI2_Y--EjKAaFuvNIChR30yyxCC18rbh_sr56v3r1aMrMrp-ZSyeGWXZFQ5W4F-4MxV_hYk4CupRcbQlG1Tpo7p_iatAVInr8molC2jSZTlseD8dCXCIOcYBWF6-qeq1USZY=w711-h947-no)

Second part installed.  Just prior to spot drilling and drilling thru for the clearance hole.
(https://lh3.googleusercontent.com/EpQDDGWEAVxPuKefVz9iF_zyZ0o4hIqbFhxkgBnkLTOPML-RmVuopLrIrN9GYY_-TS1ZlJ0l9hENlAtUohUubXgg_-52aaEUDPIo8pVXYxLxufZY5zEAGtQ3mqNlCTr4uTKER-OZ2BIqV8xB7dt-xqX75bCHhsTBxqkAjZKLpjIj8kYos2JQt8J5Kj2PM-ixQNLBTG-wjgIgVxVxm18uK1_pRL2pnd2uTcoWEkQ5W_nGgS-1fsFzOxSO2ojkroOyZuCYI3nQzky0lCyvAiDebikb6cx4K5iqgegVOHmCSg27J7FEGBWeF43veukXbDF97MYUI0LZJDFhgIq8Gw9VIVWLJZOVLw-ON5x37x2HjuRIFaG_vaVgBjEgYKBKC8R8RRWW-96mzwIHA6ISodRY60pu3DJXDVKXQyL47-wnKY6hlskXhci0rJj50kaf-686R-wIJ8M0worOjYfInjprxog2vtSHfMTGlTMszDnUZSUpa_6GxHSOPSufXgMcw6A3RQJRmUbcU83gwaag1cYAZXmqVNEl99rJwv4IF4Yjx8dEbR-APi8e6UMgUhMd4Darghq-3e1gZoyNN5RngXjDc9AvCBFkHTmLIi-XXzNta5IcS4CHvcXn6yuCSyu1bKrSyrCD2_aDrYKWoz9ekQkMBGBvad3ZusblhPysEa7wU9kh6N1IJgml8go3=w711-h947-no)

Finished parts (except for the bushing to be made and installed) laying on the print.  You'll note all my hen-scratching on the print.  I typically make working notes as I go.  Typical would be writing down the DRO min/max for each axis taking into account the tool size.  Or whatever other useful, but short term info may be required.  I also make hand-corrections, but try to use an actual red pen for those. 
(https://lh3.googleusercontent.com/PMpY4hNp1HMInbYiISRgIGplmo5FsBArUl2mLNu8x13H9xm54crhUyB6Wu6UWQL_ted56K0aPfMYcUWELGnlOfwzE_7jrJQgL0RugpOEEhTKkPNhzWr6tT5PmDzDlO7THpRsTBLNxcg2nR4JE4HDjjTutqsRSTfvaAbQuqZSDMqYv8NcxI-UnaopqWSwTpXhGWb7OlBmYmIxM2WGSzfTSvHeQiV0UTWQmYuXbQfYylUeW08oHezZrJ4o5QNxSm4zF32ICkidqrVObtXwtL784x6lXniONq5gt8O0JHzcH7_FzL32RHMCVfm6ZE5HjOxTfyGrIUQwMG2OxibTBQxgscuxlFAHFvcLRzz2akfrv7U6s-E0ROHmmLEouEbqOivD35uP5WxkisUv01BV1OTjlh-Qj6dWdCYBraY18iqg08Gcn-fiGKWquSqTYAg0MTh6D2PyuhrJvn-yHxkTiYhqexdK-qihhRLGgHe1EYOWlRA9geBrBSaP_XuR-b9lZMgXOSyxsuKACdr4pKz1GL130Nh5w8N8GcED1VI-S-bYGxgWXTzWl7eZGGIMus0asvswvaFviDCH8H4MQzsIoyDVohtNg9jfclB2qPwz7dvomvukLDDy5iuNE0nCCMfPEYHM3tsIKE53N0hsJLh-zVI2cqMwAVjsw7__x1xii67KT3TyzqtrAwSDubU0=w711-h947-no)

Stands installed on the AL sub base.  You can see the look I'm trying for with the scale model fasteners and the scale brass washers.  Those are 4-40 bolts and matching washers for 4-40.
(https://lh3.googleusercontent.com/TqQhcCzzZYtAX3CvZNUkTJuixQhJLdhbzeRB_OAQFTkedxrwy156feuJFc1apt6HqqRUGF8stJjL5PBpozA1K1ZOsPM8ldOs1YzNgP1wlAV5Vvge5FTDZYdERECf65iIZl7NshynsLlUTNrmlf069a-jU2m4C7NmYBLY3kbSPro5cgHfXwS6rxStFtClTms_F8QLWA74qVtnlJvwX6gbBFkw3ZdoWQeymj1dN1Ze_kIPpttSTvmDxfP3f0gO5bOFFcr0rq-b-LGCRAQNvtnNGuWPyrJ1yWEr8e7ONBX4ZVtIws71j0wKj64SJPisrIDsMHWXSdCNa8B-W5sGeI4KMebr1sxhdfY511d-3cmWfrpr0lqpZWq4ENQVTXL8N-1Vi2ZO4zTpSOcWz7XO90EjbCCWL7uaj6dn2D61PoiCcNNyd6APIWNDV2-c_fdfGSR6JHSZTgvn_UFLtUe_RM8jLccRuhBNIRdRM2qiBcvwLcF45vcfhQxSD2bZRUgvzxu1UTBXhm8Nkx9kuzbxWQh3erAshdLceSuujK-wyhOjslJBPPExO-XxrB7UYGfa-jTw1Ix_V9iHdhkSXhsaUEpZeZuB-ABl17q7sZ0fDbgY-FW7W6A792FJ5EV3fEikyGFo53Ox5Y34eksIFGOS2qTlTGqPCPgwF348dH3PoLr2GOFQY8N9CkPNi3QU=w1238-h929-no)

And the final pix showing a closeup of the stands and fasteners temporarily installed.
(https://lh3.googleusercontent.com/Wu1mSgeIlpTvU3F9HIzUtUdb1EwTnR9COwGsTvPlzsW-_8qxTUzz-AwDRIRET-5R6yqmzao4Obe3tg9fvZl_WG7snPJFLlP12prqD5p_Baxk7Er_pxZ2xSMCKsR9WCbeIUOIzdZR9_UBFI6uxtCsRns_UtTnCBnmtYN6TM1dXapPxY-hoQwch_E5DABI6lCw1YJlVJ_CEpDgO0tMyrrDSXxtHkq8Pxgx2P0ucToahiBDcB6TrkEuThhCeEPFAPiRuz1VBOjYkECMQjtcFiCeiqCWVdLvRhpSSgRnhVDGY6EN5w6was852iwH9L_LRhjuJaZtMm7NyBHgPu5SCdRZO7SjuoW4v1TveOmml6Rbxb0HrviML-sl3x8XjiBQvZWC8lp46bEBZQOkfNGZDsUkmNZWZt5rS7cWx4Hf8NdGQazkTvaVq2Frdb0FJnY5hKRwHSB9Bxmq1MW4x83lOHSrtaQlhyEv3T-cvkK_9lRmyaGc2wDpElXrmQykxCNJGsmf93hKB3gbKGG6aiewwPyFr5eHtmVonhNXtTrvJq9K2Jko0bMppW_izTh6a-H6EkYxQDMWTSgwz50KwN_-xDTqQdj9StIkxKsFgm2-hze48ipkxIj1W39qwXIZ7N1y5Thxs1JgBIw8xrAorCltPbgSALrgwK7n_DusCVoMMI72ZaQ-Fh7_QVg4gZBx=w1238-h929-no)

All for today.

Enjoy!

Mike



Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on October 15, 2018, 07:20:48 AM
Nice going Mike

Regarding your ? about fixing handles to files, the traditional way is to burn them into wooden handles:- heat up the tang of the file until its red hot then push it onto the handle as far as it goes the handle will smoke and bust into flames but don't let that worry you, pull the handle out let it cool a little then press it in again as far as it will go that it it won't come out.

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 10, 2018, 10:30:31 PM
Well, I'm back to working on the engine!  I've not been idle, but have been working on a few other projects, the biggest of which was installing a DRO on my lathe.  I'd had a Trav-A-Dial on the Z axis which was very handy but I really wanted to have the DRO function on the X axis.   The system is direct from Ditron and has magnetic type scales which are very slim.  The X scale is 1um and the z scale is 5um resolution.  Price was $501 complete with shipping to central Kansas. 


Here's one pix of the display after I finished the installation.  If there's more interest I can post more details in the Tooling and Machines folder on the forum.
(https://lh3.googleusercontent.com/DMH6kHVrUH1yin6jZH_-6xVj42eGDD6hQWE7OFXRUvvG3sVQoUha1QiqOr_5Ab1FQUD04hVLuxKz1wXixl1w_19n-ne4UgBW2mS0oGv9JTxn8zRUsiUbyUWH8S2VeSNmcaZJ3G2L2eyN0q5co50DEcX52NpOz6kMd24fIAwsg47jmyJ1Wfis6hLOh1mD4myk9KWmU3tTwZFQ9ZaxYkGzAG-u-hqa9T-NsEXUmG0hTcPk2R-JoNNGUcEoPWRQvRl6KV-tEynlGY-IEwUQg5_-gR5v1TpN7Y5ZICU_SuXRiBgza99MgAmHWck1coo5KBrXsXCgZo3F7npbcnlp2gBDPMuAZjKTYKFoZhyfupB4k-nSmfNSJU4UPOUQxHeH9CZB_RXmX2MfFk6j5B4BsYeSUBf8xXc01KUKVNpXttZij2aSD0LqtK2qYsKMD5RYKzF58-_PJ9ttip3kTmmpduz9Rnyrk23EQMGbbHkFe_5I0LeyduULH2bk-e4uvH0RM9Pxpd8xpxZbcsV4u-8U5SwGO-CaOIjWyYEzAUGhZHqOUo6dNUCwWZFojGK3bD2_rppy1bHNE5D-13jBo5Mzvz15Clz5e23PDdA2DwaRjAxGMd0AwHFkdYcmXbXh2rlPmy37AqltONTM2qmFg5YTA6ul0QvXYptHt871GQSZx2Pqs1SdKzLiEXgUp1bXAawtorKy9RhYOJ3o3Czatko1GDl75usQRBuvdx_fUEX-=w727-h969-no)

So far, I've really liked this setup and, at least for me, markedly speeds up operations on the lathe.

Let me know if anyone wants to see all the details of the installation and I'll post as Indicated above. 

FYI.

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Ye-Ole Steam Dude on November 10, 2018, 10:41:13 PM
Hello Mike,

That sure is a nice looking setup and it should make lathe work a lot easier.

Have a great day,
Thomas
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 10, 2018, 10:54:12 PM
On to making some actual engine parts now!  I didn't have a lot of time in the shop today plus its extremely cold as it got down to 16F last night and my shop heater isn't adequate for that temp.  I can dress warmly enough but my hands start hurting after a bit. 

First up was making the 3 round spacers for the cross-slide guide bars.  I put a piece of .25" brass round bar into a collet and polished the OD of the material, faced the material off and drilling a #43 clearance hole for the #2-56 screws. 
(https://lh3.googleusercontent.com/6wqkZNXzBd29TKk7cQOTlH4QhMRXLN-D-zVL6vHXCgUoRpIW_di1TAifaz1cJM4Q5W3lDigZiRyAow8Tm6JtdlGD-GByS-FqaRNhdogwqN2RR_tNDnQiiCzZQ1xhtxaAmM6n1i73TAkbjrLNBm_L_DMwi0VTE0mNHWIJLUAVgVzMF5MiIRgLuuE9Bd-viNG0AEIwnJSauAtr9jeG2rFMLDcUB0__DY3KhUFo_UKup33e90vMx1p5GUceFKc04WuzAgtiSkGatT7ZunKGtpTLeWkqkOdXf7zDTAvRgzBpCBzcv8JMhTgxITcIbHbb81_55R20JmEKMuS0z2I7DSVVVqjnb5EKaKNTY8EJ1S2vkcsta0ZOljOfntGV-pTqeuXqCewXaLDPoQ9DebMZIRnoJRcG0hrO39aJjTs_vbu1TzeVbynuiKYihuD2OgKYEgYiJcrJW7IgYf2FviH_Ii9EyweccHfJMrNkRQUam0L8zsaIRSO1DidCbqTdE-NeHozo2XAEWPQLp9P6kYf82-NzjSXRJzGdkxBL83mfNgJPYJs99LK_7YMWO1WVgK6dqyIBTE2wNTMR6OK8-uEsXq774A9fNAxiKjJEgV06LLGc47ssomFDqzGGc-K_FZZJYroWMASczme8eyXsHi3REZx8ORu9UATO2AfbLl8hkMboV68LGA_1U_U2fkkFFmMdCrgpAO1AYZj3zkyRx-Qz_rRkyOVk3tawx-ALDmOP=w727-h969-no)

The 3 spacers shown on top of the print.  I really liked using the DRO for this sort of operation.  Just take a very light cut on the end of the stock, and move over the required distance plus the width of the parting tool and part away!  I found i could get within .001" at least across short distances. 
(https://lh3.googleusercontent.com/oD4GJb5GFpq3_uhonwTZNVGdLCCLhJarP0QSWFI3_HrvPXHccmKBNI3kg4ITMaDU8BP-FFQXaZcnMybKV12_TbMKyLpYUJ1Gvpsn6csIM1UfTQ56k2caQPUtWPP023ohqX2tUk_jfVtsevhxhVNRHvDlYZZiqYYyGqGo-h0by_l3DLJ42DjwV9Dd2OPaRRihd_cqGwwELVClHWelcPvP7AN6I516rUxmWlyYtBfucYmNpK437q9mycQR8iBoqP2L148tv2Y-jDntiGd2Zo3aIw5RhEQHax7OMM7a4_msNB9PEwHNn7Ny-Cvg2jo_J27hAFiR9eXY56pl5UPnJlvAYkb95co81WkfTARn8n32YkKbB1kO6HDDdlmzkmk3I7ubYqmQehzLHlSZlS1qpEDmiSSOJWyL7Ttv7KAqCapfWU0jY-Oo7lF803pZphkVlQTrBbak2UlEGzEgx4kXL1CdtODG9wRr1KiLWnQZEwLZJMtD_xO3Ns73ss5rCLYKj2mSIS6gWvEQ-TKN11cQnnY6ZN05Lo8P49C65OPC70dQ_Uf3tk1lwmdWY7xbfdT2f21PuLmXM90Jmz1Yv_YNn1WssVBwoJiO4indWqNDgR-HshfRIZpDSB03QHH5XbNkqWaBy2NU-3aig_cWxxnGmSHe7WiKkKUqd1rVTv3nkfeJWZMy37_nJiv2tPMe_-80gB5CpokOstkHM3Xo7LOG5iwA78wssMdzQnsUyoke=w727-h969-no)

Next up are the crankshaft main bearings.  I had a piece of SAE 660 bearing bronze for these.  Shown is after turning the OD to .500" and getting ready to drill 19/64" (1/64" under 5/16") in prep for reaming.  I'd just spotting the barstock with a center drill prior to this pix.
(https://lh3.googleusercontent.com/xaTBaDwu-DThCpjr1T_dj_1etvSrZdNUA5zONvbPS28c2CqThI4oJJRSbOeB8527N3oZtYN1lW7HOnGd2Efyf_CDyDdCJALLMAuR7H8uOcDung1aJigZhV4Ja2lctPUDZTLb1oxOK1zxKsHJXO72q46yPlIhs3J0b1V_OH358ZZeU2Gxn2bfngbg7vSCABIzijh1sytbGOTYcyRtqDLtw_sjCPLcfxFdetKlINR2nbt9nP-C92m_sBrLzyc47JJ6t_e4CLBcnZ1h7JUFaTHuNdsPD90xBDtT7nPk_-hLe0otpk0NPmH1wWa1j3gWPaLKJ1n9XEoAyWnNmk6-CKiySD5KaU2eAQZ3ehXSWFejoCpUL_EKqdSAyQTGG21YHA3RpKKVI9tVLRoJjSm-bYGCYzTvnGfy2LDbHGF0CtDDKsYicnG1f3X-OYQuS59peeUx4L4jte1SDThWr3ZGuW_ZI7GEKKzdqr5u9EK5mgEg0DpSg-12EU8L_vdOUndJJF1eTei0buByCRLAmh-gcY--KgkE5foyliQxZMGefU24mESHS_xs9kmw6DR_4r7pGJ0qd6kqhsTf_UETaoDL7Huts4tR1bDMjke-PM8B-A0PS8eFl0QfQdRNFLSzfmCb4rqrey-BHauhI0d9ON-Lvy94xX3WgC2OobuuKmFuZ9LImmUN2dA5dq9XxG2QfHDenYkvuzukeKJ5Cu7FaQNzK8mCxdi7P0Qi9M4Vs8sH=w1292-h970-no)

Next I reamed to 5/16" which is exactly on size and of course the 5/16 crankshaft material is too tight in the bearings at this point.  My plan is to mount the bearing stands/bearings on the base plate and get them aligned as well as I can and then run a .001" over size reamer thru them both by hand to bring them to size and hopefully get the bores aligned for the crankshaft.   If there's a better approach, please let me know!
(https://lh3.googleusercontent.com/iT87aPLjJ1kcrVoKX63iNsAulb_p91MlpsYvnVlpE17tHyK2b_srpZrP5SapxK3enqxW67SOwH52Le5UYN37Tu8sNVfvk-x0udAHE3hp8yUB0yyiu3LH1hCfguBessmgmJK2auWUF-44pi5LSFVsPzOI3PWsroKE4pNeWIaRyW_VMEEDko0oFUpzINLNZpKSVfmuh5TW1gU5XYvtaEDj5P3im1mnDMnwhqbdrpJc8nSTRhcZcCU8m0RNypkbhfhvz9Fkj15zf486MpFhIGB1R5N_mDJfVpV-MM4vehjYC83s6CY53VqDTonklJ3R1eKhzIkvnp3dXhJ8YN-aXCqmwCp9b0t-ph8eCuLuU9kwL_QeHaE4sRLyX7Lyz6lcTT213fzS7Q8eNECBmcIkPue84R_DLSdsGG53SS6QVMaj7q3-Zx2wUX7GsU42v_DlyxYgmBDxe5gbB6T4D7lXjaiTriA57pyY81uOkVBfqTRAli28fO0dSEoi3wva6fVk2ErcAokTYDITBgXgHZPc8zKM8v6njnG1ZWnoJt4fDMnX1h8J3eeproMrE2vw-1alZ_T6-6Dj7pGPtmrjXNDbZQU5am3MUU4M0HSjkoFpYbS67R4YI-P-t7HNeLI3oSf1CGnqrugRPQv1av7GcqBxlkNXOYyNtECm9WRy115SCHn64qnZqCI_vasonyF-49Oezj6kzjDuwxAx7n6Dorrit4PPSm6hMx8crB_fYy8E=w727-h969-no)

Parting the bearing off.  I again must comment that this sort of operation is much easier/faster with the DRo!
(https://lh3.googleusercontent.com/3ULrumrlUSPrSlG4cUM5XX5T1qCIjBgCh9BFaejS-pwpa_Z-b0aMletiIXk5HfCGCSsK81pvtcK8DebRn-JSWjClLLG1Gv33Ik09Y0yxpMrP5e0ldhmL0N5MKN1KrLRQXTJVhIA5eIuR9jrCx-UZ7MwT6eiArqAgpDv4zBN45Bi9zuQFUoYsC1Nau722VbNoXQRcTHwZ861Iry6jxg1dKvcThMxoOugeafXenk0uQqh3l9zprd-ZBgFLnGzRz712v4djFGzWLSWuUPQjeWOKl0l9R4-oEa_3NWYbxyVKhGsHLGhsVuU_YOnXVhbssxE_jbigm9bP1zQ_JWqJ6nDkUEFBLM8Km-T19iu4kIEYSmgsldVQMu_x4ADfN-Guyn0638JLi_DYq9-XW-E72qzQWpYcZfXEqgbY07bHjvBU7ekJeuDKtv0Y4YOGVhml2ZhsXNqwj-DKpOxah9yJ-p37PMtEKHmeMYcggJ-77jihWCIfhT1eM7rN-0rjGfAZP7TWvCV3uFzYB7E3fZXgzzLNfEwUiV27hhj0G5_6fUkbihsiufvvOvCWNdWpn9E4qIDKYh7a9pdTKm7C7MlSivrurSQqSf8MUEizt7CiWUXIau__nTKLBFPFkn8Tdhgto_bGmYZKexPDRAGRS0o5xuPUpCu2-xsJg9yu_1375dln9HKwRcN_27A7gyNkUCBWioD_rg5mMcaafYDOT4eMlb2SA536yA2QjPgUbdWh=w1292-h970-no)

The finished bearings on the print.
(https://lh3.googleusercontent.com/_DRnM4DOa52f1idrrjja9xDDFwU-lvyjHgSJVa4pRZEzBJn76V5U-BD2pl5c2s3jW3an_A75ifqliHgI2twuGlq6o5XZesMiJvIe9ITJXD_T-UAQ-fBq5MRsXpFbiA-X8FVDNXEQWnmldcFh3HE0x7fGuBF7xULbYecUH4OT4cp3MmszMw8ekvU3Zg6QNaO8BS7gVc9MRaGHjZWdPI26j9rZyGAcCxGoKrr0zO8sbsGaSB22owh7ies5Q-8kLKLoGV0wcsjJ9C9c07d_hie25bCFxaXZaDXQ84BcAl0CRBMBaeO1Mghbr3rsavKsgWG9sZ8oNf8QMgIrm1bTH9JbwZk61XueisPKIlgFJc_Io3Muq7q_7n2jD93bR5GemquX5VQ_zI2N8CIfm9rWr1pdZfoIQIPoXn-XcWa2Wkt_igCc8fYlJGUvC_LxBqJbomNLe4as5qguYAqP1l5x9gmBMyLxROA_bJRfH55K-PENeq28WeXnl_bSgWNylyJVxzMcDYpLMr7YdKJllCPbn3QMTLgbP3GFsdUF_zVVoiYMruQ9YFqsNkVjbirTSqkk5IshGxSR1-V2rGHhc7IQBYSzvic-qy221bXE_R44Oa1UERXs0MUOPJvXvr41hj7JmAFfbZad2VMNOYxc5ZQvZJb8gt2-rPaEdWmoeo8-8llwMWIGTs3NK6cKUnglIps4jaHZ_CPU0o3jM2TZUrCDV2E7SpC5u_7JKcqVt1oF=w727-h969-no)

The bearings were a hand press into the bearing stand.  I used some Loctite 603 retaining compound to secure them.  This pix shows the bearing stands/bearings installed on the baseplate.
(https://lh3.googleusercontent.com/sZDQqyeSz5sbs1Qj_CX4C2GfMGwo88OtszWcC2_uC3dru4q8B-G0ByCHwOF3mSJtX9SOSOx9uEiI4KoeTUgBzj7c-mls4JL2-b9MzP_RkfFU2u60uENBBnLYnhcnamPAOLzQ6elHVnspifqi7DAn6M0gfx_Msvpq5EyICKj_gVvZ7xBu70axeDe14ZGgDcLosLToJll7sL2DT7K1m-4eErxDB1RaI3G8DCg9QRSxOWJJZIS5Ou68yTJlZOwaKfL8NPWTL4qap1zS9o0dQewpKoy5VAC4jJHIV-HNInfauhRvu_vJOEtLd13OosS45tIgLHjpXhmYE_3CfCRSLqGDn9bReL3DhHmPrmQyHBy8qv5sxNafPClpMIecSbibm1m1_itLU1ZY_H5WN_2c4TyPTEZnlqtjLk6oawa_n4RwbYEsVmpFaZL5g1kJiLAY1RFOpiZEHE7K6B9QQp8ndt9noM-2IgkFhW-3bFtMGpvG0lnyJSMlezex-Pk2P-G6LKfpo-8v5x3y-j7qskouc09mU0LVAPynvx6nUsU8JQ5N8mBA-CpOX7AyA7w9Q6u65GNkgb4kS__8aWh_Mt4OEb6o5P_LiEsoll8Xq2c_0kLr7jmUkpn4m_mh729Tr-V5w9HmIT2dk2_YEoF8TRKGqiscvuyemi-nT1UCh6y0rmAPi_SL3oAfV4fr1NsmrMM_0Q8uPP26GEHBa7nkkEbLG9oVJ7Hux1YU02nxnGvw=w1292-h970-no)

Tomorrow I hope to continue on.  After the Loctite cures overnight I plan to drill and tap for 2-56 thru the top of the bearing stand and thru the bearing for the purpose for installing some oil cups from PM Research.  I also hope to get the cross slide guides and support pillars done and try to fit them on the base and check the alignment of everything so far.

All for today!

Enjoy!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 10, 2018, 11:11:08 PM
I wanted to post this separately as it's more of a tip than something to do with my build log. 

I had ordered a number of scale model fasteners from American Model Engineering Supply.  Delivery was extremely prompt and the fasteners are wonderful.  I really like how they fit small models vs attempting to use standard Imperial fasteners. 

But there's minor problem.  The scale model 4-40  bolts use an 11/64"  hex size (distance across the flats).  This turns out not to be standard wrench size and is simply not obtainable in the US from standard suppliers as far as I can tell.  AMES does sell a series of custom socket type wrenches that fit all their fasteners, but i don't particularly care for that style, although in truth many people would find them completely fine.  What i ended up doing was the following:

It turns out that 4.5mm nut drivers work and are available from tool speciality suppliers.  I purchased a 4.5mm nut driver from Wiha US.  Shown in the pix is the tool and how perfectly fits the 4-40 scale model bolt.
(https://lh3.googleusercontent.com/t4CySzXerNsnzZh-T9KAgUIim3WpEHb0lf80k2XtltV428c3QlYHkn9xz-YXGnFVFEx8pf_ys96g7AA12npKpm-Ldo1JORoffy5WWTwsqrudu-g-bJNa2XDHYrKyCYLkxBhP8uOWAc8gKEUlaAHzRrftq18E3AoL_3TacxyBAJqCFd7vSxGxRl-LoxpIX6L94wWKw_twa3r1ZaDkrApfDkboNqTYRgIGMPMlrtsCz64PqusspFoc4ep9ZiF56xFdMF0P1nLYo7MdH7haBa3VeuCR51-XBY28qGx52_UTWBIMdFXN0RNwgxhZxB-qWsV12Jil3r6pPoyzm7uXPvP1gtRd7SKFjqSlhIvODA1521Hb-AQ0Bjd9pWEYrWXhCLrJzwn3wdjvgIrOP4VwoeSay9aedJnodvnUvXN6H1gIP0fuj1XLcWLQlVjeQC_bJGnObWtPBEGr4K75XTu2h7XQ2oBDNs0nrq4vkzcRgtRDXYK18ppZ9aYTGOlsPMK9_Ane3tE3ok95d-hLeKUwJlZA987ftrTI5E3Cji4V19oVP_9yamLYF_pWB7fbXzhg0Dp_9A2LmyLWXgiLu77WcnXoDOMcoR1SBGhbviKmJZ_vKJ2qsFqHxWMnoNXaEXgT5IHzty1bQk8_395iqSeEtN-d-BYhsxyJ6nT_DVxtZnCTX2hzccgQmQBRJx27WuQ1c3VwMRs3wiRfDvaj1GwYYZFOL_WhacSzToW350zP=w1292-h970-no)

Driving a 4-40 bolt into place.
(https://lh3.googleusercontent.com/NCUs8nSH0gG4VD7b54eGUbUB6ru_07Pd9FVWgDK8MJ0lzyygmOWz8Q1mekoagHZq4mDpdr4LwRWRHMznklaZcLMchZU7wtRkkjfii_xY1-HBx3r-swtcp31UMMOsr0JfgQfptnZEpsXHWguhN82aR59X84TZO4YMcpWX_cN6g-xRH9zLUxS2MZgUps_CBduDe_QuFHIJ4w5MKx2TuUBLXqgd-tL55M6cqynFSzw84bOkjGOG0Pd1j9ColOiZAHXXPGfvPK4iDzV7o0erJTZ01IKhJR4PdvKx_YBwH4fXytzPQ5XDmve0OrOvlmbdoTmeZ1MibSOkoZbedtrtnReTM9KaZD7ewTXoWb60LwDwU7gK3ZLadnJU3I9wEV7swrnRk2OqeXzGKfHDlWYHMzWe7XXPmxFPQgXQ1x66SLK2wS-MMkPJ-O4N5hSEjTo1DHv_6KQkaGqGg_b7T4mNlJYfULdqoJqn7k1u34upfGGNDuu1qp-ZMEie9qzMm6cVy0B4KQ9MZ2aCGzj7yyZWRXcKNPpgkunu5aicjbgQvZRbitdmV-SjqdX09rcn9Yf59Kv-fWz26Hu3VMbM7QTsWfgLkugoIJZnQV07N63ox-sN7jO8V02PdOHrlX4Nn_G6sXEzvs_aMK0c7TK3Lh-hccIuFLJdaz6N3AGVOfEofqQfOaCX4vVvO0JNb3jmHhXwRlaexhtimUGr7mDIODUKPtxEAl0xwylYYyLuN0mn=w1292-h970-no)

i didn't show a pix of this but for a sutiable spanner, I ordered a Moody tools 4mm spanner and simply filed it out to fit the 11/64" hex heads on the fasteners.   

I THINK it may also be possible to use a 7BA wrench or socket on these particular bolts, but I didn't want to place an order that involved international shipping.

The rest of the AMES scale model fasteners have hex heads that work with commonly available Imperial sized spanners and nut drivers.   

Hopefully this is useful info and if needed I can also post this is in the Tools section.

FYI.

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 12, 2018, 12:45:52 AM
I had some time in the shop today but waited until the afternoon when things warmed up a bit.   This all took a bit longer than I thought but I tend to be pretty cautious when drilling small holes and tapping them.

First up was completing the bearing stands/bearings to drill thru both, tap and add oil cups.  Frist pix shows drilling a #50 thru hole all the way thru the stand and the bearing.  I had the mill running about 1200 rpm and that speed worked fine. 
(https://lh3.googleusercontent.com/YB60FqIctY_JiADzG-r2as--m9P3Sds_WfMmd2LhJzvQ91TR36E2Q_pWNea4ElBnjw-LuvDs6LV96m9-FELmzLJm6B34D_Y17FW_2sd9jAsqC0gMjSkVn33-awvegD0dDM2ypXfqlMwTj8AQzigB-B-4QKtCUMSmzibqusAP6aY1jNAggzbBXnfoEDZAK7-bu_owy0CrE6dBF-iffgTfI7-gG9qRATX8DloFTzPMOZqP_GXX106W7EOnOz8TDwh8PhhH5tf2UGy8OOJZ2amwl8JC4lcj-KhAOLZbMaIPdYXmu18h28cyzq34q9uW1CFmzu5aWnyfyV98HKcKTYjaaC34M0PJIQnU6jMymC-xuh2yUK7JrXi8VdZyQmApVkkCsy4t4NJygF2wQnmbV5j7JcW8x4VU39Va8MV7rOtHdjgXcT3q0xBhT2IMJEy2l38u_BM4I-9iz0EY4yQamjGmX6ewkFJFqnze6-HpSJji9GbcDReq3ZSb52PImtqs7ADRaMOJYzW1UXh0kAVSM9yCk83sM3JNZzxuMz9IFWI90ysM6xjP1ZdlWi3pEYFc-GYGzLxuZrHiyJkO0eGYJs9ca60UBcqTgzc7f3Z3Xd-FTUbinp0tDci6iOHOeC2AEVmG1b_XczA8PcRV8Zl9hPHBPNM81sic174oRy-gpaxYEsmM0Sf3g_jHIb2WFwVe_WTkqgin8G2isHCbXs_9P82XBMk2GbEu7BBIujDRlw=w727-h969-no)

This pix shows tapping 2-56 about .20" deep, just enough to allow the oil cups to be screwed in fully.  Since this was tapping into AL, I just kicked the mill out of gear and spun the chuck by hand, backing it up ever turn or so.  I'd also set a stop so I could do both pieces without edge finding twice.
(https://lh3.googleusercontent.com/iTMCmGkO9aCtw2wX_UNOOdaJtOc9zEsyVPmU6UQ1lz_hYIIif9wFEOCyfZ3l2YLNMSE-nLeiAA0_I8v1zg1BRho5GQYjKPH5cs8acJfTzPbAwe98zWieigX1kj-ohFCL02k-e70AAoLsQhD3amjFBpMulOBjeb7sDmFWV5ojj2VFPhrtGxrkMDTZys4GwTIa5kjhFkiz57nNihuaOuPxaSnY9TanYOXg0K47g8NDuCcNq3ZLRs5FEWzhIxS_TAOKjOdc08iivhjM6T-cuUHhUDSTLgZKreAbu1_MQXcMN2JHB8X-lcH6oBf2aEOCQEGPwqlQfmZqcvVLnYnf-C3f05Xzv810JrfxpIonyu07XBWDfoF_5AS15YdVUacTnDT7tX0wOaxrRBvcp_i9CkZ3U4w0OtkHf8v0bXKs7mFzWFTOEvm-mIOKq2fNo6YOv_CQnD4wJ9XNDw4HwRZ0DNr5snUv8xQFzKm_I783EVP0TVB1ndjepJi78eYS0HRWwfItqcUkuURapfsmcNUVyVvZ-2SltQ7YIcwW78Rpkf_Eum1DmfWm61QOiX6-oDdlcx52v2xxnQTsiPE6t5T2dFWj6g3PlWuiFMiMB5swbmgv4ppmfHxVoqmT69DAlavCkDYrSmy4eTV9zZkEP9CwR5mQ4op4nc7qKM_E8bVpTfzvGrEwQu-WRyGr3ujThphBi47AMn1N-aSJGKkfhDOySs4rYPOloxfsjkXBXtddPw=w727-h969-no)

Pix of the completed bearing stands with the oil cups installed and fastened to the base.  I think the scale of everything looks pretty good!
(https://lh3.googleusercontent.com/YkNjzJTDb8kw5IDO1tUSTZaztuT2LfLggz_S-q5TR5oILhixN2e9XmYQ9zuBkSjuV_-B9PVdmpbWjOHRlTt2SK2hGt_Ks4vg2MZtwir2TzJCOENfgABT3aaIBiPvFvGH4AbWupYx-9rPc9TCYaFXlf8yo3NWaoMCj42VNtmMaySgl5z-R_4cEevH6maVDJMnE-Ty9EzSrdb6n2QMHilltfnmY02FeXnFE7cvbYNVA7IqNQ5HOSpnuAquUFttiaEySk7M_lRmRcggIgXBrxloOIrBo95KT2Ts-oW881dKNQ6MrmM7FgKq7uklkG6Nr001Mx5EgOG3D_eOgTR8EpgNmVxZVKZcXWmU7VZJ2idA0zs1ySV75waPjbGs7si1XjobdgIjWinxxHg8AyHTn9RP_LQZQGRM34G4SZAdzOyWLRiv_48QGtkAfort2dIPKRLOWJ59W9WKrZKu6NmtpV1UKmwjojHTy1wLBRiwOlfNzYfEHqkzunIVdXuJ_EPk_J0Se0QBQA9nxFklfLeZVhge3UnsRzWe0Yt-1_nrYEi8crtCdIQZpNZhQ4q6X16W4PtaeqJbPYAWu1k4T9dzdhbcKhOPl5GEkNKALPUGcXuk_g1rrdvyrKHo8oGUg3nw99gfOk8RRgKOsZyFKj8gxIprN4s-rRKH1RD0DXheN5DosF_rsOVzu0iUg5BO-RkGC4awxe-c6n6hiEJnBzxyOUUWV2yeQnxuVf9lRDzK9A=w727-h969-no)

Then on to the crosshead guide slide bars.  I purchased a stick of square 1/4" W-1 stock from McMaster Carr.  I got this as I figured it would be very close to dimension and would be nice and smooth for the intended application.  Measuring the stock, it turned out to be about 1/2 a thousands over size and perfectly square so I was happy!.  I cut 4 pieces with my bandsaw and then, as this pix shows, put them in the mill and took a base to clean up one end, but I did them all at once just to save some time.   I had an odd sized carbide end mill that I got at a local auction and it worked very well.  RPM on the mill was about 1600 and the cuts were light. 
(https://lh3.googleusercontent.com/TpwqaPoMLxAEnsMufDTzwk6nOC4K5qWUKmrxPjPamYXULGbSa6C-uxeMQ_XPmQlPA9GpQfd955aDUHm8X9DnvH2Z5YwlutBc44ez-h1n9R0Xa6JPXb9FShhfl4xjvCunSqhX0Xzuex34YQZyctGQM1i3YKLavsmKig-PGPCuYKpxBiOlM3d8DkvPRLkMr9LrL8T_J7ZEtxOzFT67DlDZo0sopaTdlPlgJwiDcJgNkLLb14k_m_cI4Bh7EZWh47WeTDRwNrWCUjwTnEfAxwEkZzYdWA9HdJ9bRbI7df263HyW3e0H1vhd4n9_hVZlqPjtIg4V6dcEWnq7Bd5iQkfB9i6_JEymaBpaf49be1Mbm1Lhl2vO5fMgMCzoGzvoP0a6HAHvGHEkI_71UJnLo3OuYDxXmwWR2kAJNZ22IU_ZJd36TvY3pLLjkhtEQ1J0uF6QikQ1phTKVz9Yf-2-tcBbOHU3gCFALamtvbZh9BgM5T_yrEOuerZDGqe--B8HuHkRkcz2nRA_h5mUgOc95o460vzXFl2FBipi7w5M92dANLCxVw45dqqU7J5XYFMAGPmtqpPP4zRrpyqSsWk-BE7w5HVzEIVGysQWnNWDohEJQG31MN94EmDjIfzosFwTqkNa_Oj2oO38a9t_UQGidH55spCkXIA-NFzQMPKATL9DFl-mwb5I-VGIfMJmnPBgx3HqAQT9iJvGPcf1a-pe63Fv830tM0CpOCZCF8wLxQ=w727-h969-no)

After I got them all to length, I extended the piece beyond the end of the vise and used the edge finder to set the Y axis zero.  Then I loosened the vise and set the piece flush with the edge of the vise jaws use a 123 block to make sure it was flush.  Then I used the edge finder to set X to zero.   This pix shows how I went about making sure each piece was consistent in the X axis.  After I set Y to the required position, I locked the table and left it locked for all subsequent parts. 
(https://lh3.googleusercontent.com/rt_Jwu3uZGWu09Y0cTSiidvm7RV2_vd-Pcdypq6oOxUz7p2Dgg3qAWHKluIAoVASPusyl1Hb5MlFImzPLq1a-EE7TZyzuP-WHbeDBY_IX6BC9BINtfvh5QMZTp1tkg97u6Z5hSfk6PrJQGFgNiu2nvkoyWJloKSyhC_B0OegnfXmpkiZtzEMatDlPWtBuig1n8YRVXB63A2XsljJ_LFtdDImrq1VWL3L5hIa5i3AbLxL2i5Mc9pkKBQW2J-N9ZDfR_fh9GzAMbKMmUXr4gnc9PmLZo5ZNy8ZAl-NNUoc_47pitsSCxMjWNj7WWEXTrpIZ22pEapVqtyWte1z9eC1_PXR1Vn5BkeFX5QAw2K1vKk3CM7yYfAn4KCPbHHSw3Dx-aYwwaJHvBGy6ARKy7B_yrSxWLR4C6oX6AfQn8wrGRKBPAMh2vyDLTXHn6n7cYsf33kmIkqaEp6r_JiaR2WwPaJvNrWWkT43cfgS4SsdFmlefbmR_EvOM8jQmjfp_XXge2z4XgIRHZ8WCXVbH1KYzXVvMl9jXmvliG1ZLA-zZMJWW-GMYoB8EcEsFMlX5V9n0dGL-fvvoCgTlVEUp2whUHJsvfFEzYI0NKs7ib1h-IScdwIo3F2xbpxPhngshKgRooxoKdeJYaOLUvyzAtoAQHlpl4cnYKZ8tffDlPnWYgBI23mOB2zIST4XgGzLkdeSZoBGJ-PaEVUYvsOsvaKPgsXGawISmv5MuaAwZg=w727-h969-no)

Then it was a matter of using the DRO to move to the required position and drill the thru holes .125" in from each end on each part and on 2 parts, drill thru with a #49 and tap 2-56.  This time I used a spring loaded tap follower and a very small tap wrench to be as cautious as possible when tapping.  This worked find and I managed to not break off a tap in the W-1!!    I didn't show the drilling ops, but do have a pix of the tapping setup.   I did use a very small amount of TapMagic EP-Extra (the dark stuff) and that seemed to work. 
(https://lh3.googleusercontent.com/zfoQn7aYfWBVbK0w5p3_Vz6J51empvrpLBWaHFO5GJKjQ-N1O7o4QGpWwvw7EY8T11-I4-MC2lA-0Nlt0LREZxuJAIY-tKAYta3YTo_p7ZFlZgJHPxTazF7566bI-w2Pn78pcaFLkY3v5Z-ETxmvatLRg09TABQTwx4sUrkMMXz3yztfQ-MYTO-9H9AogcVf0lsi12vPTxqQ82h01Y0GQxnqkjOSmsGhXnxuMO8VPx7s6JT5aqzSAN1nTzt3cHmLyLGhM_LMStDAdw-lXC0Lqol7cabc3WPNXg7dof6fsnxr9S1xnuy_DEVL7y-t2yBrP15q9aBhuYMXLd8yGnnFR4djrpCLtw42NgLfq_vz8c4EI2d2GFP0kuAW2VKvHeMfhQo0tcbSEiq_4BYyMoRb7H0P2X_ONc55wqHTlkyuqIhnPKnhfMoKx3LK7eePfCiQYpiYaRiwsu4wV_O7vLBRiq0WtgwosIb9SqsNInIpHDaIUUfVP81IQU8Cp919uj_AZfflL5gyvYIeeJAbZySlKE1SoifnyHyWEmGqwrPrDaHZPqXp4-5xdZAa0Fd2VrqB1288HMqSodzJ6hjEjoaWxXjgtzx_GjvXxupPtK5kTB7vsKo3atpfYWh3TdkqcZjy1Nx39eJHh7d4UT4Uou69hquy_LurwHt0nrJpWeT70gHhjFzHUsiumx4KqAWqjRwaejKYqJcnY09svQtEE0-4EgOcj_nUPzDuAmKpUA=w727-h969-no)

And the final pix of the day's work.   This pix shows the crosshead slide bars, the spacers, the fasteners that I'll use to assemble and the oil cups.  Note that the top slide bars are drilled and tapped for the oil cups and the bottom bars are not.
(https://lh3.googleusercontent.com/XBvHJAAjkWPVT_SKAj5Cdxh8IRDIWcfKQPxocpleKQ2rSe85X0siQytl2kZ7u28mybkJSlR6lqnFgdi1rCCr4dhuqcwwNHB3r-62DnDRHSAT6PKVMGjeh0zkwJ98tF4HSgxQvb9Ece5U1ZOLt5U_mORvokqk_XdeQiX06O42iks8pmYo1lQkihPOVl4SmuB7jP63W8WpU_hdJaUXZ-pnJ2OmYu1RB823xAmYU7topCOexVP4u_arX1MvjVK8bDDYhv60J36k1Q9kjF29kMuUCnWpG8bqykcZASRmnPDF9Xefsg7akSnQNLA1Hmo6wfCRQHXp4y2OKmOs4Kj2xnFDN0cS_djXA_ahE8i2BsxSgGYhhSTLEjCVxjlpHFUiS3KQQ2_2dzQCkhwzkWX5VG8qa-2FnHdIE0f2NklV671EJrtmGSorW_FX-7VI3zZ6C1woEqdywx9KZyEsIFF-pC8H_gtm-IqN5FXIvLyNvW9Q2XNL0EnyMTEv_8mtoKDBurU608uhP041xmUtsHdCr5966tWNobylSgWol2J0qLt5FzIhHzADzh3lAVJfaNrIv2lNzTfrKNFCPBw3k0Xhcy91Snq7RUuvb2Cwu8oB4Hm9A61quOn4LIdaroqKb5qwm8l99ZEtO_8WNiYj1KRiBhuZASDRaIImyGdbUhPl4Rvmz2WECmyyo21qX3VvbdceP2pHN9lt9n0rpXqU48uXIOVVI-AeSrbsPZDGQg0s0Q=w727-h969-no)

Tomorrow I hope to start working on the slide bar pillars and depending how that goes move on to some other parts as well.

All for today!

Enjoy!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Gas_mantle on November 12, 2018, 12:51:45 AM
Looking good Mike, I'm following with interest  :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on November 12, 2018, 02:56:05 PM
Just getting caught back up with your progress Mike. Things are coming along well and look great!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 14, 2018, 12:39:19 AM
Today and yesterday were extremely cold here in central KS.  It got down to around 11F at our house and the heater in my shop just can't keep it warm enough to work in there at those temps.  So I have had to wait until the afternoon when it warms up a bit and the heater can catch up.  I do see an upgraded split system ac/heater at some point in my future!  But in any case on to the work done over the past 2 days.

I decided to make the cross slide guide bar support pillars.  First pix is just turning a piece of 5/8" OD brass stock down to .563".
(https://lh3.googleusercontent.com/yd-tGA_bGZPORGI-ieVnXXhHIRygY0RSeijjV5GKApKDB3ZdqHpvf74W6053ZYT8AvAQ5OmM8j868NYuCaMifpeFR0S-kbrgdLDlufy930-RS0nIUwMfERCZN1v-y1yJj985g198xCe5yB_zseNV2LD-xD0Q0nSWAAlPuDiRbYkgS3e5XqvY-ZmbEkPjFZnQ1a9qAq0kdjKRdjLc4nrSPNloqUeHSLlabqLahbYEzn3phvbEZOKHkUw43KKWRXAyQtC-MenorVFeyc98i8GJmLcMAmh8OvmYT3r_-PMnDbIn6R5kuLK552B8mc2TnIL5qU9jKFiTjKZjuXQzYbFj8hi5T1rClas3ObHLUPEgXAVphCU0jIxCPYre7705zK28juthN3ChKha0NBOw9Rc9BoGpTxOujOgkRuA_RUuDlBGYAnZ3t8kQtcuKTubcZ18gWi14C326rNs74JVppAIJNBZ5zGrK9mfQb3zTrZ4QKwU_u5ymTz5n7BQMSY7eXQ1G58CojQlC5dUMdBtQDnYQnV-Vfyu9SOsdBkVj6qzCIh8QEWjufLPhLBzGVF-gfCCVx1CEU9RsbgDEVABd1NbSsRfKvkILAZNc0HlANLmYnRU3ExEF_zCJjIOIy9H59CF_-0pG0R-VwX-V83imVlr5A_s1w-GG3PL-IzOF3_RGCEZNUOz8_ZZGNYmks2O4yR6c1RMHrc-DN0mlRLeC3A=w674-h898-no)

Starting to turn the 'top' portion of the pillar to .25" OD.  Nothing tricky at all here!
(https://lh3.googleusercontent.com/LLx5ptZVyJsFuw8NnOnKvxFMZXJSyAMPi_4iSird9aJwYpJOvPUQz56N9jgHWqyEctqdygGlm1nrIH2mvgsIWamEPT8Qvk7peZBPnbbHWHNg73i6zku-2paBOJezU4R8ZorxoX6EDQTxHbJOaMkzJwkgIKEAr-2STz5vahr8ETqBB6IIiexAwWPzb7HNaV1DY3D12QLJVAdAUWCjryY1lmQzpps04ymAJIeEARANG0Pa0v9Kopfzjj6eTf6m7cCM1vHXC2S0QBeLNlt8ZI4yv5wuel96dkNZyYMmLaamY4oyw7lfNJFyJxCDeKERVMrp0GqGVNM_Xza6yiGPaWQ1HPpgkwYPPScffHKFMHDJmM96O9aMkbvTSoGNvU21xIytCHYD7pqiAvo0bAiqZlrbrLTJ9ihzJgQDtI5lbO58LxZr3F6JTO-yaIFkYcLnfOK210qDEoPYhzz08iKTAoS0ei4xCPKRRWqlFYb3vveNkm23NgM-VrRj2pEpR6ylHHkuS5dy80Jp3hk6qAJnBjZcrYbMcZ9kTtK02YwYpW4GPtIcRPcVSWnVHaXbEaB0y2LbtpgpOUWDfZbSmUwaFS-iezK3DfYbunhujYzpO-sRbOpszoYLoAw4ipDoT8xWeeWAEUKUPXmYP1R6oLKyDq9_SYV4DinNxiyIrMW9G6i9894NgNG-nkDhjSO2j23zQ1YGEm2IvYP-xvKVuWNj2g=w674-h898-no)

After facing to the required length as close as possible and center drilling and drilling about .300" deep with a #50, I then tapped 2-56 using a Fisher spring loaded tap follower and the very small tap wrench you see in the pix.  Brass taps wonderfully easy!
(https://lh3.googleusercontent.com/n0JKOg8mCIdwARY1ihZ6CeGstUfP9xn0Jx40Wd84fjTIAX2EONFWH-PpWDIlqz_tVEt8dGg6zz5vWFFx5hAYCuIJDt5WF4CzYH5__4ful6hpzf5JYMyV2FKI3ykNdi-19XFUGVHFMInV5Wu0vp8d68vfwFt7vW7bdcoxRFZEPCgt5nk-8xG7Z9Et_61qkRgoN6KZ9MgASK_aPHkHr9EX2j0F9eVYAIvtmYaC3558d7YOBup4lXLqbZAo2p-llglaC12gghY03GNODvxYbv7YO3rajUmAsvLijJnp1HSbYoF-YGbnzHWQ8U9C8Ucca9TUbYAQfK1kpx-uCoz-1ZhrvmxUUx2bgt56poPkYxr9xkgNiJJyHknDI3aiPRQvOCKv-yCff0ZQtzP9T3s01Yi-gOvWZrGT7U1oanLXCubxBdaLwaUvOw_an-yASy34nPlIdtwnteKAJjPx48IFD39gqc02layy2B4PY9KRCj08yFKfNv5Funh3lzVHktH-n78xA4WQe2hTK5mcGetNtmyMDREwIAQgiKq3RzBrvjlxvrKbH7372G0ap8mFc_tWwK0B55SWHVlR1f3c31IR_4o3nqu1133x4P256zCA0Ht152hNxZ021HYu2K46pwrl7ygGT5BDfA9MHvzF7BPnVNIZzN8YUDAFbeD1jPvuMtM4FnLs-A215uV7DZ78omU2NY6xlXgsn8JPP5zyNMz4zw=w674-h898-no)

Checking the fit with a 2-56 bolt from AMES.  Good fit!
(https://lh3.googleusercontent.com/kbV35kS4ZxoZ6EmBTwZLLeZhbao68QpyXzuqXmJQfgDaD98TYTH4nHYpig6YCH3RcEj2kk9q8PczMZPd7t4ZtxflknDlREyp5vxZzQ1gCC_bAKr8L4WfRWRqQqI0FPa5vWwZ5nzZGj8qDUXc_v-Ua9320MKrNqXw16Nos1katBcf7tMg10ZXJoxfnqg8aeR6kpU6GoQlwHjDyvSHKW2Be6Yoy43V9K8UxCWe-aVF6sks2M51nLT2evHFuKkZFO-YsD6J9ROEdkLKqkCIPMZ8SBz7OKldTLyidkNx3BXszJ5FqYC4WhSfHQvZn_TlMgi3AKQqsoS1Gt8IpuJk86nIAEXugmVsceEGgVRMr7c7nQwSAE2mp6SAM6ZFdfYz33lSVqHGeamn6TjQrRYsk2ZKDMJ9HIL8U7eMMKTNVsfw2AsA_TvRCg3NLDDIG5Ltblg3awNoUZarEsl4N9ev2hhm3F5yvbowY4dW19f2Whd2AuZY_QKXXX5I7l7nZ9ke1_anwBRXl4EdOehSQ9mOkFYztNY9_OYofHzm_0kpdY5RNTwJ87SVv7gnBedMly3rFYsWQygbmHgE1Kb6d7DL83k1m1fqPKoT_EOXbssZ7HLiZTgDPV23Wvmmr5mo213a5J4st_eIQvqCJ7Nj4-aYHf8Nx2ZBcWhxPG6QwmW78fa0hllHcn1aw54CRHZ5CK3ZVpLiJx-fYwjzPJXoiiq7_w=w674-h898-no)

To put a nice radius on the part, I ground a form tool out of a piece of 5/16" HSS.  I made the radius 3/16", or at least as close as I could get it.  Wheel is one of those Norton Blue wheels and it cuts HSS remarkably well.  You can also see my home-made grinding rest, set with about a 10 degree tilt for relief on the tool.  My theory is that even if I don't get the radius exactly correct, each part will be the same so no one should really notice any flaws, hopefully at least!
(https://lh3.googleusercontent.com/2DQAMp9I7eWOsdrbiIC8kv7sM8lab79FzlxxllDfjg9RtpfhKdcM5vIjBcbe0G79p-UtZNmzo_Ow-m5BD5j_30UZo9e4NbN8_qS61wHEAvmOqsshH26nyfP8mhunWpCJ8f5IWqIGHEtLiq2F-VBcQgtM6-RF3Y_BN2H2-22_8E4jdfZGfxmTwoc5x8Jky0CvCGt9ZqtTGVj-SIicCbRd8rvwYPJzSUyQmDr2myLAGdbWuWYZKatjik4njrHqlvALGrkLH6X7Lo7qKPv7O3aEdg8NIuiWLGy8FVvKxVJshwsq_ngr7BUUA6HzI4-O8z-hwtjRYR4wepPm9Ll0yrp03B3gPJJrfCNZz2HCEuLziJvk2q55aLTbP3BqrqIIu_MgSCAUMP1Sf_N0sY6qgAweGUgB20OIIdJirgSn4IjfVZRQOAenuSCkjw_wuV1VOkB-DSg8bsWXTdpNRopdsflmkMAU3goe2_-ZbDKWqNrvb7FsLCzjjjLM63BfDG1_XiUe8ZWFM2TD1gs7TNc-aTFm51il2m9P5aBTWZi_jgWVw-h-Ot_DnUrSPrR9eqvf2PVz2y5kNfHyBqxxmWQAtXJXIQEpg_zTQmU6JAnSeyx1gDwGnndHQ0FKMbxekcDkYXF33uaS1SXlWOP5GMI-BAWeFyarSQXAJkot2o3opO8XYbHd4fMrkWZQXZ2lriq_mRZFFjOSSDlyrpIgekQ6bQ=w674-h898-no)

Pix of the in-progress radius op using the form tool.  The brass cuts extremely easily even with a large contact area as you plunge in.
(https://lh3.googleusercontent.com/q4ay53cYonBYlWOSU529uGZzIj5Aq2M0Jo9GUHMuycpFCwWuVj7nlsuuDaCdpF-C2i4wBisZv-5PNlTr_5CLv8TXfToNk2mxdUsoqCrnqLlMiFd2GhBS_m7oO-OyRuCpTAguFOAJ6qAkO2LiHJdic5xlF9B-IfZQO34JdQpVCUAevYkZKBld2Rk6BpGaJ-G-erIOUo4jVV-hpcswxEK2f7tQJ_hOnxKVW1MVhPYnD7L5zw6TE99PyHxaBZfTQSYBuV6XtpBKFwouAjk3w9UHX4mBpFF2Q_lRk6S8fzsyrKbPjInyPxCdso2S0RDF0YgZDs_8mgdmHQnPn_QdnjoaVw7FWBoNPIfDFkUcNDtbPcRMbGv0LChbfnDWSpxrm9Q98o4GmtHK5voEyL2lQgY0LqkZYCGXxJnokdG67-f-LIqtNMzloR8L55uSQXaKQ1HLTGWu8U7cKaNNfWMnP6WpX_adcmnaAUH_XTGVhcCt-5yZIxlThFjSq8czG_8Wmkca9UG7IQyqmNPcYNXYbwZCsHRPewbR_HMYpx1hvoLtdW-jDGCxkW2oChDfucNr07kNqR0TmTRPXYVeUpxCcvBrg6XJv4UAFmzlS6I_aFKCisyml_y12LDWBeEEwa4i4LgmF6WNicht8Qe8q-xcBKl5HHMk3iDVdJRM5cuVATRqBTz_jGSTLN5KMQSvxlX55nmeMzh_iMrIQrfpzC5lbA=w1198-h898-no)

Turned the piece around and gripped the just completed end with a .25" 5C collet.  I carefully measured the length and got the overall length to 1/2 a thou to the spec.  My goal is to get all these pieces as close as possible to the required dim so as to minimize any binding on the cross-slide assembly.
(https://lh3.googleusercontent.com/H_VLq9HlxbwyABaCua-efRMdsq3-tD1GNDUaaBVMtuFfkpKjZvDVX2prfRM7RiHjaXtzXVXMiV3TywLx02-oOEOtJ6lfo8wb8r6ndzXzVPZ2_ZbW19q_QI47Vom0r1fNe9pwED1hQ6gqa8T9xooAI0xHSRAiK7LVc8x8zNVBHFTS8sujjLzwQf_h_iKtkHpYvB266Ojf9VEVZJncnv0_c9xsZg41RpEkf-j_roe8q2JPuRfRnQUOafz0qJRItSHGdv0ttbKyvRRdYWc8RZQYUr3MkqKa4QJb4dtMPI6CkLHx0o5IJf4NC1De7jrYKsObeZHnMbplWnZ1IDU3bGqZ9w6MKtqItmIWUNC63SNbPVMjwOuQIVA918PiFcsR1PajW_uXucfpyOYeZGE5ADGRL3CRK4enshXrhrUHgeLgU5DH-b4SMfjGKzcs3et0gayrMHO48vr6_fGkZP4Ww7hz1RI6T4t-UeRQxd9VpLrAcOsXzrSysqDBX-fHc-atoNVLqGAmOwdzkLKJmElDSM2-xBz7_OCSrWNpGgkpUsXRuJioJYUuqCLcgGO765lvXCSgHjmSkle_uStZTZMSVou2qK0NZYjYfcOyGTTEAOyJ0CSxwG3DsMGIpDyH6DuCs-w2vQqF7c1H59f891zw_BZFDEd2cdSwB_XiCDoOihweTXZVV9EhLLLnVNqwR7zlR8XhPsOyO0dXawRbIpCuPQ=w1198-h898-no)

Spot drilling for the 4-40 hole on this end.
(https://lh3.googleusercontent.com/Ul4UhSwg3qN1uO3vsT2TO1u4B1RRn0xFlUGczZVKQcXVlJcdtV46I_osT7HJG9WvrLyQI_odaKVOGqfoKX5nCww6i6bw4HQsHDwqbgRxOXLT62-BaABgW2vUiyI-vpjmQCmEygD4cw71wvkYix9Ay6KR6FmJpYZdiYf_IAHnCzEmlIyU4KTmJB3HxmGwUTNwHROSeqj5PGaKkHbicPFBbPJmQGmiDGijZzywXHftvXW_yr93-bBuocG1byZWx6Yvg3yDvHc4kQvDDLZXtVid2suSVBCL7Y1WmCwM_4rUg-NSygmOxPHMFMmCnNxJw0tccvCjAQ2PZ-R_BIhdg0x6r1Ej_iE_lM0rIxlZpg9JlYBhbQvrj7Jcv-fUxmMxMcV9uqaKmXEmp--fsEELAW4SW6zH1YSluJWVvces7lXMH9lMB2cM-ArigYsNzqg0az6vdVb0ZUUPzlShQfrsOoXpip6aK4Br_gOOirxZlaFyg_kfVPnl4F7TU33wtZCT0sPocKHg6lNl5naySDd_vKn84eWTRhb7XtN2FJR5XSmf5ayF0BlWVpGFRPD2iWjyv9dLC-Kg1yQ7FDydrfuTYuge3nfylCMeo4xcOf0GU8kMVj4siHqGnOX92RX99SoGjNX0eNIFozs8eDqvjlzm_N-sKuj86x9tTyrIVMbeZpK-6ts3U9XgevpYE3IRJBCPPvm5ImzjmzpHFqwSJ7bWyQ=w1198-h898-no)

After drilling to about .375" depth, tapping 4-40, again with the spring loaded tap follower and the very small tap wrench.  This op went well.
(https://lh3.googleusercontent.com/-GpLzzBQlAFSHnXrixmRvGYCPR-KhK5u14A2KcbNanlN5VwnOI4JxJurEcp1EEeJNH3eH2jMiKG6e_GoP84TcRCbYVKmuxXv5yxYdw7RY7IeBkjOmdlFN9ngdbnf-VGRNZE86R2oxTEzwYBG0dEDCJM3Q4RrgjZO4qNZlD9vvq2Uw7_B5UeNO6_IEo_-JdlNs-XgqFxZTA2sg5gTcaTmuWOaBsIqhwybi8HeEyhKcIo-f3GwvzsoeAimVbxGJjO_wdi2wF2UASe2NIO6flxMEJEZaPqpN4-Q6z5o4ZhHus3LwHstWIDu8CslIal2PD3F1RUrQtq2ckZW3LWJWlpijUDuA78E09zMeeJWp5GyqeNizIRT7Pui9HNcWra1d10RLtmYX9_hiZZRDJ_ynq_QBwmxYtIvFpDf8rha0k-Z5MWNNH9HjrC-PxRa-MuiBwQ4Z_zHKe_Rsocb4Nlgx6QmBlrbNS1pZdbn3Itgg20lCSkzLSJrUBuZlEo84nPbF0CmEGHmVXXgLeCY3tg-bpmPaE_-Yd9VdOibIfIRb5Jle3ekOQBe5n2_fQxJsJztGiLZTtc64QyZTBTqQTGNFKisyNSp7DYknZLN9GRKKXs7aq-IITRBSVaqclcxGNDmq3DQ8Frrc38a0eNvA0TstGhYbFt2sQqA4PoqLG4eQMt9WxDlc8pzyiSUSKLw4qz8tL5MDxY-v2XC_-Cag82O0Q=w1198-h898-no)

One of the finished parts on the drawing.  I think it came out pretty good since this was the first time I'd made a form tool, albeit a very simple one!
(https://lh3.googleusercontent.com/mF9YHOY7s4mplEAccT0mRP6jYnExieN9pIrTGSSTip0vt25Jo4vcgTuFwUOKp4AEjdYvIyHK4GKSIHhIdncdf3Ew49rkzLBKsaWiZ62P9wkblCEJU0HtOQLUX1JqKc1b4VqpQZoSsxv6weKET9vIsczrGLqIUQbY8_BvK9c-PGz0Tq4qbcK0ezAYCFDaI_rIA_ktyUNtfn1OBnAjYWJykaZZcrDMbQ2S7zk33xOvi-YKOCEjjMjq2ieEcpF09jEW4zGQJH27RvOAapAeKs-BWDF_x5yv6cB-izMjn4YGZViQvUBQDckOhOz8l8a3GtTb1-t2hpLTWh1dA4U0CgNG5zlx-KrBz2zHlqNHhlEWK2xNJxX1GO-VhcVw42nEm1FUKok36f_hhP8VFJKCuy8p2kW96UXFh5v3MDbKw9H9X4edWlUinNbNk3hqTm1VtjRIWKleJZ8lpBjtmkBeRze4CSNlpm60-yOZEAvh2OfzF2l2UP4yyDtbGufmjOXV741V3_e-m2b5DczI4O0ABKeXOE2Cbd9vLa5utJa-c4oy6LY10hXwT_CgxutXcumtr9Hn7R4uanAFwBOh6bc_KAGiQZzYSp1SpQXVhJ65bDaVKptY09fXZ-ZaqIAS3OM1j2vI0c1m8Tx0u026TNMBUJ6mTNX-8ixv9LaPkQxjzCBEscdudsq5zZVLOcwFo6Y5sQYpPogx-o9-QapF9qbR8w=w1198-h898-no)

And the final pix, showing the first pillar installed on the base plate.
(https://lh3.googleusercontent.com/P46rlJVkSAzSO7TZNvZITtUdg2slbUDvuHecKaQatqzxz6GR-dlTC3MXemxHbPwdQZYJdwdUJnwSdMLYSFDzyxtbUDRqjZduiNscXtxcinpmrOmk73TFUY-M8-Lr-ZrnsabSr3r37ivNJg7GBSNDHfTyk_WHxd7GRQnjd268tOrbEaUhlyS1yoLqYUL-rGKSWOmmVZu1XGZOFb3ehMoMBNRJBYUmp4bftySEoa1vEHAkjdnJ-RcbesAsp4nIUw3WcnleqhdxkGQAyhOmkb5BtkP1dDxJaVifmEfDRtTzFnO7bbO_C5TDO7XMMAmNXpb5LVu__L7DKG-trAXeKJ-P7NUUbW9edgk42YbDPP7yoV-TvdD-23MLsXDc97pv9adXiG29XFrjrZvQruclncniAXnxwppXvkhRDvB8TwZqegSDHQqvxWcTLEScLo-v8aeoTe4hBvh93qakCLjXF6w6LLFOIr52yhwE9l87gXjwqoU3XidgZ3ATnXNCm_0qPuPd7yUo1U2BOY5yiwMRGXV_Us3vWCxkx4wkyeYbrnv1zx_r_5S89winY0Y1k0OFw0MSe08LGVNhgDktJU7rGyGFaHeZFasj-pLPJhrxyc_PypqDW3C5OW8gwGGvcYtkmXXADryWQLYA1w96hOTvepBRP12Kqk1tHEz3_dhlfxkXW5pwCc-7uvh4LyWmcBwPsVxFBqjaESPIUwE-JOZ2og=w1198-h898-no)

I made one more of these parts this evening so just 2 more today tomorrow, then onto the next bits! 

All for today.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on November 14, 2018, 12:47:08 AM
Great work plus great photo sequences.


 :popcorn: :popcorn: :popcorn:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 15, 2018, 12:20:23 AM
Just one quick update for today.  I finished the crosshead slide guide pillars.  Shown in the pix is all four of them loosely attached to the base.  Just in case anyone is interested, the way I finished these was to use a bit of 220 grit emery cloth, particularly on the radius created by the form tool, pressing very lightly and constantly moving it.  I then used some maroon Scotch Brite followed by some grey Scotch Brite.  I didn't further polish the parts and am not sure I will since i sort of like this level of finish.  I managed to get all the parts with in a 1/2 thou in length so hopefully that won't be a contributor to any binding on the cross slide when it comes time to fit that.
(https://lh3.googleusercontent.com/XW1P_vxpogFfHfOASfgurU4kZJsHG16e1jXJcjp_3zhbfrsX-6HGKyHlINOxssjkX7G9Ld4FFs9h6kJXR8fcj-4KN_6akZ8ZUNh7q42Ri2legAH5yQRzQgTaJGmAoKtbcdPNY-m4NpgUJNbP-tNSDjjv9GSkTTLoORLRR6sGfFB6wQlidxSryOl12WLs2hFKBMhBnRvtNDcSbePkv8WEBrE6SUQYo45T9SE0HpeRJsce2V_eXfdr9EJlGTyy4J9dCxyxAGLIAicvMMe5ocaGn9zc5IBVOR2jqS-GvFpJQIA-aRjHx2woQOXV9MuDQB1bEtp2jbMIxcIB2Di8CvO3H50HgVhQBu7FUrxUCuE3hn48dMfFpMQAJdJv3b6WInDr7dS7LPdrXOvqDzHQS3SOJT8SjDlBslummBg72dVLs4WVRuoN939738WuA9MoAJV9uBqLIach38BytljbERlygJZbcV_S-qOgRgIFmKCQx20zNrM3QbWJVIy7RX-9DsB21_YKgab3b__5_VkITBZN3H0WoYT9gxyCzO04ZMtkqdE2n_6jrd9kQ9Hw78S5gEEZt2KaOevXEePKAUN9lQaKzuT8FVRipCQuexYytrC3cpgFKGCYfLIqzxYoEazwFjiliuf7iI9t0T5d2ho-Ie0JX9di=w1263-h947-no)

All for today.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 18, 2018, 11:57:57 PM
I've managed to do a bit more work on this engine over the past couple of days and thought I'd post a brief update on the progress.

I decided to make a start on the cylinder.  I had a piece of 1 1/4" cast iron round bar stock and chucked it up in the 4 jaw, trued it up and turned the OD to 1.25" as called for in the drawing.  I believe Mr. Hart's original plans called for AL for the cylinder but I wanted to give the CI a try as I have limited experience with it so far and figured this part would give me a good feel of how it machines. 
(https://lh3.googleusercontent.com/dDg0hoe7P6wfv0z3hg42eFjg95jGpFaMI9svOwO5DsmwXAUuy1q72jJ6a_T8OgueS4Js5G_gbjOIHo4lkA8D2VdY-kimSNd9j-vHqWMxMkrWEptsrtWNJXqi_P2tL8QL3W_xtx4HhJrADwR3AdNEakyl9e43GyhhyQzuAvVTPu7qr0yyYey7DOeOYxKOO2-5l0T69wawnOZt32NkqMVkypHam6lbd3YK4pt4qwsEvavzcaIllEgiz0iv1BDaX-atJLO6dvgF9NDZZaEwLN6dc6MN1uFl02V2BHvmVvkAoi5chHX30UArtu7Str65Sk-WDXsGVI-ThMDqibV60qFpXtGuFwgR8iAQRMu_YboIKa5BnQfsI_K4WZVSHLwpm_hq0foKxmbdAIS63N7kfuWTCw-xSPSMwixDjK0ANNfXmV-Wj-1iOMVvUYNoL5e4eUePOm9WAR-VuY23IXW5vrEPvqD91VmkqGou-Rs0rIz2pL8yMQkmDEme-MuNrFmcktR0Q-jhdBReNrDwsQt3kR4p8AcVYONE9qi6VAHDweW0MjQIbTfp1wunNE1RL6gEd4AeigsUBr6Z-eApnHWD8cKEZLFrQlY1Py0UivOrDJWto5BQrBj1W_FsPuLghCW38CVkrNLAAG9Rc-bY8GpgygiOqqssidYPU2GUT7qyHgR6sQaHZTDciZxvu7yP9nYBvKQWdPxavGKWzyKaLqUnew=w711-h947-no)

After the OD was to dimension, I center drilled the end and drilled a 3/16" starter hole to just over 1.75" deep. 
(https://lh3.googleusercontent.com/euozANbWvBV2CvbmOixjM5Mf9JYd5FtBmvn7z6VodhkoztQQHD3hkBH9Z7xDtblE9oteKCKpldcDNBZW9a_mCXjp-hfFecyc7b9GzYS65n7e96MlX0c5v5__JmYaVV7FYD6TMcRMRcOXUeRV2JUR9-wXQKuAOtg7PqBAOgvIj_dxq0TBukkECs9cmhZB1Av_hbBFhmhKTLUEe6qLqmz1ydp5zUju-HQFgc8TlUU0U4Pi7TpO2y4frvlFKpziLRY7eJI9WrwpYRIYU91RcaI3d2NOCqFP6zuXroS1fSEqoOTU_0R3xDE015UdUGol_kblTztLyeOmz3HMkZQtXmEbfCIodw13434ln6nRkWqT4TDhpfB4M94B7PeozxTVNG66GEI9ymBkUxP1GqmtXjwpmiECdN9KzOQ24VsQkSgJf0Gjg5ApnGjI_I0PntikoKYmUZX27J245DxgzST3soJuGg7f-d8v6JnYuWdEyFkdVE8HdlGV-xtC0loZN2JKZhUybWwpRDiUxcVjATn_7r4tvH3AsBUjvKzojY8oPX1dh3y5CrdlgBg38tb1mknCBPoslqMG0teKTIPRrvOyin_gjrtIa9lInUFkgXAy_j2EqASgpME7OQr42W8bM-V_k5h8r9izL89zc7MtWq6wiOIxgepdpbg1qqmbZcUNBjFNtg1kXSBF0S9w5BuylM3cNitLAhhx4GfhJUYSk-PiOQ=w711-h947-no)

Then drilled to the same depth as the pilot with a 9/16" reduced shank bit I had.  Reduced the rpm to about 260.  I do love the way that cast iron machines! 
(https://lh3.googleusercontent.com/Va0_hCof__-qqJ7plIFngYfxs5fcUNFMFxVZ0H49Zxb-0iv-H2oPe7Wuo42_ggYlz9ThJpZRVbDXVyOCq9yM-o8Pr5RuePhg-pPLKQufvKhWj_lvZAPYI0McWV3eV88BWWypxKb9tCtX1cr_sJHQWxEs6vA9Bew4ziUCWsME7-j1_dSUih0shihuMudVxgcKIIn5yFPHGyheaoTKecaNb_052ayCAR0zk8wmMFNhtMcfG8qRvA1Le3MwzzFDdL7eiHf_zwlQ-fn_BEdiMLEMOJAjwr3ixHR2yRv6J-fTHMEe2AD6amXuIt-VliwKlgAcTkyUcIfRkmOcAbfHLpqTElQaMdOtgnEPVx2O3xwaBoMV92lgqm_lxFuzPrYVtRsgTMh_Kig0VEn5EnEAHo6JXoMEvHblwSJFw3GD6PvkQbEH4jsyZibIN5KsDTYXgnZl7CdHUOJY1-BIY6QIovJJ21t3nKGtIHdiLQxu_tvb0rzbWIShbrM2k1HCa3ibj3x-BqwRqu2jQ42GPPDktQPLbwZVBaQanZkDs8rZ9f7VnXvvu_KWB7vngOJqev83Jol3Bj1iBVAI6B9u1FfpMEH4UZ20cyRTw5l48plS7fuux8WbwL8JSYgQK1yPJXamGI8hi_5L6u74cczfdx8S_xo1ileSqR1dfVQDHftoDB6YBjtJwjndEEcbi-HRkD-Kn7d7iVPSL9vDZTEnj0J1Fw=w711-h947-no)

Just to make sure that the bore is true and on center I took a light cut with a small boring bar.  I took the ID to just over .60" in one pass.  I was again impressed on how well the CI machines!  RPM was 430.
(https://lh3.googleusercontent.com/k-ESUXJBWDBp2XQgmF-hjhWH741ZQp9n7H_yWIsONeO0d6pBIlw4JKWY41s_Jb_RR8tU5dQBkLmyQZZd-cTYxisI38-7Msl2E0Q62reKZeDBJaahqLK-_0olz3DYJzQJWQXsBqw3F6b8WLKeGO0Fl7urDAouHGk020HGP5GJhRtMzLXtoPB3OJmlnfLgq8DxN75FdtjWwwDbQbRyuajpxgwAqyHNF2wrBoHz6qeHkUpDfk4eYOW2pEt02gPUodxmF2nKiQIdqtaeZuqPPpBuwwApYpAvzBWYbGSZsnx-QNJupiE9gnP_1_99Ryy929Pa8zXJt_9CpECHAUYLsoIQTYj230pKOA9YEjBDlWuaONwifIObmk6qOLBg2kovee4wOJ5559gZLnJi8H-EqCKp8akO06SsuVSfd4KMWvVo5UiceY41gsky4ZiBlAa7rF2VrXyO447wAj-HaahG85Uu9bRQs4jgj89dqKksfFoIs_c2txjLQxqdQrmoj_vMLS7aMt_XpzYb2Or3Jx37aJxMjAZJIZuxJ3bEk8lO3HJT21p1f6YBwsPGfltfYdrdBqUslil462EWdPPliwwbqoGH0lM22aWdfbkAMzVtD1zhdgDN75jisxiUBZ7qKdYnq4Px6vyuTRKtvpD4WfJkmrXIAkiTNaCmL2Pec6_-Xlro45Sj3TtDAVv8HgZ_DjZntUz67KHHu6Z8iPbwINme2g=w711-h947-no)

Then I reamed to the final ID of .625" with a 5/8" reamer that I had on hand.  Reduced the rpm down to .260 for this op.
(https://lh3.googleusercontent.com/NVEJx270_JB6Kfm2YfeP_407PGWvEz92qI4L7SJNCPQtNJU8EcnEoZs03oIC1-m_pNL-KVnTkUDgIbEM3PVCw_r8SHI6Gbx5yG7TCLwev02Ahag1vXUodSPiZ-N6KhlGhCH9JFgEeE-nRCT-mXWtm1hkV0SaCFw4uMmP_YHRSlFw36w3QmbzXG2i0BNtvm-7HREsbsg7yNbOm5QM0E_WbhI29y1Goo8sg1zknDtHnMSjkceg9nWSJ-Ag9vBG_FzgleHAmjU0dTbifv0Fx_T3Z-TPxAgEOZvM18S3PTItSgYjlldjjsAcgYEUj9HyoR8Q1zKNsJ07EYAHHr7op3E0caXr9TnMaDurtDL7BtSX0LPbxSiX691n5fXw35TV-jb_ETNQhp_LZe-u256yak1_4b7MbrnBpcwJXa0tcWLU7VQdnd26EZtnDBfYdt5q2t18N8hkJ0jX4j2lsCP5eNhWBQw9I0PKKFjPRBiuSpmS1MvtY11V9_ltzqSO-9iESYAyqesS_lS7vw2q0unrVjSH-1KbpH9T2Erb8y66zY90UFl932g68NrMfRec2vhVipWCiKBdRZCoHvM4Yx_nssz602opfGGA46h2FoD1Ox_9KWPpdPuC28Vp2CYhqjhzVybrQs-O0tKK7Y9DjCrlIejeLQZNDr2Qx3c0pDhI3WalAvXxLO3fJooePfucmBI9Qc11xmNYFRqgcYX8wZIz0g=w711-h947-no)

I parted off the cylinder just over 1.75" and then turned it around, rechucked it, trued it and brought it to the exact length.  I also used some emory and Scotch Brite on the end to improve the finish a bit.  I didn't remember to take any pix of those ops, but here's the cylinder on top of the print, with the length, OD and ID completed.
(https://lh3.googleusercontent.com/DWaMkLxZvrkyQ63Ww2_sijqIat7WRGnausSNQu4T6rLYOUXZ5dH81i9gZKDRbPtygjwTi8cbkiHIebEDaHFZyXgIy2ISkX6egfOXUXSUuVf0Da54sKExeehlAVIZDT-WAhduLrP3C2PHL0AZXsnZIhqfN3KswS1-X5DVIJoqaN-ZdMQeBsvfc3lZkPtvDmI1CCOunLhgKDYB4HHanzx84BWFyVeGUI1A_3OZ06bJQW-ZHsQCsKQH89JMads4qWs1aTSmoa5cFKh4KaA9mBUN_00Gs6XkoIcOYKztsNxUPJ-_WttgOtyH2DMyqhQpKS1s8rqvgiUbinM5i5ZBsUOtxTsCE0Jxui0BPFpqApCqbh9HBr7uCpeWbvAKgWL7ahMJFLIkb1ynA9Vs6j-CTMJiiJgXJKtsLUxHBv6_P4aK7pFTQyZ87GQsPa7UJqxIQYy0Y0n4x5zJkVLRECr2-jFuPCZmgrLRj7E9PkYIAYixw4ZtST9uUWDB8MiKVPGRpQB_lJSA28Ejls9KJThkuhxrXRceCcW1wx3f5iw5PqOB15Gzp_gfeVRjTfWxpRSQDv1DVyoqCblUu3r4TRuSqjeSjhu0De5Bq0aYrlDPpSrW8EnUkEU1kvk79TbYbmh2ZFeKqo5bsWA7qHfP1yKnLsWQlWsRZmgKii95VvVoOmQYAaAjaFI9RV499A_cyPt507p7FsReN00T1u4hUJVrdQ=w711-h947-no)

Then on to the mill to make the flat for the mounting block.  This was pretty straightforward as I just put the cylinder as you see in the vise on a couple of parallels and took a couple of passes with an old CenterDex end mill to bring it to the required dimension. 
(https://lh3.googleusercontent.com/iLIrCI39GY0Ggks7EilD6tL9RA4csB5UBR_GZVzAZvOqBmO1gUrCNC3qZs9hN1OjfPS9w2u6vJrshrZ4ayTqTTagS7hB9hWEFMp1BTScGOMyzs3xCRzNWaetuWPgFu4tF0s0MzwtPbjIfZMH-VeDouRCrydZmm4YTMOfm1BF88umrEer4bdaHK54gm-cnpVhRGQ8m7pknHvKo1Ot04mIETEvAhsZv5Fnm6j1qfl8hzjC09A7sDwqANvN3XIVhy64UXimHLTZ8EFQHPUlXKwMiM3Y7rrSQwN-9F-5fRv34jJLgYgN2K9kfAlT-kVxfyQVPBfmyvb2M8u9sVWG7JwKq11ACa1Su7xfaDX6koN4a8-myZ67T_HLermvhVicrCUH7OQQS4DhRFL42rJZC6AlztjKZ7wi4ahHmUqeH7tJnN2t4yAnUNKQBcVhdEDmVybx7GU_494WQt2TQjfb1vQI_n3faCfsVfVVQfh0XuXbDjf5AYlAmyvIdgKBvt3MGgvWgM3hhjPjruSvMg2Ie2wo4PBKEac_ucq_xvmoJl_W6TBisppGb47fMIg0KNJHW9b-1K-20hI9wwSzxmDlifdQ4-BhFPBvp-wAFYB4q9HZvTO4rlmg1F-0L5BzIrHUINcZHwohxJUnn75nbHMUyzd9w3rIh-TEEr4tSclLL86jN4KOsfmWnZ6sIEOagXoO3AKfvPMrkNCzBdaGeOFH2g=w711-h947-no)

Then I did a bit of edge finding to find the center of the cylinder and establish the edge in order to get the tapped holes done.  This pix shows tapping 4-40 with a spring loaded tap follower and the small tap wrench I commonly use.  I started with a plug tap and the finished each hole with a bottoming tap as the holes have to be quite shallow to avoid breaking into the cylinder.
(https://lh3.googleusercontent.com/G_seAGWRwJMB4Q6NctI1GIvJCRlF1GzC2QKATVzwNaA_XCSFnTjQAq1N_9LzNemttKw1ERPwdy4PRVEVA1Fu2c8-NF-6rbQ7InRad1jiunWVe-qLxpUwBJ-I5_2X9lk1dPNjdnrkJlyTMRN9aupXBiglRV5nW089nYGKP_ytCUORylmksgOwu2Z6KUMbB8O3pbnCVGMqCKMrPJ3rC30uMFIGgUii21r7LC5b5TBQdsotc-2e4ZCKuPkoaLVPJYV8E4BnTVTOsxjcJXwACPsH3eAkfpbj9LBevqFwJgJBMn_UBOXGwKmK-v6yr5rv7Vx-M9gflJT4DUY-3Ob8ma7aew5NVmfQBxOsDnw3msOQc27Ui8cHXk_5gaX2GAI6qqjFiOnJEXvHcfGi4BQGbNWWpnvHx2Z-9bzslfF92z7V9PEOphH71H-zk1b-ZI7bTvF1z8GjilNhFPPgEgkyk16h5pLuZ1WhYB97yWhgbA8RDoPn2tQKCNEp9-Gpeq73U_UrNquLuQRmypNrKB5uQRVhY5hZiXUCjO9bd2xaCY0icjgP2rQiN0nMBLSRPoinzoOwtu3lnLwaDvbPqGtsufbndY2_L8szH2vbsTINkpigGwx7Db0B60avcWriUgVm1FTdPgYZpDUb6TeGVeep843HasQ3o6DfQ3y59WGvACKyZAHek1rl7BoaE6HZH9LLo4LseefDV6melZYHWL59_w=w711-h947-no)

Testing the fit with a 4-40 shcs.  Both holes were good!
(https://lh3.googleusercontent.com/fT8D016so_9O2vh0eNjdWQLd4AU8RWUal61FX3YY4i7kkq9u_z1etiB_ogstduY-xB0CW0emzwZOaVQrb8EutvPrX4TCW09vLZZcPCOu9vmAGfvvLuW_RuTDKKOf6i3Hr7boFS0IePb-JLTuy5nHwU_MgyuwG575O80D76w-ICy0cPxb-m7yNkuCwDk_deXfGFgCABVTENWPLLC5fcFf0xciA0Haxam2KQw7Ht3ws9QuZ3oQoG1eNFQoQ0qLYfwereFHF1OaptazmRnjr0YoK9dCyG_ia-FYPrh9tp344ahCkVElAH2jtAPCE26QseG8Vp7KkS3fQB6qa39PtVgLEcZEG_fn-EI38lfPfXB-XJ4wAVPkiClKNMmTTdpz87iAaO2Yu13aJPgq11yc4nIJ0f-0bL2l9HLnRpvSgqURYD9e9B7vLap3un2qvLqUMO_nZ5h_TK9Qjh_tQf03gUHYWJspuhnURkHQFkOsZoX1e_BOyR8EneadhlBx57qXA68PrzYH4rELW9U7Quw7bxcMQFGQmvNB8_iE6Sag_5eYkopQ6QhL4Ph2zZGAZEDsV2Su8XF4HQDazOkloIiS8rRUvCMq64NPM2AWUELcVXmMM-5Uo_YIdXcxwHsEC73qWVH1fIBQ9uHEQByxFO3GbEr7Q07Q4XC14Qxm06aBTgiwCKXGFkHHXRokNkcSOGYpTbFKqxPQdElyfzsbfkcs2w=w711-h947-no)

Then I made the cylinder mounting/riser block.  I started with a piece of 3/4" square Al I had on hand and first brought it to dimension.  Then did edge finding on the piece and drilled the required thru holes for the 4-40 shcs that I will use to mount it.  This was all pretty straightforward.
(https://lh3.googleusercontent.com/FPiWXQupZrZkbtclRVgk1NY5Muh5CtPpuAqooSyRnvk2-COdNLtx3TKg6yAlO9XEfmGxPsgu9JVhiHgp6jn7Fg5jDIHisuF73OzP6ypUW7NBIg55wOcCXal7Ce6egt1VvIGDM22T8bwEq1CsAU4Jz7exQCCXhoGEEbFY4XhkaBkr9CapBFQuhG9bSn2X4Hb5PUUOpkhdi2-MNxXRUNFKpa7W12UgREuFsjWfEpzEfRNDwxs4S_1Vc2wxmJl00_7Mxkz_RonBx-kWoaglibS30dr_qI-tfY_HhMMGsIgofElJk2t2pcVz2O50EPMIlwn6Ea-wJEdofMabRK0wyUJf6h481eZKGQlpvP5uM5zCWbj_9ppDvk8n-vztg6BOq3-dRLGSDt20pkXkXs_Ig96mtOBr1H-lkvKm4692tG63LWjjSPPO28i-XSd-QLhRO_EFL0vCte-mneGU8FXAcGcxemADtY0J7RhEi_ViK3XzuPABlgBKti2CUpPoXTBWX234HDwv62pXhOMW6mYESqxnewrp2xMbPJfExIRC-z7PfZRkQVhsKWYcQQ4RUV3FTGq19yAVqoA6YKUagF1jN5EVbMA8NkzRf49Vzqrcos8xQhCi7w7-JU1caZSlnAjjojp-jLeTSHGF3fbQrMQgMQpaMHakbbVAXSGXR1U2VZ0cAtC7ys4kL7jC8RWnl5x2t1hk0qCEpP7PVGZt-8VsrA=w711-h947-no)

Finally a couple of pix of the parts that I've made to date assembled on the base plate.  The cylinder isn't actually fastened down as I didn't have long enough 4-40 shcs on hand.  Hopefully I can pick some tomorrow.  I'm also missing the little square valve rod guide block but I do have the rest of the crosshead guide items done.  This is the first pix.
(https://lh3.googleusercontent.com/ENLt2mzMetSo4Hb0w4f52VmUj6l1y2MSLe1z8URjGXghLjTLf5VpGgKKTsW6veGPN4-odA6L5WeNfaoT1X2tJU3ockEvH2fA6GnmdEEWOGbHozsqUEhs5B76i4DC7DrnJMawMCKzTUlmbBVvgmOYB_FvLhwha9eL7HwVDkJPa7zrQO3V9rxGxEsA_ELYHk8AF17EAl92AJQhKI5TNpCljD4-qQLa0k4DaiSktR5ykE9azNAYb0MkWH0iytXsenaa_0o7nP9wK4XPL3ljtkuqbH1pz_g-s1qsXjBKgFo5XOyeioI5DkpFvnlzpGifqwxwGW_diS3-cHEMtjOX6JiVLhLh7XRMXFUCnzU0ltj_aSHNWCO7EjCzFM2q27yJS53x12J9f6zfUPF0oGHxSDvTInn8zOzAiJUL5_3OqlrMcPJaPiUQNn3JqbVvLijVEp6y8QEZcLYWDgMcEISvO6d0_Gh0uv5Zf-u_0TgHWgPWEwmP-q2bBhtHTFJJQmajNiafXV589U5Al4LC7sEImcaLqPHsjFfXA-ZBHAgpUjhGsdDxb6F7Ej2SFwfJP7reVeTsfJtykrOOzYs76m1LktGobGxl4kRClkd2S4Iby3fA4f5Kkae7wodfhv_4Y86mdhD0g2idQZ7Sq_R5tB303lBEjVTfhBSuDHsFzGuz6XuDoXnmtAJ4kkA_ZxaanOOK1ocTD8HurvDNIDw3knMFBQ=w1231-h924-no)

And the 2nd pix. 
(https://lh3.googleusercontent.com/NwNwWT9CVUMPoH0o_RI74d6FaGfiDugArl4rSaV_ApUSp0UaMpUrVVVS5sFOKJ71OpFLJ2ARZgfARz_jULqJli_fSsgi4WPbZt-_4jw5YyVD8mcf87aAK0rSU69idoxCpeS30Y9pm_Z3yRIATvfLdL5QbTjHS4AqAUgAimorufkLMf64Pk_nwVrpOLj4xYGctDlqD4IrG5bKmj9CYZnaTlyCsHeX9yThVt7n6CObwzP9vkb0VjQW6jCCohC3VjA8EZo8GXYetOwQxZevRdow7Kf6v1B5TsX1dyNI-8-AUT1yn7PTZzH_wE-REO1u6o2Nf0zF0ZlOUYIhn17UnUN24OLAUKp8efzP-482A_x2EDbLCExmEC9xT3_s4FaWELv2IFlhtN_OExsIj2PsbYFpSwAPIzEKDCwHJAcAwLkA-OZuiK4ZnEb535jDKN9HzzUfnAtQv7pjbwJzA_8efOUqqjywN1EmqM7AhjofdSWdf-S67kXhyslGSldGDuupxU1_msqITxOIkUqbUifO4wLwqW6r1lrlW7Wp_s868sO1KYcLdZ0Ftah_q-aJwo6aV3fIobfztc7D9xVcQFX4IKhR4xCFQAsSgf3_7T89ZnK5TzUCYbXWncE8VLdJJIfCIHpClfgcb0UYZtv2aMsGEhNDMfLiCNegOlmNIibM_aYq1wU1Fry2xg-LhO69RGQxqqc8-xAlkSiwEQOqlF8Xtg=w1231-h924-no)

The astute observer will notice that there are a fair number of operations to be completed on the cylinder.  The cylinder cover mounting holes, the piston valve block mounting holes, the air passages, etc all reman to do.  In other words, the tricky bits!

However, at least now it's starting to look like the beginnings of an engine! 

Over the next couple of days, i'd like to finish the cylinder, the cylinder covers and maybe make a start on the piston valve block.  It's supposed to be warmer this coming week so hopefully I'll be able to spend a bit more time in the shop each day.

All for now.

Enjoy!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: zeeprogrammer on November 19, 2018, 01:01:50 AM
Nice work!

I don't have a lot of experience with cast iron...although very messy, I enjoyed it.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on November 19, 2018, 01:07:19 AM
Coming along great Mike! Great pictures and nice looking parts as well.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: PJPickard on November 19, 2018, 01:13:24 AM
Mike,
I was thinking about building this engine next. Nice work. Where do you get those little tap handles?
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 19, 2018, 12:53:11 PM

I don't have a lot of experience with cast iron...although very messy, I enjoyed it.

I don't find cast iron objectionable at all to work with!  What drives me crazy is metal with rust.  That truly makes a mess!  I have a bunch of very nice heavy wall DOM tubing that my brother gave me but it had been outside for a looonnnggg time and is rusted on the OD and ID.  It's great material but everytime I use use a bit of a I curse madly and then spend a bunch of time with mineral spirits and rags!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 19, 2018, 01:02:15 PM
Mike,
I was thinking about building this engine next. Nice work. Where do you get those little tap handles?

I got them from Little Machine Shop.  Search on their website for 'Tap Wrenches, Miniature'.  You get qty 2 of them, one small and the other one very small both for about $12!  To be honest, I also have the two smallest Starrett tap wrenches and i prefer the little tap handles from LMS at the smallest sizes, that is 6-32 and smaller.  Even the smallest conventional tap wrench is too large and unwieldy with too much leverage, at least to me, for tapping small holes.

FYI.

Mike

Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 22, 2018, 01:56:38 AM
I was able to spent a bit of time in the shop over the last couple of days and made some good progress on the cylinder's 'tricky bits'.  I spent quite a lot of time thinking about the setup needed and the order of operations.  I'll try to illustrate what I came up with in the pix.

Since the 2 flat areas on the cylinder have to be at 90 degrees to each other, the easiest way that i could accomplisht that was to simply place the first milled flat against the fixed jaw of the vise and then space it up with some parallels and just to be sure I didn't mar it, I used a small piece of AL between the cylinder and he moveable jaw.  Then it was a simple matter of cutting the flat to dimension.  i did have to slide the parallels out to get a mic across the part as needed.
(https://lh3.googleusercontent.com/LRQkG4ycCaFV2jCN80rQ12yTNpXX7Iqy6SysW0oET3Zm3Stk6iHrCfVSglhsunm0U6Xc3gldvq5Wf1rWessr1yVgvIRhDuk0SUFOlaL3hT-GnF5l0ZBCH2Uc2VDD6c6XKVFZZJ0QMEwGlZ2TO9puCHUsb6s8VR6ApGgcocMnB-JeVqyB4wKtCNJQzu9PPClnZxW7cASufkVjqlTmrH3IlpZJmq6zy0e2uc3KQrpBvC5clzHCUnqzOQsjEXWHmjYT5XhgLZpcdJxTjcvbgi1adATDTLcMJUb8eZ25hNCPg8FGyec5PTaObQf42l1o-Jtozi2DPeXTltx2tai59zyJYIQLmMr2Xbel2tHeywFWCGmiP2woxL50EmXgYFiHIb0vrwNR9ALnmdsBRwiCgfyjWq2jHkRQAylG6BpeRizRw54WjqVIS-yZCynmkpazUytDEmSHl-bstNEKBNDV26IgNDgiHNwqoohrJdOGAB9fw__4kipd61qLt1TLnerLegmd6XDnOInRwJkscIw2lwTn41GP7v4Kj8yFfa6vMWYqHlOAzl_fwmaUMfJg6rYdaB2biAYGMa1KFOEovbZsA5YuPI8_V6vBTVkMNwH8ZnXUtfy8aCD6viFI-inQhf8qmJ47iZxcy_g5hPChdPQNKNHpmZ4gJrshJM_3ZXUbx3AmYbGtoKvIA3mh8EPXzgyhT5ajKhImfRabcm6R91tZmA=w711-h947-no)

Then the other tricky bit that took me a bit of time to figure out was how to get the holes on the flat properly located, since the cylinder is no longer round.  What I ended up doing was to insert a piece  of 5/8" drill rod thru the cylinder and indicate on that and that operation enabled me to move to the centerline of the cylinder on the DRO pretty easily.  The other problem I had is when i drew the part in Fusion 360, there are some strange limitations on where you can put 0,0 when using ordinate dimensions.  So I had to pay attention and offset everything properly in order to get the holes placed correctly.  This pix just shows edge finding on the drill rod and the end of the cylinder.
(https://lh3.googleusercontent.com/vPNG9ZFdSnHELnaZ9N4c7flrCROA2h7NRQyy-P4-J4hdxV_xIBzs_aD-D-qPYV3zRO8C9PsnGqSuiTW8XCb2yMqAtY6JmM65aX0Ae8brwLxKLwy7tvbQC2n6f3yBAvVarKiFxsO1Ly_qDFypqsXIHPPivlcNsr3U3vnnQKykI6bembEUK1b_9UTIeK9WKm5xgUsUp25AZhAHHML-xcEnRRwmrWAfOU3k4ryGPyxtCeTPb79sRMNsamMe4_cvLrf9OBr5STWL2abS9cHmLGFx9Ghprre_rg7DuJGRr9mW22k8rpX53FBH2MzHNFIYklSVciTqpis5rmR39qIPfzCnx8rlaplYNd07Ffksg9r-ID4H9R4DpfwazSUix4a-iLv-mtaddZ1fWe52WlQsEN9dvOz1PCvGlGm0CBsUG8yyLtLj82j-1ayLJ72pcxf92TU8KN-jfvpoM7UKNNi4_e1a5Ca7sEAHssT0pRIois7cqrAoB-64EyxEvjUMrjjC_emuS7H6RWheMsi_WT6yHiaxmym-mGW9xFGku8kt3FbgeQIDw1hZyxdwqkpY62pS1S0eCgnNVFGiw9L5tBxzR1BNzsAIubL6yH2ZyhzpTb1w71gS2QjTAgEugnGb2-i7Mbmfm4lzeneapLhrGcNyEd8VlLqkRo9Mg1yaaHi3E4n1ASAaw4RJLbc4LEz5jrKRTsdfhq3wPaSfm-6ZZtBWYw=w711-h947-no)

Then on to drilling the air passage holes from the face and spotting the locations for the piston valve block mounting bolts.
(https://lh3.googleusercontent.com/R_Dlgn5lxh6519ACryYD2wORJsQ0z-kAEa7CfP7Z2AswEx2YJZHHs2wmQgrbYl8ehxiGaCPB067PSwP5B5NYHInQ-mjlyoYVGzFlXUGNhfU6q0MSu1m75NU4n3so6Pc4Gvu4x9CgzQJlUv0IppHVhtLL_sKg-y8aE2JUXupdJTkHQ9MsD5C3pxVAI0g7H7--dxLECbm38LQ31J-en9d8-IiyY3LvnsUAGi7t8hfQc2LV4sfdt_I4fu_KB5iB3WbsjhE53Gpzp4X0JUqR95JIoCYOS2KooOcrDC6hPgODMUdOvq4UT1Ge784tmp13bNjbpN8PdVr21HHaZgpT2lwEQU6SJ2VXlXOG2JUbDWc4NhU4BiP6jaGijEtciLE50iNO_Fi1SaEIaOLJOQpjL9gdP_x_1r6IK8-eQJor1d2Wi79yvPVFp69dG0eMP-hhB9_FtqJdfvVD3o_3cMGACBMin7lxedeEvGV3jQjwy_DqvEDQdZ8HJjQI9XDjLGSxt6FlIB8fUv15po5XbaHjJuI_XH7wn0_GN7ML5Qfu0FNi7N4omUXA6SDy-LUtsoJ-IDrs3LQt413ABeWEoR0lhQhz5clR8vX4Y-aJurkeMm-6bPmKQH7pKrUpBjVpxXDoIqkz6ZFtPyZCdGotbuUN_VwsW8zmlK6MuLRVJphs1AxftWGrKJyheZBJoTcfmjyG5UGyjq6KQe_2rU5BheeICg=w711-h947-no)

Finishing up drilling the #50 holes to be tapped 2-56.  Since I had qty 8 holes and was worried about drilling too deep, I carefully setup the quill stop so as to avoid any tragedies at this point.
(https://lh3.googleusercontent.com/6-kX36zBUAcCaBsY8OHYuHb41YQr_5SHo30YU-0ch1Z1iWNENTh4smjW1qMEpr7uq5uRQVNM9UxCOAaxbnmDu0QbQ2_aCQPKR-plEF7iShLAz7hkGh7T3tPkATCld_jAQooeuwSNXHCOckFsVqChgRmindiAFoFbiN-YIjMrau9_Ei47DkFyKNiXDQSTHMt2ozO_nbv2AMUolIUV0BPDw8F-J6vdkIVreQTaH0i_Ww1UNbuo1b8Fg7eXeBBhy8qVxZ0h1oLGiRN3Tz_pjaM4DuRRQd_v-8jqPMv3CrrRIfukWj9E7kqxnlce73kpbbJ0dd5sNffdo5Bme_fwHyvnOLwPKUfgYb3v9nYIB0zpJQ4N_ez0wvDAlZZDFZHAXMusboeG-n-wE5p_eCryJ7z81A3Xe5r-WU2NWaGDqBNFOOhjOtZeysJWdSxNjdhI4MrI5hDq6Vvl-JUKC5Z-nL8iOn24RjlL9sO6BenxN83B2o6DrYfB9Kna2e2Z5JcJYwgUzwUzk0naEUTVgixyPL0IkcXsinzMyV1fe5TlGmwTd9IhhAa6Jr55_jRZxCrkzf8mYZ-PO2yPGDv3hjdJKUDmrZSebhCrpGJBCkq3UlA_CDJRpgINQ0FNopBHkHjQTz9JTX6MrFDoPVJwBguM78uQI3LqHziQOoJud2G-ODAmYE9rorrakbHcgVEDM67zod2uShmipTk9D9WyKuI43Q=w711-h947-no)

Then tapping all 8 holes 2-56.  Note the spring loaded tap follower and my massive 1.5" long tap wrench!  I tapped as deeply as possible with a plug tap and then follow up with a bottoming tap in each hole. 
(https://lh3.googleusercontent.com/P-BVz0K8e6-an11akJ2iK19-GFsAKSSDIG8xmm4MKYh5CW6AhmYPvxp-83eNYWINnAy7quYFk38sk1OAxQarAUU82CHPehbIypm9SEpuQyoARKjWe1BFRHz5GHkWDHC7Jf0PrAkRTdafnciR5kbe5SQ3xzrwWO-etvFpWl-0b9BeUdaGotKxVJdvrM2nBxtpsEm5mhddX8A2mGLawl_why3qOOseBbeR5ztpIFScNzbeOGv33ABBlVOfqwXwTSvKgO2-DiYe26uQKCeYeWrAChxmvnu0ikIBhE0utLmSHCEi1KWR_Oy1oJ9LtOOs_bBkz3axU6Dh6ZDYpdhTz30KPxvzJTwUXVNPK5Btvv-DznIsXDVYkCAevpWe6KJ0UMOaVNv687O4jlROYrWfSuT93KMkX9aWrPWiU-3ImtxQ2UdwapAmwwrfBu4MbTzwyHzNijG972fMr-DWk3-6z24ebayp7HlDOiqIvxLbITgJVsZTwOJAHrOj0adyaGsWGuLYJ8QeWzJ_v9mK3OzdOicQT74W4UEgNxmIs-zxGLcs4rz8dZOFN4tvJNTeySJu83wGPEhL-RpiXihEW2XJki5y0_F1S1dWE1SFgz5LsQjxgII78CweMtKEGZcoHhbBxgKoBhNrGAlWFRBpjZ0zkBGtCYOms4P67MWkeqIv9wf8IGRqWIp40pUVaLiIoiWwdbvQHFMTdyfu2km6ucG0hQ=w711-h947-no)

Checking the fit of each tapped hole with a 2-56 bolt.
(https://lh3.googleusercontent.com/OKs3Pgn--YAttbfBxiBYZuSJTPJbJpE0i2KnEVQTWOtMcsNB30J8Lwg-1c3OO6tQwpstB9w177XT4chM3RtWYwSoyNc83GBrdALoRMia9DJOcxikiXgIyMlrbYf8a7CR45ZdxLI0lswdnkmiahYb-vohzEco5W7iSUYiRHhytfNey3z5fNYB8JJHga6ibYNuMFos5YnXtnXCKDnZua1oZVwx3lv9wxArJWqh8T4rukYRYC7-Mfjh_Fjn50NL0nalsRLBzKP9HArbk9zcQGdXYRvnhEO2-du848iaaTELr7a7d7oSL-OiU9FFhInRZ8HlH7f1l56AzNqNEbn4WCm67Xnssxcsb91wYxLOhnAlBySRGzV4rnvVbK8BFtgwH667H1Gnrzs40gBgiN9-V0wjrzCZVdDEP1ZJyIy6ssk30ZgjArAa0BPkaf4BXuR2FBc07CATLT12ZinDLAXC9yWUlR_tka_YBeOYyMC_3yYcAEswcJepA60IPv6mTYNPkdx3dr-Z0o7p4I6uHBYSBeOA0lvDmDBbe6W3Tg2rvqvjIjaCmZ0L_6Eu8z2JiUnpei2WMdVqJxrR9vqV_AAZXr5CZFb-8eAPlK1AfcFsKk8Dx57CyS12HY5V5ocm185mqyu4AWDQgd6P9w9UFfodrmCysB_H6yrUHi5uF6zIPeURIEP4gtSKx7JGK_yiX9qBOWuPmEuGZvH6Oe_p3MYgBg=w711-h947-no)

Then on to the operations on the front end of the cylinder.  I didn't take a pix of it, but I did center up the mill on the cylinder hole using a DTI.  This shows starting to drill the 1/8" hole to intersect the air passage hole from the side mounting area. 
(https://lh3.googleusercontent.com/fg9BfV50lSJlFGwUwCoIOVfB1tEHhTtOB_zbbNx5qcJcKKFJi612xK-IsVjJWt_dSFKAky-QbFFv71ppWEgWqlFtETyi_xOVXt6SKutYOWVxwaSWXUJfVc7dKP6HfKyISwmwNJZsYN8dk7SmM2UiJgSxIAvqY-zlYH2Z8b8BQLrhy0FdYzc6jVeZDb_-7hZ3nC_jbzMTAlrwQozahVoY5JDnVIyUtPpiTdUWOW2x_Ulc1faL4X94ARtPoLPbXg4Ze_j7viTUt3CijYnZZ7d8x-zQH81MrgcRa38Z09IMzwW9pl_5kKKr9-MHQHeLQtU2d3pgHWaY7YWnwAFgz8jp-QCYNndZ0okafgeX_pwzpKci0FDFQPzNu1kkKfjw7Hxb_HK6MOwa_XJ0LjAU83pgZajogTpMsfSW7g39cUbcquQG4rZP4-rEUIIIdplnRkP6cBwFrN67iUND2o3m1tCmQK5OX4s8o3TWC22PDYWmNl2sFWsqcb4bS_cJwBgb8R4EdQvKnx0qhjXomAXwNmBLsvi8Q3cViEjBtXfxmoMPpkYzhqVbav6kauOKfOFibHtDht_LttbDRQdNSiK4DFo7E_ApT17toHqJVUrJG5fCHGVsj_z-w-fLoDwleWItnPVIYx7pON_Y0HJ9_5yugwdLDebfk_rv2BgVDXAED9uBHhvKkSWDGDThSM-7_IWpCDAsnqHrQonAl2PH1OnIiw=w711-h947-no)

Then spotting the 4 locations for the cylinder cover mounting tapped holes.   Since there were only 4 holes and the geometry allowed reference from the center, I just put some linear dimension on the print to work from vs having to rig up the rotary table to do this.
(https://lh3.googleusercontent.com/-0BYOBcg8RiTXpG3WBj13V5hm_GmlSbOsOP95wPR0Hk7UHlNoGlgNnV5mzCt2oafwK_jIkr1KRM5BVxSVSaloOMQNtt66oOjw47uYPyS8ovmqCI2EO8-mpdrsqsjM-incjssEW5e4cz052jPM5HqjEcEQEg0NZXetI_vOpaKMeMWhVyFihUgPVSRpxu9L1eUOz2bGfT0_Tm_rYe5T3g533Dkn21UdMEbqPlx2Ab8yt2zTjN1FniR0gKoaX6xBU9IROuEuZY7iVYtHJDfvKALAVAahGlHHrFBRdILWCSAfoVI5ZcU1_lfbxoGS446Z8758yYwFBwZZITfjzl8OEEd-KgGSBsFjzjqR1Ff_1gsxv9c7s47J6nRGYUuiajOongMZ0M3mSWbF-Cfe-QZUJY7pkQ9DVGbQaxK93n4XjSN8kOQJQxEqHmfP_dxTmynHKTovaQvDAtYkeIsIUi0VsDhkFYDgDlSDCyssCyUNmfOHl2iu68UjDY5JbziCC3qJ8u_QgOF1zPAw-YLPIxIC-bHqHffcT8QhuwE5sABiIq34t9XYPuMpKiIVCtV12-pSTNz4ZMXE5W9R1C3IJ9sTdNjtgQm_xczi4vrtaJ2t7XFk36Q4ckQ-iiXQ2ohU_Ay43ZdzqkoZL_PTPSv9x9o-onnTYsJT0hgo5NsBbnJNa-iLHeyfuljsQvRNG_kmQle0bZL8ZGC04DIvQzj3aTNaQ=w711-h947-no)

Drilling each spotted location with a #43 drill in prep for tapping.  RPM was about 500, no lubrication and went to a depth of .375"
(https://lh3.googleusercontent.com/GEnqq1avSZ6fMncnMnkhnFXwfjFNLHKmnFmMf7habPjm3D0g4yzBk2kQYqvFIUxf7maZaet1VlKdhMMzEOSJ0AE5KcUwzqAYn90xQEtBxAP5CgKwuvlYKK8J2T8SPXrCqY0ov4bnsJVPdOTmQIWHmcHMRTonaCJGZnnzY4cPTIdgxv-GhRhZduebP0BK23XwArKaOhqSQjVkjmSrr51aO6OUfygwh3p6UR4zYLcrvSsJ_Ctb1gPytNHPomP9b8hEyat6CQgvdEM-c60BKoogEOFtfs4ML4zdSCKPtbEtZzvDmYGimB4iCuVfIGL4xdpZOVBNd5om9XHplf8d15oJ4k3RKtUivs2d_kXUXMZ5QnaBLQbJTIQBPwgjnFXaQ_0Qvx8hH336Je4AlPicN6yaXvtzH0KhA4zy6j21HS5RY1NGLDvxZrx_iP4Z_PfCMLRMbukY6ebU4CzD9DdfBJeNzp0IHb_k9UJBu0hKdXzLVhOOMhOdNy93u4DVLCZIvngUPGHtWMbucudC6NcBl0BoNYvwl9ihUkMENllW7jZvGftmVeAQPKaFxjIvbyvMRoa0MfEj7wCmuCbhMD0uuPPb-fB_KuubT7vH2X_mNUR5siWi0_B74beP6q1gpwxosO3acjm9Tqs5jscM9MR-pGIVoPh3K3c3u9pue8DHV-UxO50zHnQgqRMwHP5HVJFZmKox1HgoUSVWWl39F7qTCw=w711-h947-no)

Then tapping each hole 4-40 using my massive 2.5" tap wrench!
(https://lh3.googleusercontent.com/hXvM_W348VIzmF-8nDR78AIbnxZT9_4lmQ9jVw5zvq_EE-UQtuGksVftELvjXFA1m7ciyPk5HYZroZAvFWdmzYaBe9heX-3i9ZyU60UDc0fF-cheaKJVIZrYNSO7Prk9jRcbhlf0FFSIonj53Qzau1-UdgMM4CX7AYjE1BU_klZ7rvWQ4tvXhAHjUDaHbXCBs5eM5ayFGk1TwXJWjTvhGzFkDEEv0tDqJ-aoDRn8OnE3VrRl8iXYnbbrg-2fWknBjcSyUDEIbA1hxwxho5PeXEjdA-sWjPUWuMC_gC2pr4m2nR-vdOdhXgeW2yB9pVIGoN6WsxstznEaSIcuh5S8FUAW6nSIj4fYApb3TqkbtDkqRIXYlwua3EzGPDG0swGE-olONEg3uPY0yEQ69Utf_GKnlU0WEhGOm7UXOHEYnR3nGLAgAIUMZvf4DLK0i4dBJrBThu-0MYibKfw8ty_CbzllvNwTCQe7N4AJ0BXYoMJFMNwg9BmwHqjeafHr226G3TTwaDCzLgBPtEmcOT0WQntTfDWxGcPk0F329Gw5s6hFcaQf84lsWkOVPRzkPTown4koxmCx3Xwp16IBcqwe4uq4HzsEu8g4cXx_qrS_kvjl1k0-PyvmCtYQqfH4D-2CdgWsVI9AnK357uAaVU9K71N_IuJYQxNvrqPnKXrcJnsrXRAsalOyUSEAsUeeYFAFCANk-Nbl6BE0lifo9w=w711-h947-no)

Then the last operation on this end of the cylinder.  I milled a 1/8" slot from the cylinder ID to the air passage.   This is to allow air pressure to flow into the cylinder from the drilled passage.  I used a 1/8" 4 flute carbide end mill running about 2400 rpm.  Once I touched off, I raised the table about .020" per pass and made several passes from the center of the cylinder to the center of the drilled hole until I got to the required depth for the slot.  This worked fine and I could have probably been more aggressive but I didn't want to snap off the only 1/8" end mill that I had on hand!  Sorry about the focus.  I didn't notice that my camera had auto-focussed on the quill rather than the work.
(https://lh3.googleusercontent.com/GLeimiUJOTDK3qVfGGsXon75QWqjK6ksGMwu_pEBYzJ0MwrSeOzpRSUL69hRF8HyTY2Vl-aFatlzvdl8WnpihYJhhENO86bpACWWNsW9J74mwccprqGy6EKzBvR1NHvxaSTq-dYniHA-onTIv42uBFYtToTrgvT05B9ZwyfIn6efrYwRsLx_rJAYSPNCBpqLwlNSTyn_i4yjO7HUvuugD9axu13OuiyIrw7eh3ap8eywDCLlFhwpW41kSS7RqY7ceIvK5TYMzagKGH6LODzSVOULosjW2lO2ikvnYWhai9sxF3nYR4PiwGAFCW5Q6C4JtAOXbICCbKkgQ6g3bFgtnP8yFKU-h8FG_h9Ydxq45IVlHcqUCaf4OiHpYr8fSPiqyvtFfPY6eAGj2szhNGyLoa2G5lQJ151tXrvCnY8k_uJa17ZRj5w-XNyDQQJVGB15uvaKTDQXekQU1HcheUVeOeJiBaTlkoJepVSFuf_f2_MVD3pnuuxawGmqfw25TJ_1kf6rgN-wXpa1hQWgJRX079pcSSP6xzJBdf7POBgGcFBJ1aPWYbViaaqA4y7kfc0d5TjW1ZpN_TOv2rAG8dckvuty0Jp90H3vU3pVrX4pSIgBGfFWakVX4nApq9ase3foY_tPsSJwttTOFcnVhrxh9kvzXeRRiGwYQ3kqjWlHj4mwbxONTBEMcXg5Q3TgL9yT21-o50S0KGfRAJKr5g=w711-h947-no)

Finally a couple of pix of the cylinder.  First pix is of the flat area that will mount the piston valve block. 
(https://lh3.googleusercontent.com/-DEqVG1JQmvn1Z_WSzUyUR_UfHK8ZHyeAbdQD9wbYelcu_8QjN9vGkOMfAowBDkZR6ZI5dXhnAxs_H1Nl71CAoHB8ERzbiqDQ9t6a3YcuKsPY2dSQkSKDct8lqxb6MKy087nlIaWDk5oWvzYE8D8OAL40I7NsAcKB-FhrHoCOym5N49371c5X1UmOvprdX8CNScBkPu3PhVqEOWnKuAJOHnTO0uix3iaoo5nTS38XLCMSRQugBPCGJwPgEqRe60CL7UYgAeN7l1auftriGawovuSgcXROXfxHcxrjUv3oiC1a9BZLvSwmeV_QpEmGI90IGrv9JkVR9S3MbsSnwYxza3RpATtysZ1d6WtKE3NdgQw4UYrJTUlOvz3v6xGbRN08wLNjDhFSQkhMX9JB8jgboxYcaGy39mE2mldrV6ZNvRArrLQb_tDZIzbVX9p609wedFAxhQ5B3iD3mmB3-7apkpLI4vED9fy2U1Hv7S_ZtJajQgg3VpqfJbx-10a1mFOGLmhxqoZQr7RNevQWJHMPfbYOxVI6f5NAkpplfPi4WxaPx3L2bh3Km6RzlcC0XxKKNXv218PvWk1JSNenJz7971pkfrbNeXuungCtgWWvxsiKpCVk4s9GzUikL5dbQdNn2cWcND6zUh9Qw0qCcLMCpbMf5DI8YuJbIzKHh2l4wRQrzeXhvb_q7O-c2i4wXmp1DhDESmFYVhwO-ljnQ=w711-h947-no)

Last pix is the front end of the cylinder with all the operations completed on that end.  Notice that I've marked 'F's all over it to avoid confusing myself on the orientation.  That either proper cautious behavior or a sign of my ever-increasing age, I'm not sure exactly which it is!
(https://lh3.googleusercontent.com/5O_vfzIXx3KMsUVDoc4tSmCQkm1vGeCE32L4VJRWoQrWOpQy10EgDuJxqw6DfSvr-TYlzBJ4LlbIiZDn2hnjOXkBylx9zN4djTleiZEAt5cQfL2uLzni9G6b48_nK28lPNeP1O7TLEZ3nttFiy2ukY5fROLBDmkAYRoax0OS0njurtMqqfEaOUFeO7J06QlaC1A63rdImxlqz2UQWw_7rlnLF_uc2nGMQwws5THbiFdlKI5k0_ludiCnp2elQPsJBxyZd8tOLPQtsgEM08k551sEMcFeHmY6ZECSjQ0AzIVQmdfw-50YRDZzn27_MPAVMScPiHWalRLGxq3puqgLyOuWZI8s_dl1muQ3oQ9hjmolzNEurhwRSvEvNMkus42mxV3a0kTQ9zmPaYL5wgJJYtfUQgN-FhlJPvyQhu4nwMkSOO8JnPwllqTx9dCUd_8ANChhdDyI19jUB7EA9ApZ8efET3UVR3A9MUTkDIJBO79e_bOEARvsgobzXBT4WJLMxJ4kDOJSh2tD7iMn__mALOkdMRzWZNWoCKCFqrRJdUkZEmGF6zL3G2nTLpkzZE5rgNQGYZjSuLpaUJLh3VPj_3KbBBAFQD6SWmijvld0JSNAzDyYs0HCjfxSjZLj1pImxCNnFqKi0Ka0XnWgxSKGpjnGFjG4PD4ZsPxwCM3wA0zIGG2t5-RHNAgUeavuoQ0Aei6QaL4EmYgRjGrFog=w1263-h947-no)

All for now.  Tomorrow is a holiday with a later dinner with our daughter and family but I hope to get the cylinder finished up and move on to the cylinder covers, piston valve block, and many parts beyond over the long weekend.

All for now.

Enjoy!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on November 22, 2018, 02:17:15 AM
Beautifully planned out and done!!


 :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Kim on November 22, 2018, 06:38:56 AM
Your cylinder is looking great, Mike!
There's a surprising amount of work in those cylinders, isn't there?
Kim
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 24, 2018, 02:02:44 AM
Question - Machining a cast iron flywheel - What's the correct process / order of operations?

I started working on the cast iron flywheel that i've for this engine today.  I finished all the cleanup/fettling work on it and started to mount it in the 4 jaw chuck on my lathe.  I reversed the jaws to grip it on the OD of the rim as there's no way to grip it on the ID of the flywheel as my chuck jaws are just too large for this 4 1/2" flywheel.

The question I have is:  What's the best way to go about machining the flywheel so that it runs as true as possible given that it's a casting and there are some bits that just won't ever be true. 

Here's what I'm thinking but please correct me as necessary.

- Mount the flywheel in the 4 jaw by the OD
- Roughly center the OD
- The use some sort of an indicator or fixed pointer on the carriage to get the ID of the rim running as true as possible.  I'm thinking that this area is the most important to true up as it's impossible to machine that area.
- It looks like I'll have a little more than 1/2 the thickness at the OD available to turn. 
- Turn the available OD to get the rough finish off and close to the required diameter.
- Face off the face of the rim to get it cleaned up
- Face off the hub to get flat
- Turn the OD of the hub to get it running true and to the required diameter
- Spot drill, drill thru and ream thru the hub to fit a mandrel, in my case it will be 5/16".  Make sure that the mandrel is a good fit before dismounting the flywheel.
- Turn the flywheel over in the 4 jaw and take the rough surface off the other 1/2 of the OD and the hub and the outside rim of the flywheel.
- Then install the mandrel in the flywheel and remount in the lathe.
- True all surfaces with the flywheel running on the mandrel. 

Please critique the above process.  I'm slightly worried in that I did mount up the flywheel in the 4 jaw and did attempt to center up on the ID of the rim.  But after that it still looks to me like the ID of the flywheel is running out more than I expected, but it's extremely hard to tell with all the other wobbling going on. 

So please give me your input!

Thanks in advance!!

MIke
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: AOG on November 24, 2018, 04:05:40 AM
In my opinion you are looking at this the wrong way around. Your reference isn’t the rim it’s The hub. More specifically it the shaft your spinning the flywheel around. I would roughly center the hub and clean up one side just enough to make it round and flat on the end so you can get a good grip on it. Then I would flip it around in the chuck and take the other side of the hub to size and drill out the center. Put the flywheel onto an arbor (expanding or superglue what ever you have) and clean up the OD, sides and the other hub. That way everything is concentric to the bore and it won’t appear to wobble.

My two pennies

Tony
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: john mills on November 24, 2018, 06:27:24 AM
when you set the casting up you must look at all the cast surfaces that you cannot machine when it is turning
that is what you see after it is fitted to the crank shaft.All the surfaces you can machine in this setting will run true
and look true but you must bore the hole to make sure it is straight and concentric and it must, be a push fit on the shaft  by hand at least if it is loose or sliding fit when you use a tapper key or grub screw will push it to one side.You can use reamer to finally finish the hole ,the reamer will follow the bored hole .the shaft should then be turned to a push fit.when the second side parts you could not get at in the first setting are to be done if it is on a mandrel then machine the mandrel ,don't move it push the casting on or use locktite only move it when it is finished.preferable that all the visible faces were done in the first setting the rest are not as visible and are not so noticeable .if you move the casting before finishing it s very difficult to reset even using dial indicators.inital setting should be done with a pionter an by eye ,you don't use dial indicators on rough cast surfaces if you value your indicator.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on November 24, 2018, 06:58:30 AM
I always set it up first in the four jaw chuck and using a pointer on the inside of the rim get this running true as you can taking into consideration its a casting, then set to work on the hub face it up and true its outside diameter up then put in a big centre and drill/bore the centre out. then lightly skim up and shamfer as much as the outside diameter of the rim as you , remove from the chuck. Turn up a mandrel that's a good fit on its bore, mount the wheel on this finish off the other side, and the rim. If you follow this procedure it will be running as true as well as the casting will allow.

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Gas_mantle on November 24, 2018, 07:14:39 AM
Mike the way I turn wheel castings is as follows.

1) Hold the casting by the outside of the rim in the 4 jaw.
2) Get it running as true as possible at the inside of the rim.
3) Machine everything you can on the exposed face and as much of exposed rim as you can (leave the rim very slightly oversize for now)
4) Drill and ream the centre hole to its its final size.
5) Once happy with the appearence of the exposed face remove from the chuck.
6) Place a piece of scrap rod in the chuck and turn a mandrel to be a very close fit in the hub. Centre drill it for tailstock support if necessary
7) Once the mandrel is turned do not remove it from the lathe until the entire task is finished.
8 )Secure the casting on the mandrel with the unmachined face exposed (Loctite 638 works well).
9) You should now be able to turn all the exposed face and true up the rim across its full width.
10) Finally with everything machined remove from the chuck and apply heat to break the bond and remove the mandrel.

I guess there are other ways to achieve the same thing but that's how I do it and I find it gives good results provided the mandrel is made as a good close fit.

Edit - Stew beat me to it but said pretty much the same thing 😀
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 24, 2018, 02:18:05 PM
Thanks to everyone for the advise!  I'll get out to the shop as soon as it warms up and a bit and will get the flywheel finished, one way or another!  I'll post pix of the results later today.

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 24, 2018, 11:16:23 PM
Since I managed to do a fair bit of work over the past couple of days, I'm going to break this into 3 different posts just to avoid too much of a long run-on.

First up is the piston valve block.  I started with a piece of .75" x .75" AL cut to rough length.  I ended up with AL for this by default as I couldn't find any reasonably priced smaller rectangular or square CI bar stock.  I want to look around a bit more as it would be handy to have on hand.  I figured though since this engine will probably only run on air and only intermittently, AL would be OK.

This pix is just of taking the stock to the required dimensions using my old Valenite CentreDex end mill.  Old but it makes a nice finish!
(https://lh3.googleusercontent.com/UGtWeM48lQky7c_cocBeYTHy9hCbjmWmRcS_Zmd2mkr5ALfrK83p_VR3k6Cgc-B6LxWQKSIl7Tse_GRlFYA6b0OygCn6lFzMxuReWPvLFivrU-cdWVdWqbHwtbRf7ZRWApCfYwHDLqkJwNfDYcOeJ9Ncixo_IFP78qB2pqwIwmFuYcRrDl-b636J6YCfzf3KL9laGe9dES3qJJQUT7vjbWDjDuHN3-wm4eS33w4wzaa119MPwiCMWliow3S17z5SqOqujaQCJ5fv_8cRoxakOOGO84RIJa_iSCREK7iuHupqk7CdcIjlz81ee0KaPqwt4F4beAEX4K7DJNwY9Nrzl7OmcFupmYXbgAz4fPmR7-5HX5VDAzSUXSy5b0LM8NKW7ofqCDa7Hw5CyXRnlCNZV238HwvJm2mXJkUdEmNgPsWNvZDg4GLUxfObwnvhemJ2ygDJjTsVOA6XmIl4IFlZzfMZORroCG5jS6kGku9q_VuQCNU1oQKWu8apK8tHvZzz-CPwm4Ec8H78v6rOve0VoVEzUtwpTvgGCryZ4r4L3OuZIXSFUZast49HrYkhsV1XRZYh15CYcE5F1g-MlfMAdckK_WaTrQjx7O0Q22lEN7myHSWYzR6RgGgw17_z_4YcESDZj3T2GhlTzcgHHS3a0YlUACpqRoNlSdMda3FEyHI4oqxiIUqZWukbKt-LxQyqZ1WYwEKsSZA-cA7AEA=w711-h947-no)

Stock to size shown against the print.
(https://lh3.googleusercontent.com/6pIlG_vpZ8QK6QSfy2DrCtm-w9dL4GwgJaXGXtbVMNA4uI4mW0_iH6eAwmJNED4IcrLCbNWrgRUtLs_gK_hALgqZBZRsiQaATinOs971ePy7lJKD2dAHK-NTN9c6UbHQANGsTj1QvPRwZkLrmUMLtM-x0soTj8ibgmvv5A_YG54SZTzY_yy5bPtHfiHWGo7YpF4YhMEDuG9hdHIAXnGJzkoX8Y1Mp4zORF56Garvb_iVOKHqBhN9qOGgI-lnCz7VrTQZzN18Si8iR6UEi0FWL1IfA_g8_aRLo40NZPJ0z1AzjNQFmN6XePwVg6m0s26bRpHtC473Wq5suEzt35ONYQ_fe-XDqSqh8DNpdy16ygz_ueEarPacb4lbUC2JbYlK3SU-lnP5IWDUGuo0_vAdTW4f5TIQqMIbuErTFS_ebWlLMXe4kcOPvTlvi4D3peEFh37K8xebhQ8u9M7kA7fahVbjJz5l_9FYnVVzSL56ypm7eMmWc2BUP_mW9Klq-SjjmK3f3rxp0R9VJSHfGXgJGd3N-WU9lWvSi2jukb70nlrqYaUGR6Y7tGqaH2t4T50syYQN7YwKKLpm0nVdQqsQfZYPcOidL8hhDlYIbe6yPEcaSBf6bJx5doQQTpsaaTzzpPV1LN1wkmD1tNQkXJminJMsepSP8wPpTZtR4nM0hGaeOcETFTR8CtiSmYdUQ6SOI-pJjN9cN4fQau0T1w=w711-h947-no)

About to do the end that takes the piston valve rod packing gland.  This also will be the start of the 1/4" bore for the piston valve.  Squaring up the stock in the vise.
(https://lh3.googleusercontent.com/tM4lCPzWMnRnDKTKso9uIm_qXgkc6T76bnLkCzWw_2F_7EwQj06cjoqxi310G8Nxt6LA47AQx6oGBUPOd7-C4-4nJG6wuhT8O_TOF5Or4kj8Maf8SMeHYgmqKpJxK8LPuSbkaBhyCxGj1TDtE9ksC1n3ZVIlRoBI4zbm9__fwO6puS--8PN_GATIFfrVpKNeepA7CmagihGotRJkBTkJuNgQQfS71aZGytvf_yF-mAH_5RTWg3NuFxCYeivaBC2eOrYKYnfcFy6YReisjRMy6xueo6gNlDvOzSW1d9Ap7B-mqCmNlpTYpB9-ZIwEEH5mdMxTEvr-QtoM7-FxQxqljxhIUVEvfZdYK2yWesJ89fWeU9USeR0qodNeeEBXGI3bN8IK0SyF6tnC1OMQOYFBkBnp9XV51Os_Eoxt4zqVsrfYVbpVerKA2h7caiqUDPhkf1bY4xCfR6fhax3qVvkrqdHtQ0jerJ13I9dBeDMOGTiJHlU2zsCtp3jjAliAMA5znyWsdybHf9gdWTiwrKhWG8XKeIy_i5xdvPRMEpK5Ht5pJ8zTCFgJ1eVfO_LQKQftl3_nLCfGToyAkoPPh_1AgjsQBaDRlIEbUqNth9-omAVtusdI9Cl6XMOPA9IGFe3tsurs6XwuZRpggdFhKkerxp2GMyhtZKQ9Qhiw5FRUh_w5tvSDW0U359UNacCXlZPxtIxBtstPlLDGvKtmag=w711-h947-no)

I'd just drilled thru 1/64" under 1/4" in prep for reaming and just started drilling with a "J" bit to .200" depth for the packing glad.
(https://lh3.googleusercontent.com/cGyv8emtf8Wp3136lAehGdIhPbia458ED2BvTgD6Ow0H4plh3dDeZVu9eGwrpFHEhHCBkcAWMn5IEBydy_VFQljmWvjwPqonCjYD3dRxLVlz_sBwXCz9VSPfAKuCb1ltjlRqyw86tT9l5djqwrNzc9qLy4YWab6ChhAthhFeoNKSWV4lp-diFXZMKXAdsy1o2cFXsaj5FOKTr39QoALhnl53BDTDOVdvcGHsCEBqhtNRa4g9bUhwEjG08ZiLBxEVqUKuF7XtEt9DF79Fr9sDfY2MWsAs8J85CaQca36WXDK6mqYDYU0HFqrMbG26ZwudAIodB_TCaZRk_VZk8_fKHttuTp0FHHYZyxZe_h9mMGgtG_abQBj66gMPCOF4jYG_3rRFIEru4izF-Dv1Z0CB-Tu_18k1yBbRS8zJwMj5kSB9qc8PmpjFXIWdxbp4-ZwCG18YOz98k-mecrfg2sPlqY7WcJSIqFYt7b9qyQ8Y9JQM34FLzsYxu3ulmcbRcJm7_-iYZbeV66IqsZB7lw-Rm_83CFFP_1ZeR9vXGmQNDF9wyIMl9kmVb3X_1OxonFwb52ZYDQFoK4hXMcKunFvmlDHRV9FwBwA-whpNCWZTbjSU6adAjaLDS0Sw1wCp6VmJCXkTpsFSjhMGEmfV141MB963_lSG7Jg75Uhd6YOXp4trfa3GeCJ-5XLeWQlynUBkAB6864qxSX538gY8Zw=w711-h947-no)

Reaming thru the piston valve bore with a .250 reamer.  I plan to closely fit a bit a drill rod for the piston and lap the bore to achieve a good fit. 
(https://lh3.googleusercontent.com/XanrrjDh5gz-YyM9E7TwaycyB-XtCv9MFsoU_ClOnF5lahC2fVkG1dCm7PO2t3VYhvsP1TrxrLcP-aAjhaLVZpUN-k9KTnp5btgBl1xL1NcyPOAbD7Ok9DJ5KfZ0AS9vgwC0j2Un3oF_eu7_Su8rZE-ynd8A9XoLUn4V2ypMDQMquLW1CKv76UX26bzsKL-WXGu2teefMlZoRQkr7D6xyP9xX8zlmC3HzEAJ-qCvkrMA6DfYPPjTAzBY0zi3fLdBo3li1y3LAbE-QR_I-_GyYkN8tYfErNqFSpss_njuSlYlItCKUBYVhOAdx-zo2D87cqsGBIsnsEHRbWvEzAMgcrE_A5yLvNUgl3YWYRG0RByw3KWWdat3BR5yS7VNT3PEV2EpkeXxNvGGd_IRU2TqLoL-n6eoS703aGbzhYDw5kJKtXoJH3gPzAxk2Iay_VKdnDRcYKmEyGMtxic_WHx7jGqrBd2VwSDroyYzR7RjV0XaNSgID5wTGmFwzb1Fy-zO3iccvT7hHc94rR04oZ-BVrTxMK8ofxyvqpMiqLFEWoJLlfWthgVVpc9YalqVjXpvC7lnTT41qNIVBg2l50_MMx8957PEHYkE-_OS7kzANbH1uyAruVTC0Z0uGk7ZJqiaqOZV04Ox66soCspQzysfEkbemp7ffrvOaL6TEPXECqK3OscxZemVTENuK8IYvDvify18e6Pdxs2gvKfz3A=w711-h947-no)

Tapped the 2 holes for the valve rod packing 2-56 and checked the fit in this pix.
(https://lh3.googleusercontent.com/Ox-QW9j1foytRCDxSD0LEyWrLmp6bpEyrLpphkF_qq1rm7e4K2oJv6kqn1o3nGLOjNbCDmDBaJpMzRJdYi4olWYlyxIZYJfmKKxbXP_Qr8ToMp9SEydtIxv-p5EPJ0Fk_Yav1cPUGcdimLxpmEAmMva3os_XzWnCg9gpmbwlYPvzh2T5go1CkWWRQfR02T86C23BGKRuP2dLaKGem7IvHfeMFd1oAiS_ZUjjs0SCovGLIWGMl9ufJ8Sv_p-aQW1_g_GDkr8bBHrNfu7GGqnFLojx_nuIITLYc39Pm1Md5HlQPagP3WfSfOmnNR3kcKNhQP6ZBfcHJwnAw2sLGUBcliArbbOGFAswXGVcQ5p36DgRmwGWePMj_hw5_ZmkI9_LZn_fZqBwFlt__WgluRyeeiTrnbkgqo4CdMW8xMLQ-rAMlW8pZcFN3uZ_-PyQ3rDX1bnGQSuMQtyC8jmUAzpMjny_4sfNPh5ACVjtcG88YvDw8kwV8PTkNHsOsLTCl7GEbOyl4MKH1B_jnTkRLr13kOhYeO492vB4N5r7t7Nj_QV7nHuvaOv0RpD1PAn-T5Wnk9PNIY45Q_xNt3voFOfiA5_UF2L0G38KrAkMng7LzcvUeMYtrOL7KH5rdwi3v2TlaCmaouc4nGGN3Azft_WtFsTCHsIy4UhCelbIS78WIyyLipnHAjKBF4mFQBOBfU6o-0m2UvqgBanmyKFhBg=w711-h947-no)

First end completed and shown on the print.
(https://lh3.googleusercontent.com/4HfLkvuzAxTU-6KVJaByHVTKFl7DoTSGTXTy1eNT4ZcJ2-K_c6_Q9gyge_uNEzbuHLwPjClUI9wyZUF30Gy-J9vzsHu8ztPKVJvjDDhklo7yP6ilxiGVF2tsO12_g1f4PPIZVm7nLW9GAXVnDYbG6BHKmxM8tr9OhFl3Nhw2Y3DWjzheWkCnaU0KgENjFXv7tFxlX504zDLRoZCkQSoT7QF9C_B-gPTP4tl1gt9RvnUxTze-5B_rtBGjJvGvB3eijMH5GxeAOUpt51GH83qd7rYcIVsGyY-xYbcP4xQSGS00PFZ2-cDWnjjkdZAPfxD0ZkXuGdPIyABFaNVwlv62Bo6Gb12yrld192Swe5Qc8yw7rpJAX3Z11Ih09Z32E0eDf9BIXk9i5jtgHRHKQvl8s57eMR1xmLfMdnIq02pK-puYR-VrFn4a0n8hkRQjX67-z86gmdaT2oOdR8OrbKooBFWaPUNNYkHbt17qtWxEIKj7ypAU7wTjCx6zd11I6kik7p10Qu0okZnWd-hnzRC2gtDlqB-wnGCZU-chN7P2Vtt-GxRbTL0jNsjkzbH7_Gx5zUd68sxqcJ65GR3iTdogQBPOqt9U6M8oJ6AIxs9z3aTARTUj5C5rPshuKyDaufO7OXjZzvkMLizrvbc6sqgWm9YBN0Ro7zteNxTpPFuRmMmD_w0M1jnh1KP4yzajAKbAvSkvRXfgjP-I7xS8vw=w711-h947-no)

Starting on the exhaust ports on the bottom of the valve body.  After edge finding, and spot drilling, I just drilled thru to the main bore with a 5/32" bit.  Worked fine.
(https://lh3.googleusercontent.com/q-0Um3T4iziBKvwVjcEYdmytjLV08fI9Of_-Bd_UT7wD9CLiVcvYOUilWnsr3i7Iq--lvkcDhHu3-YvPzm7iqc6b_0_Fc5KOg3Y_gUOn-uoWGGDCNHC9K1pZVuutqeFBg1cLAnGtE0pZJOTKB_K9ked24OX2r6Jh46UCTM4Xxme-Jg-vnkjIRxUE3RdlezdwG37-Nrbl-ximLmkj3_RBRW7vgJGkzt-U0sxQOoTcMDdZa7MHk1hDALCJAhpNBfqFvyrZpzn2Z-0XbYKfzcCvEJQhiXFEC-81Mmr5KSScFMUWZONIRupg8DsztF56jIhvVfmGXuBpWuPA2XKWHhg30_VNOB3wBBswPDQdUVC8uOmSipLgyyReWFMqIuaqnnC5S3jp_L20uzUMXwrc37wdmyT3rTJ0ZaPNkWC74wath54qLuDccHC6yYjx1kuEeHQlNykALlP_etnsbgd00HFW-hIrAA3vj4t2apCytJwVRmpZdc9AvrcTr3R5tYL1auiRLUHZxoO1abOxMCGqNpMDUtBwApj_PS4nC1TtDilO-nJLVpxntfJZfJ9ToA3Yw6dLyB0-dnE9vuH7zfqS8QUUvtYrmYihUT0IalGH2YTRmNm9mH4NgvP9VNX24IFmN753GMF3DI8_SrEjmo7d9OTXZs4AE6Y9Wu8i1t3arMMHnJTT3fJ6u4kXYrMKWmJ2Xs-cYS9sAxbX5FXxCnv67A=w711-h947-no)

Just finishing the air inlet side.  I'm just finishing running a bottoming tap into the air inlet port fitting area.  I'm using my typical setup.  Spring loaded tap follower and my smallest tap wrench (1.5" long).

(https://lh3.googleusercontent.com/ugbn_eltz9LVhBQqi-c5Pe7lQhLT_sYAHiNP5AZRXbk9zDbiR96oD_aiOSshrqw6eIrQhS6JXq_l1DDYDyCzqedbw0qUdxJb1tZHdDzoaITRO8_e5m-zL-IQC-k8EgBA7LhTs7KyKdlIuOwEaEqCCME_6f7LlIXWyHJD8K5sNZqGKYvZCTfDN4tUoJNBTx5Lt8blvhpRv8U8slmbNpanwZ_CwaPCs8xk58tIovUOiq4KsH6PTlb50PcmtVcTEonraYSrtQVgdkO8Q2Cdo-HDMtxVR5xuBQIiyJncvo22nS8EYtSuFniymhdAO5moYOqbMpFZ9PAM891retHqc-uidq5SF6Da_r3Uik8Pnv9KYQERzq8f-JU0LppBpKdkWokjlJt-ng_Ni8JdZB8d-py9XTE6dAA-71yKqCQfsRJomUw1aX_ArMzlt1kKODc3s9Wl-uJVD5aGgf89J20tMJOjd_nMOue8r6CdzH0ympXmW7ysXnnPuBRdsns0sX8hK2rA4BUmaIIHvpieA4DxXNJ_DQJlJLcYkwX-u_mpP3XJZU0w5n3QeI5h6ThUH2jB_ho07BiZ9UITGJ1yNIxDAOjTA61zhskKcydljjkv9pCJD3zd_ogxXsUGaf3TsgzYpFBXnrxphL01RBXVB2dPWRq1Six_DqZtWTVs_3n7Fl57AsMm9T2GkWrmd6Qt5iqwOHbZQEFuSG6JYQmj_F8dPA=w711-h947-no)

The air inlet side shown on the print.
(https://lh3.googleusercontent.com/yIAZss0kWuwHZX5srUndPY2nxStQ9QMyXX8HyKkm1Xk6id6J7mXA1NeS4AF2L3KvfnN4KT3NnXrvA7entkoQWrHTLdRWf0Whuigrt_EOUnx1r-uFzbrF0iC4_od3Jbcurm7Hb6vN0hM7R1oS1MV5tcK7Ac5_WD-qXu2ydnbxnQrMkeIRoThyK4ehKTy1fIgBTfXvt1fYDLgNd5XC0H2i4bi5oIWdHtEM0VieaIKtnoilOg4VTMR7y2upE4ROXLxiXqkHuzkM2uOM-ZiU6VLFNbHLPzaXbxj-aTTo6nCSttT8xqYuoOM1itTfC65AN8sIE9T8veSjfF9o-ugZJiawGWethGKYqwwQ4NvSN9cClmuoHLn94hQtYK5aVI41I4nBSE8vwM_SZIf5fCpapyAaSTJJIthzn4RRb6K-BBd27ED2WqYkdOmMnYBJ2gexj0Pon88ck7WwZeuCTtRDXfe8lIUSddXWjWvtz4lxZrbt7HWqXSCTehq7GtGnoFIICH7ZHKH8fZgZd5fX4rPRXjFr2Bitqhw15ugf-JvwFA2d_T_mEWn2mnoRuMfKemM1cGlSGTSg25Y2fBNPOOwf_dF3NqufKpjEaqjLPxGtRKEY17_hapcJ_0qWFCtJ3LmqKllWw7D2rX2bmCQnVpzKGeDruaoYJ4tyEPMLBEw2s4D1gKAKwlYhz3h9nIdEJfe5U7YauMgPY9_1np0OoliBSw=w711-h947-no)

Starting the trickiest side, that is the air passages to the cylinder.  This face will also have qty 8 clearance holes for the 2-56 bolts that will fasten the piston valve body to the cylinder.  Notice that I put a black mark here indicating 0,0 on this piece.  Since this part is machined from all sides, its important to make sure you're working from 0,0 on the print and that changes from lower left to upper left depending on which face your working.  Hence the reminder mark!   This shows drilling the qty 2 5/32" air passage holes.
(https://lh3.googleusercontent.com/6d5wxwkucJy3zW7-OtGltJXdE3WM6rgfYmSd-68DY_0sqPJNVfz9OzkQ9NMsa-0Rt1ytfBK1hQqa2VMqsDkZa1FySDWHMyCUJTKRwmrzqiDfy-5o0_2XyGW5KsjKJLNjpv3xwSuB9q9K5bjfWALzsc9fnL5ymwv8sMus7Gyyw3iNFyPnPSG_I4JVBs7ieOwkmnX3x_qDyEQtjv_5zq22dXn9Q68dZgFYxk9z94g-R14eydbaY4OZO_9aY8jUAF8nDjH3eufAKUK3bykdltlJIii55VcqWzdI0mkQZvQ3Jpb8g00izB9DOxgU729I67GSpmZsYbRDDJKh-8PWeRASU8oEBOsPg2FIH6VT0yYANKgs6EbF9hlDkcR1DMOird2Hy0t-Tmmgd52vw1KPe_zLsOkWS-DaXqy6N3Wa0LMjnuE9o9KORGl-Fbi4tHC3Qd3I8FfIq-u7O1X1inTz1E5KA_tjxrrnVuDfkw-dT4WjOD9xg9lVnQF7oSPJYxIcKmIR4wBZtAQg71J-trLQoVvR1NU6JKCc5iB1_6BdSQj7bL0MjHQWe9fQrof65s4WUR3yK80VLG-FLJAgmV64iWDoEDPvWFZQXrjvb5OefGyB0qdF0-UnCOqtuvXhH33Yp3LW1Bu0q5M29KJ8V2TLM0QwbwHLOo5GE1YxHl1W_-n3mi-g2LFAus_WtogqkheL3ds6v-nBZrG6Ob05L_AbdQ=w711-h947-no)

I didn't show drilling all the thru holes but it went well.  Just had to pay close attention to the print and the DRO as I moved from hole to hole. Shown is one orientation on the print.
(https://lh3.googleusercontent.com/tNmZruwQB_duZIACdTTlVtjKfp349rP8xBxKqVv5flw87lueiW4AlJtFJIBPwK2XGyHR8OgNfbHkJC_3te45JmDAkvilrtr_3a_mdFPNengTfXoteOsEkKUyJHUTQMfiEp6rCK4d7SJYfr4KPRxWf7wva7OovApZGlLsHyOPtXJrdk9KnTF5XsPS19FOOxmh78xHuhz_K5qf_5GDmdR7YMXY_sTuZzmvFF-TG1j37bjCfdIVNEl3IePRf1DDmX_-ZnVTla_blKGPCxooh-aJmuN9t_NGMVLNkETpuizItim4Si4aktT68d6W3-m3wRT2cmUQWwHW0wZmkf8hM3uUhpEVANJcNWcugVxwQFfwGAynhH36ihvUbVZXj2ncSptevRPLao9_shOsh7uWdTc2aqOgztBAFxSzlk6zvGWY8Y2JeCh7lCTKpK-R4v5HCQ3L20g1rUOsMhDXvxTP8pOj4jut-ESvsk6YHdOUOPiUcASGotcPUPyuC3Gbo5TjxxPu8KRJE7UWMj2-1W1MgNcckyHFUhgs7UVPZYDV-BCRe7VmX4O78Fc_qpk6QxPvat6eKUtipS9IBzEhkyBwe-GBDcU7horSdPduI_Iubbhxr2xlc9NKkbg7tpnOOGYUZiyItNnjQHOiDUnWom0rkliF44jHcFi_jrI5_MpDYjMairZGJxkepERSCblOlgoa392DHGwugjd77GTVVuhMlg=w711-h947-no)

Showing an elevated view on the print.  You can see the air inlet on the top and the piston valve packing and piston valve bore on the front and the thru holes for mounting on the side. 
(https://lh3.googleusercontent.com/pxsuxv4CBeJm4iaZcXrrqJCF0a9umPSJ_TP0OKEV9S4cxzPrCMuznYCAd4dmoaTgXhgfJcPEqNBjfPWCZ14bUPVfNfQgHLXMsLj_F1e92gdRtBNwaA2mybuvYq1gnq2z2mqEuZNP4VsaYRNIaiQW8NqZqw8LJUlDMsRs3aNnoXSvFc_W9_Sk9spnPaLiMmnvkwpKq8Pn3gxnVMSz4l944a5m5R_UR7y1xdejjxLyokdhz2CAe0qpqXWE69J2KQwi3uD_76SsA_KW06VyT-0d8yE-KeofM25vpiqI2I9qSqbNlswsUrz6mT2sPUkezUPF0BxhdAx3uQdlnVUeisdtbLZ5LPScsU0Ks6tv9AQiYnDFN1HBKXHhsu7qenok6E80m8L3wJNrvRQy72COa8Z1IdF5bX9KmISWAeQ7YLDEkQHuqh7epJbAFQiQ0_CBckmDzWuzR9ajPBeEmO5L34rULUskFCODTnKcsmtZ_7_ByA2qQbyy4OUpkUQMzDHpFQjARqGmoZsjzZbyMtFeR7eAgpLF-gHSy4cK_DNOTgKOA-HYuKf9sU2adU6UHig2Vruorohv46TJkTahI1SXWxesBwig_xcvn6-88Uf1Fhte8R36KjRFo32Cg2XWRjMix35zcAibME8YVAiyewatkKIEffAF2v4DxHdYiLatFMPsuOMc4uONu21ZRQEc49ZdNDfz7OcE0fjx-1D1FAM4LA=w711-h947-no)

So this rather complex part is now done!  i did a quick check against the cylinder and it all seemed to fit correctly.

More in the next post.

Enjoy!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Ye-Ole Steam Dude on November 24, 2018, 11:44:37 PM
Hello Mike,

Some really nice work and documentation with the photos.

Have a great day,
Thomas
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 24, 2018, 11:48:30 PM
Next up are the front and rear cylinder covers. 

i started by mounting in the 4 jaw a scrap piece of 1.75" OD AL round bar that I had on hand.  Shown is after turning the major OD to 1.375" and establishing a 1/32" thick centering feature on the side that goes to the cylinder.
(https://lh3.googleusercontent.com/kioXciE2TIVoCPDbJjkPkgRDVbDDo7Ig-v7HW1eAAMfCf68QwOZahRUNaVWVJUZvwaR5YgU-x-Orx9Bsl0PeKR7JMR8MZZWnbS2dmBXjrIRf_8YrERMUnezL2i7-oYJaqMaY39YwV5VjpHbzK7Sd-MU-92ExHH8ZcMIkA43IUCjLDDtCWE9xbga2DfMibjrk_nzdbpjMyiXOlA9T5m8zXfj2RjSV2RENuz6xZ7rHJh_8VshM0rOrI86lMjXoCInobncVPwpjHAEvQ6lVg1FfR0kwH5O9XW9A-mirVZfDnJFTklHeT-uNZtbEiP_-Mct4hFY6WtCyrVAD9fO820bALc7P3ikWgJEIXCLxAS3zWkaMrFi8RwTv4D_24zTyHWmaGwLLQ4kAwR_6KIT4jTghGmDfuusWPT4e3y8AgHS5SDQxeyIwsJ9mRqlgPIIPXlj44bleUAzt7K7sZ9nbtHXD1CjZDAKBW7-GoAH6qp5_SUTeJTJD1TyUXrfEEDaVAr3S2RDM9VP5RM5mSfpAsVv7bvn0_Bj9GSBCF8tyXoQ7qRGTcveK5_2j3BNBSQzyoF56WbjoL8ouuRbLKe-vI6z1CcR9OJKSIIGbgH_CClRa1ja09g_bBSxPE-wdzC_K0n4GcFIiuP5yMGwB42J1VTMpbef_ToHWpa-xPhSySMrFSYAdKUj_a5yHKW9bwXmfVVvI9Jn3WJe_5o9Wu5uaLg=w711-h947-no)

Then i drilled a shallow center hole on the inside just in case I needed it for centering later.  It turned out that i didn't need it, but it didn't hurt anything either.
(https://lh3.googleusercontent.com/6It-xniAKpSpjGe2egGfp6e7a-yRQt-QO-BuQx7r66JxJoL3TXaxCOaUnvkoR26x2QrWSjbBw30RZHxo-usVzr1yxNXbRjDox1mcahlplIKqbU5vItAAE72kmSgugdQsih2pqMrHtcZSm7r1_QFFgXIHQS3wBNPXyueYScYxKztfIvu9vSn-cMOCKiVueoEaDpUVPdY0bZTfQWDmHZO3eej5RYF36OEiO6IUGirPdn86J7QWEpp27exJZKVVPAy_VoXpYx-HR8ghWXQRE_kclgcB5tFHtXSn6C2pWs9BZeXV_Ee7v5SanVYqnBAvw-PeI6vCo-uIUUTYzBvNtyhv-eCl2WYWlR7jUpKe_cd08tEsg42M1iN5QMpWEyG2dHbJyJt3br7MkOi_iEKCMRS4HeaEyCeCgQCH9WTkNBLTuKQgklfJ_HszTCB3y1emMDWWC-jr-wuLTMmkE0lcPUKkJiGn6LsNtiK3fjAPpo3fGB31o3Sq137y4Wt9lToAs3LxbrsoPpVNRrwHU402gdkyBASilTBoY3RnL3C_qPkxLBcbpnbLMRlis3AQbovkUdegrZYoPn58BzaedvmUgbpszKSR4XsU5BOIFd1rIubIF4F2xgjwToCxavGoS7vtGSS59r6DKrnMfwmVDttIZQmJiQBynUBCQRjTbfDRbm6Vl60A6ULl-ucHWu3Gpf1E_HBfSro6wYd_r8mwuJa6dQ=w711-h947-no)

This is the cover that the piston rod will go thru.  That protrusion will be threaded on the ID for the packing nut.  I'd already drill thru or the piston rod and I'm getting ready to drill the larger hole to be threaded.
(https://lh3.googleusercontent.com/bga2t5jrcLrWWc3DgyfBBeN6_bc5uf5EAmiZkWqzdCGDDEgce63UydUNKOOI9zLacDY-XiHzYg8eQAkrAQQmHylndYkWeBS_jZkxY2rMEFA2JUEe4rhnaJUuTkewb1oD6WAEZESGCipRysnGQNRJLTJsznvP848Nz-LFUp99oDkm1BNHvczOAhM1X64AVebmH9Ji9ikrF9FXeQAThAmR16jX2LhlxajboaqEDazR7WLdIBzPT_bjIX5yTr7ppoHu_u5OoQUp_9pHJqo8ZA5ws6B0BizgECcRLB4BTZMAnlDFvPmgecNlNw50TshtygkSWBtKdFQr7gmQA_7tu1YZJ0-Hsu8fKma2i-NgX8cpeuPyKqXCP2YT40JH3jtDoSe0_VXi1uruvEaAnGTnRIbI-jxOh0Zz50XeF4yBbt-Oh4xoNWBVzyamAa1bCCCmuqppxwzpBC8Ov5wrHf7TR18n2NblYunEBt5hp2uSH77jJ166HptfNzDNufBRCh6gkR5OKpszzPO0NQ4oUuAoR2zxWh3Wrv7lW6CduULnSwzVplzU8Isbt2rpL7gRDTmjaHsjZmKaWS9y197_1h-tRtciFagjT9lnnKVbnTJuo_PlmHajpLwevmxzUn_fjuHVtp3CO3hXTt0vgPOU3QJ7S1QxG5wvxZ0Op9M1OqYduA2JjvdSgapaAZ4nieKIpAfzGOklwLzaCcIQHKWxqbJuNQ=w711-h947-no)

Putting a bit of a bevel on the ID of the bore just prior to threading.  I find this greatly eases the tapping process.
(https://lh3.googleusercontent.com/FEeUnRE_luAofcnPJr5_l7tey5Pc_kiZEUfWXBgpWFHjb7Uu9zhgEFKMxmVBPX7nxFg-NlkPzYtyM3JP7eJrIUw-NWWDwW2FphDgYrvKo5bIhlLBmEZMxxirOlUwpkCb8Lq8W8TTwxeqARNk4m0bOEb6jeeZhu-YcI5WEbanUOE_PWX2Xyk43l4UN4nhBMFs8mqAofzafoQkNZN7onTJuO5814ZFMDxmr6HUIbm52WKiKcMzVp8LWuQh8kbV7i9KgnfO0H4OE5Wm5t4AvxM4GIcH9gXpp4sQ3ESFaoVaUPF_ETeM5D8_0aUNQOa_DGl9pxmLaEloPO9uwbI8uP_7x6G6DeWWtVJlC0xz4CrZtdNGG60mwldfuaM1p9TMCz33l0WK9UsBiI3leVhyDhlsHUnRYnbwZFCRWh98-sV8gByyfnnYmCzsEgft0BnQ8tYfd4-2u0LN_4aIT_vlLepJBMNnCXz4KnLGRzudI98TfJdSpZvqgalFhUdGkA3myQfxwWUGm25LKZa6Pg6_ttpOqZ4gNvN9zUQm3JH9LydPBGmXdsLyEupBJ6y01KWa9tGAEmOJLIYkopuLGXqjKdVQIlMFpjWfTTl3IfmpwdXpNBhL-7sUeSuwO1kZT9L4oKamT9sL03O3zIgkOolPCbc2Fd77x4q_aK5WNaOnn-s0Sy9jBWx5i1QKLUDzAKs1slD7hIG9vpjN2Vjrz9vQ3Q=w711-h947-no)

Tapping 5/16-24 for the packing nut.  I just put the tap in the tailstock chuck and kicked the lathe out of gear and rotated the check by hand.  I'd drilled for 75% threads and used both a plug and bottoming tap on this op.
(https://lh3.googleusercontent.com/iiChS7x4Xk9hYXs-tLo-6QdVBxpcltiHxkiYVwAyOoaZRC-3CUiP9EQzIUy9RBFvdJVfErSIPpnMMhGX7BfLsrOEGpSu6Nok6k3uXIOI3lzJzGEp_mhhUQqg0gGwuAzMHlmkwx9WxseiTy1A5duYaxkM6DMG3KI-R1uhGkbm4rqHnPJMN_jBruJD_mvfHW1Ta-XS11JTKvnwndg3Pl-T9n14y5J5sTsk3icjxyawsWnllSKJXzIwiKwqtT6JzwonC5rl8UrO5g9QvnjZsqT-9zAyryMz0Q02sCb1s_PW_Eiilk82cfKNwU8aoJFTC3zeErf-jJldOY4CU81GUCnIohffrQttn9ycbCGb6WUOMoaNz5bSjZyzFSzS4KCTo3WxUEpzYxhdjpsdH4vjtIvp5HjZR4BSptyuig4vJgIsU1frK1e31nJySuAJq9lun34GbYOIgAcAlXtgSbkmFl7--Njlmkkj66cE4EU0Bf-dBDrVdJrErM7RCcWAJwi3jl1d8Bj5q2CqQ_XIMU-_bnIkFqEr-5Lb4jeb_K44kYyG_swvZw3TBK_uBbeAOMwmqcJFqFBkhCJ2_f-E_yBlxiDecos0hN0xTzOU49AZ1mK5F6ySN9b9PtW2_fkyGPCADNVC2rztnufyD605wkNn25lLCVn1c_qmdI2qP3R8q3w0gwlQaP-PfXmsOk2A_WqZA2_liKKE8_CPMjLFfvw9AQ=w711-h947-no)

Breaking all the sharp corners and putting a slight bevel on the edges of the cover.
(https://lh3.googleusercontent.com/JEV08dfaNc6q6a7X69tl_ABFNz5WMy5HDfLK4rFE5_L6jY2o4sCxbEi22C4CU0I5T4T2V5vsJ0nklyKZgkws1KzO47tYsphb6JSZEuMn99H2VGJ9tbQDsY85Mi24aJzBmiVGyYLsb6yajEwLYFG69JzZtm7AbzuhlNpDtbrR3M4INGvb6nrW-pC0ZGMBwC6f7lHMadyFRDhCKLZYo4bICmYgtAqIC3D2gwSNAI1Kirrqr5tJkCXx64KuTH2SfKr8eGafqQMJJIPFA57lDasjOk-HiBT0Kb3C0sCRDLv0i0HpsCR9tDtRiswvPOCzAPG43f4s-L3JvfwVyEmYZzXhc77h4rOMpNl_3PvuJKg6TilsPvjTLQtDZFs_nbdM-LU1rrO5zUtO4c6o5DoAj3F-mwQyy2IyL-OB7GyZFvYMY13jhbQJ5_l9g4Itac6L36ViMRa2vy3u89CD4zTgEJph8PORrSzqUH8DG106L6HWmt4ZTA-qJ9dmkNZDrLKs-TeZY0YHCggpg3mjkT5pOqzo5K3OhMetVSwIGf1aCJkYun4qEmXcSof5GVzqPW-kjfPUj_LK2sZ4WYP5ptXRF1X8nUOzccndyfe_ospcwbRHGSF6Kljw0bG9XstM7guBja9k5uNPoSIZ0pM37MawtptFqplWFUOS4stVMhgrjHuRGNO-4ykHjW2oJ4abFRcCETxyTQyHkPhixQuuip3Dzg=w711-h947-no)

Parting off the bottom cover.  I did this dry at about 430 rpm.  Worked fine.  I left the part a bit long as I'll turn it around and finish it to length here shortly.     Parting tool is a 3mm width carbide insert type.
(https://lh3.googleusercontent.com/S48fKfgBSqrmT0Vae2pMA2U3Ts3Oj8c_oqdhgoOGtbwkU07bEcRIv2MBTTimCT97GCQhij_FKGAYNkW7HMuvECFoDDZ5jQqOIf1FOsJn1id8FAdNC5BhMA5TuCNS_Bc0kZ1Ey3v4pgL65bwKPxeBzujpZ8KVQV11jcIYM5YuOMnJm8UEIVIRG3I0MdRz1t2ut8gunnr9yhLez86NCjoyjX0qq1SyZ6GsGxCRcjohrLugr1792egY-cB3c36ELfaKF_U2gIKysQ0zkoeeA2FU_ueMcGs7c2BXOAjWWVo1DB7TLRMchb7NnxldMJDT2St0XlEh42_CbM00E2W1dKxfkqveZh4rDfHVL3J1yJ8OREJST9jaG1Y4mi_ZUMa_VAov-FFXRhlKt9OseXNO18PP3ujSsLFgvoF_S_PD3-tk_DR52JtPi4akUVBQLFwV5DurJrHz7LUEB_6zGM8awqyKJIjymgcfgrQ3RB8hVpkl_ass0DPgFKMEfrNAHBRrSq944sMA-1uQUNGoOXQikiFNp0K-8MMUrSTlzl25U4X94T_qT1UEulJpUi_3210x4_KkoliniNsaQM2-6FaBMCC5eJ45dQf2Tf7kF0Qj3WU3W_x8dJmNN1Iuz0w9hJHLDqwp9rAtLNdJiCZ7Fu564mw_OeZybhx3YbhzPrqptgjAT31T9xGCiIW4lLkbe3A8QFklCC6yKm9bVDOXxirIsQ=w711-h947-no)

This is the cylinder cover that the piston rod goes thru.  I turned it around and gripped it with a 7/16" 5C collet.  Trimmed it to length and cleaned it up with a bit of Scotch Brite.
(https://lh3.googleusercontent.com/WveWZy5WoSyfusScctIt15-dWh1QJ3NqJRo39lbw3YOEMrLOYq2C7i2XWRBzaCr3e14KjdVsxKi5CnPsjlGm0741KPu7e49NZfU1aqvhwPWDhkUs5AzEABb_jTaJdHj53KI5PqmrZCvEJBEY5cAi_uMU3Bd-5AIrSkY67sI7HsMC8MFNXAB3ewHh2xCtvtxSCt1r7oXNEyY0LkgtpjbHjVphruRTySwArIoxcVDp1-hzNJkVW3yqM0-2tc0dWUpwFgk65jITiJvPF3_xAWRpZO6NZcSHSY8MDCB9JLEMzeyKwrIUxZlDizs-YIHHAyYNWWfYCKl47MQ3RGKW8iB8LQ6XOV272JdbzJdyi6ctZWGUfMYAJWQDq4M7S6wcc3HUawQFd_ZMptG8ATIECsCgxz_c7LussfaNcbesCIbaafKoha3592WgEPndVi1wFYUCZYg2b8NvmGUjEY3qIbPA5WwhTT_9hEIp_XK4O6fiZaXNf7jV3hdJE-xsvAzkEyRKahlCA6Rj8v5T03g-Lk1JGEIP4T2vAm3c1OiyGujszDPUbkkdXThUX1NZj4vfYiD6PVdpBgGuGx2Sfi6AJEjXxXhNpIcjcEm0AlqMhzK7SkIg6PdzPBkR39a_8hMp4mkSjJZcmwJS0qxVDvmPuMS9tjcRGsR5aHAG9hHW-dFZO1S_o2XZ7cO7tUYq66PnCSCjS684_kn0jJ-7QJRtIQ=w711-h947-no)

For the other cover there's not a handy protrusion to grip so I used a 5C 'pot' collet.  Shown is boring it to 1.375" ID with the little 'stop pin' installed.  The collet is tightened at this point and brought to exact size.  Then when the collet is released and the stop pin removed, the part will be gripped correctly when the collet is tightened.  I bored about 1/8" deep which is plenty for some light facing cuts.  These sorts of collets are extremely handy for some operations.
(https://lh3.googleusercontent.com/WSxwC7dT0XVSa0KuqL5QjJUtfb3XqIC5C_9IwB9fnvfrQP96hFvuWZB_hEqhmntia1y57G9eMO4BCuk6YTEbTvVT_7SHQH0FGiyZp_IlwTcXQeFTghHboQJlfv6VLcJ6hputUUgbU5G1jXTygZGsRkVsfyaW9eamkX9qSd73Ors8LdBNanNbmR-fw-pIqwjymyzS13HSPDY99C7Q2f-b2UMhvtF495KtqxmllKhmAIs1bNC5CRfdbBugKexj10AmXgwsoLCHqEd9L11piGQnhtZ8pYmH60vXHwWbPis8f5Fhp_VCELrUKGe7k_J68FK9M-iMyuUPPRMQxt-q3HFcAFIwQDuQSHC5Rxk-ofcuFBNnYWTPgpGQ2wy9pugetJfhttbvT3VwTJq5Ck7inyaxwC3mSqvXJy_QAv9hWMyuOdP4NizY0857AElD2YNrjEQkb5tntCtBsO6sYUpLvmoyHDRwlE1RsZdk_njhQ55F85EY62vTt7_g1Jdj5Pb_6PQb3gs8yhpsskaszsgphBbigBle4je7qC86lYxVn7ZMSnd65rFUu59NpS0YU-42zgIR07ZAiT3dxMPmu090rqUc7hi-X1rUPPIigNKZzThXiZJdOtJXYfRHaD7Td2dUWl4tu7_iHqu2y-y1nolHKAEIzwYpoCvoxFUlE2ftGqtCqx0d5Woa-06PchZjIg6Z27Uk39OvBpT6u7r_Uzy50g=w711-h947-no)

The cylinder cover installed and being faced and the edges beveled.  Notice that i have plenty of clearance for any ops needed when using this sort of work holding.
(https://lh3.googleusercontent.com/yGSd0mjvItrlrbp27YxeCr3T8mTfWmmHNgCMgaePenn2WfSYrKXZgEf4LgkjH6FHtp09BAF8XA0rKukVxFCGesiRsjj9EADOZWrC4XcPXxoJgLUrPsxklOP5vZSPVXsNui8SnJrxmKQw7WeurNGUOAR1HAjARoOqUKTs5F15pAVFvKqTCGoWkAmFXS5FQWYbhAzXNUiy16EOracttVwH3oQAK_j_gBfibP7tuRYJzfbddo3WlveB0w8KtsoDQJW7cMvhfMPFfgFuwMulh122mNOIUpYjFWLqUZbs4W9dPMzm04YcL8LFB0o9vIu_TgG6WzzHe9JV5Y14wLAMQsGumwebUBZlKuA5Pdxl86d0AytLAIVu2fJqwjAUaQtBbma1nv2fGpkHOqcFVJosW8nfkrdnA0_eM-oGGmr0ouLt3V_M6F_FClaNWTkL6YzpI2EU2YIxznPme7a-Da5XLJ0CnwbCXq0amVriNVnOcAl6OETbPmlQfJc25bEJCXIUOYNHDeYnmWheDGAcO_acX49vVp4nAAAmS0c7P7Ov55cMcFLri4K2h9GiBKBt88CqYv4cZYnJP28PyHuDxApO-QFrut2_Lj0t975Wz4rof5IW_Myxaggtf_wAuc18U0KaojDH6JhQJi1JPB1fY4Pf7gzuboGLnK8nnUN8gMHobmD0Ry_4PgpK98nMq0bpHldw_MQGyAOaBkM_2r3X-Y_jZA=w711-h947-no)

Then to drill the holes in the covers, I mounted the pot collet in a collet block and squared it up in the mill after tightening the work in the pot collet. 
(https://lh3.googleusercontent.com/XgNzDHawRPIl8oCCovDuoyGqqzUDbyzQneDupu4XiubHreqrh-5KIpiw5RhMjBCQaV6nisX9FCKQ7DYgMFTjAJyFa4GU9GSTyKneWnfyh2fHsJFdq8Kyq4dV8O3rrH5P6iIoAV6-TsUYDTb4Iv2hPfB_wVjKWlsvB04R3UoDu1m8dQhlqov8PiEfC1fzKwWQqm2vlL1Vb3n31C2HbrZEdcxtWQfGGVCK6h0PXERqrZG_KQ_TlneVvmGN3dluLJwJR7Q3RhwVG3BlqdVZtJ7EGBY5XjsVHCQjF7qUNRTHR0smf5VfsncML2qNn-t6_w5AW_FEuxtYrwIT9DHeLoJhEJrDDrvlFL0umebJNupazRcvz_Dn4jh_580_hExlDDtET6xfpSC9rSLPqzcMqgKlhltWvo31nOttqd5qrXm_mndk9dwCvgxN0HS5-vtiWIcj-6RuAPOT8HYDbyVcnPfCkBSGYgybU1RCcjejV8VrLAaE87jRIMaPUHv8NbCjBab7tZLDJyuL_N00WZ6ZfqlAZ3-f-zuPFjrTpVYw6ZVicMLqugKMHKzCCT7X56hW3_tH5zb2ILXPIOxVSx6MDJGlVbwvPBJM8YIdcGg5Qd1WMYWd_DmogJo1_H75IJoGgj_qMpgoxtSbGaRxauWFwDQEc_mfN22IhluItmudE1CQdahpMP6Ov_r-OHZf_VXuyZXdo2cke9Bt7Rrx4-M_4Q=w711-h947-no)

Centering up the work in the mill.
(https://lh3.googleusercontent.com/7cfzR0rwg1N6SrD82pBzpRHvP6aStg6ZIeB1ckIWyaO76y8DJI7_S4pD4cr5e9_7c3c1nu29Ry3-WYPD-ZEIgT5-7JE_cILveDgGo8Vpl6HNwbDbhQ317mVO9TvBiZ9adRsNVFikcaJEBDWy71Vw6CYp16fti6UY0s0nLzuT6fA0xGTy7GrQMPlRzdT3IuGHidJ3MiY6L13L_jmkAuHXlpquPZohrFy-BYEbSCS4tMhckpu1AMG-uHyFa_Keiskoq2GzVBYMQqKdzDTUK2cgYaT7UlvUgf6YYZdTRIK2IrxX7a-1sngbbF0OEmJv4M2wBs_Ue2YLmaSdmETT4crdJAI6IZHtSwHn_X7LSw7WsrAsrfYEWD03Jls4aw7ewLvJ2dgjHN0fj_28Nz4quu4xFe4qTA-Ds_UraDVaGmbvgLlnLy0IwIrzyAaVlenrWqP23SLhIyaco-pHDtZ_t8KVypdWJt8Zp9lu1BUXx7Zx4E4zLcE_qvIwUxltjVq8UxgoMgfrupisX49Mbv-O-Glw-vKtfGVIz2BdDbDJeHqxlDuKZsg_KIt_gXXOxcL_29qJ_lhkQNFM7RMBhAqvMpEupEgMIkzOQPBEzpmwUUIKUP6NxX2NRsNOPN7M9Ls1bnipg7qmK6gcgYZkWhd-XP9jaGTrptDSlTkWRueKPq7zPvbiIqC8c2jZhJj_cDnll-YeSK3lfyDMx70Wn6Mp1Q=w711-h947-no)

Drilling the thru holes for the mounting bolts.  This involved moving from 0,0 to each x,y position.  I'd put both the PCD and x,y coordinates on the print.  This seemed easier for just 4 holes.
(https://lh3.googleusercontent.com/Nu0cZfeLXVdF1c8HhAARQy9AdllMbYi9rzNN4HY809oHMTKUaREdD4GJ1Mua16vvJUfxHBHKbj_6zZEJIBZ4FejwpDKlsYxmpjh7GsWLNlvkoNyW82Q2m-t5RCHZS-JNXOSJE1PBm-RgXnHFnObOeVTyffxO3s74zgajKhIwg8A_R3vg2OQBjmCMVO54XxGF47l5_NYyaWIocaaMYiaQQEqzA8qF5BYtnrMqnR5E1HKHd8gIIFpdTukS0y_3pzxDC4jNnwaK3hfoWajtixp3QYtPBJgtm8PNfBMMnB_xX87ocMoC5vt3PesUN14_CoC1KProiz7rNAzCEKr4E8eOwzYAQViO3zJ2YGsgB_EQ1tPvN3a3kIg14H8lAnM2CZLm3zQ1BdsS-nT09T-8ijrdxWHxjtrKFlGkN6cTueyeq8YF7ydoYebC2Rq3ck11tHVxLK-Fy6EMUVmQ7tJSgzLHKpIRMrheXCNczkbxFHZNK7tHPrwde-zkjHSDQurZl4upgfrrLQHi2dXGlPOrG8emF8B1ZmmOlW8bnLcRB-1-MppvP9xUWgP8z5pGUS-foYm3rLwY96HjoPHmLCLUonA3YaNWTofbxTujbcPlhjZcCmgjvPchJx46aZD48QVPS-mKL2j3As8nfPDe5dlP1kKXRi0ZKGG2K2f6ZMEyklCg0XsPD_gFlL-X6WU_BTCwkk5jhghtuYrbUcydrKnGHg=w711-h947-no)

Centering up the other cover.
(https://lh3.googleusercontent.com/-bmwxQAk9KRkRjIi9muvzeHK10rV4VnQ7iOC2tpV2iLK_iHDFSvQ1LuztF8tjqvaEWvNXm8SNa_21YxMVS0JOly_hdFvP3TFNkwbOcRlNjRCbnGuTLDx_gl7K0OKGp7evyWrMNpxP9YkGwRXZW3EPkPW2HzMPO8YYWleRqvuFrK5CmHunZezQ33MUzOTCX6u6gVS0Tft4lBAwAXAkyLIdRe9sqsN6jQrpImDt3kbq-YqkuN_cEAJSCV_OxmGTHNkPPe9tzD4BjZvBy9WZGsD7qC-c4Iy8505pO9Dt48Zlu_JWguiAY8aohOyKOuJwxBNDIFdxp84mCJDspqN8TJcNNlHsKpUJwAOD7CZBmQb5Hx-Sg99Q_n1p8dvZcRyhDuYJ1DebCdor5ZyP53vW2LnktFQ8KsQLcHyCL9xEY5reXq2YFWYQnByEUL4iyu1gbnsL6gxzipUxJhmKQCxQbQYxEM8hS0K1cmRXz3SccBzyp30b6POhvSIVuAoTkHp5RxL7MW-98Q5wWSxzOo3wr6GE9i6dwEesJf2Q3hPAlucwsdbEZMFwRQrbZBx--s_HEbxQgZoD53UchlrCl-9_GVI1BWpFfcd6qYvXexLGmrdZ32AOH3hmQ59I_YrVHDN0orOoAH-Ueo0O67E26b6YbARUvHdKr2PTibfDs0rA9OaGeP5VAGuKqF-mKjAwSvCAn-3OrPMa6KyqUmHA4ndcg=w711-h947-no)

The finished covers on the print.
(https://lh3.googleusercontent.com/S4Pj52y-aXzv7FgQDXxpmL-BqetRfG3Vt96vw15zJSaAtTE64zIEow0XmqsE4G4FX00BkS6lhwWGN3NLZN5HEwqZSxkYGmnHNPWfv-wTXGuTQTiTnSOSKcSQxgnrwVMqAOBwWFEbI0SjTdfJQEtknXAH9sNNwoxcq17j1332Z62DulkXlvTKlwAntuedJWLPXGRyEF2VWo-AhBxYCFYAqnnrIjJGNHS8l8R0TBHv0RPvaWAGCGI2Bpy0f7cHx5lplfbDpkJZK3mAc1n7TWG7DKyRKjLggX0tVn5Afro6xycYZWl0zRxLrkX1vpidcVNY3xoZ7flcOw3vMx3FXPdE7rkyJIPW5Q8l7mEN_QHfzf4m7TeprZoW1V_mEuuG4gizRpCxJLLeR9O9ZILmiq2ue0PH8DJC-EKXGFCaSlF9qhLkvciMvnTh10047-sbsVGJ57n9jEjQIWwY5ZtkIQiWh7FN_NkJ6MqmmJCL9OH7aaCPCw_rS9vxlUB1JmmPEMn3w-06Kt_6GYHkvaejSoc9qBXxEyx4mv7uRh_3xLat1Vmk_49M0Af_63J3SdupfnHN7NqgPVnqRYmkN3kZ4Ykr-M9sh-oKlX6aWb0qcz5a5nNz-sTZ9hh2SsTYr4ebfL9-OmRBH3gdHvvsRDoNtnhXJ1mJqJmihK3Z6Mx84aYcYR1FiZp__HpEojATreNa6025yK6761FJ8Ok3ha7Omw=w1170-h878-no)

And finally 4 pix of the assembled parts so far.
Pix 1
(https://lh3.googleusercontent.com/6HT_wjG0IbOVcIplv_1cUoDXX5zmz6z_gVNlXIOnADyIF6quUUhsyzgSkS2z5gJaNF7opcbZEP5W-g_dKTheQmm2vK0t44aobhjNTxIbJ8-I6qkJq66MJGjXAqcDnmdgxBYzI1_wzcpuARrWTEIzkzN7ac9I10dJQ_H9YW3KL-lTr4TxlZuYXx6G-YP-F2UN_QJk1lMeSbZzuooYBPqE-n4xoQKunDOItlfcbdOKty5WDdI-X-cger6eCbQIyL4kB3xFnIEbkW4aPtjACf8fXeh1HxaKeq_7N1n0vWjlzckzCEvBMgmRQF6yTtgSGJMFR8iz4YsxfESL0_xWiHIAhGg76tnk2dTbVSZfgD11Alq2THkJ7i7mOl40wea65YkpzZreeEdduMj2gAjaV8XAnZN5waZBgjuUXUQRta_W0jIABAJknYzyp5wJVxoraO-8s-WY-Ct4plgmKoogd1pouwYqrgOmDgEHAswEsNhgnnXyqH1N1PPpBBfb86LvGgIX5VJX2nTTcIsSr5gc2g2XpfIYtNPGn9fLnbJfrXHTMg2n3m2GzpvC70kU2qfEV5047HzcoqaVYgEJousUYAuRM6GqdiyPLUph5nJhI60VTFzNfbevKQ3FJj7OQUjBFdpdyDkCIOJAZMoHbuRliURZnghIiI09r0svaQhrOfmK-N77aoxm2PoEHjOXMByaoI6ZwZLjfq4dcURC5aYXyw=w1170-h878-no)

Pix 2
(https://lh3.googleusercontent.com/cBQZ45UJ_ylqCiBNcwnIy4ZiYcahM6AvsF5wXr9uNYxpRzbomKj4Tci2KpEU6D8QBZA-RmjK5qgcfpOD1eNo7TbPpsN3dJjGZ0M_t0Yp4sYEVJWgdBksCH49eNbZoRd9C3VSDWR7K31odtL4sLYHGiLY4hcni5DMXumhfaVMX_7pdA605hX3U3QVoB33QNQhUvSzimQ-g-2gtssMQuKXoMslIfdKpx1vLEd0m2zu_g8vFWoXRwlPRl_Vq5Cg37KTP2URmmiJRbwrZA443HUsca-SoDSjX_iZspgKl7gL30l0Z99ppc9Ow6eaVjqGF5khPkiDPpAKhAyT74Op1NKhAYN2137dGnpdJHA5wyAQr0uFacuWYZjgRXSgXy2GVdVrl3Or_RPzFkPZOAxWaWh0DZ5K2h0xG4fNs5IoXVK7mWXS5aEQkp7gwPvx3tubzTS1tVxHFcJO0DAke74E7cwR5TpFXZjusFB4xfQ9ZfbShMLuRAXmjUTLoHhs5YIOhxWF-iN-DgGuBzZ9o5nEMNNFuEmy0ANqe8BNEMuRF3dY2ZzuX4zjWPjTmH6huD39C8nDbG-DqFTSu_iEQ5kxxQ0pKCv0NOFTA4kBfzVr5r1dB1c3068GWC6y2g2O_gHmK7Ow6M7P8i75pfMnXY68zGoXju4dXEn0JEdBkU4imaFT70ZMPdfY3vu8REf7-dWMphQQfNU5hn-6kdmK7BMxag=w1170-h878-no)

Pix 3
(https://lh3.googleusercontent.com/pae9-OxvwazmC1sK5Mzzv0q5wYERND839OyJ2J7mWJ1GJp_SMw82qLM4ldExV36agByh0fEpT0cMlvUJc_xCIwOIfVcZpSNcBYiFa7OQr9HOqwP7qpzkpChrxZ5B8tnC4NbhVcJF0CC814CPgXUnO73MZbfjvwmIlXmaO3i0ew6NCLhkMLsw3ZblbD08CYCkn8GKOqmigKiFaRPpN-If1lQRQSb1xEM7UIxCQ2-h9dakfHhPHweFkxJhlPZV33_MlEvW211CjYIpx6Iz9opeq3lAKealqsMGEwU3tWlCvnw5qRZTVY9uNFT7o0hTmJGeJSq_zC71Dgfpzpkp2JQhWb1UJ20TFCbgpBiI7R7Kni9AWhdbnizXaAQrsFoMyjJZLdYgxV1vtXpUx6hJyKKxDFd-4tPQYBtLdDoB1JdO2a-M6qcEquJtm5r_7erU20Y9-TcxFQ27ELEbqs6tZ5iwKfYGyoJhu9ST3UWhst6eKU4ZWJ5epYLS0HMGgr4GB4qdbsYEr03ZBoxYa9EK8nPbUErSjIXFkUaRXuDjhPd3Np16tErJmkA9n9dSadQYJsWBT8ryziBi_UPTXkw16gvaj5--YEbFlkommpbH2_FFy7yB7yQR03Cyo2tckE6CI0CFM1NFppv0kiSL-lAUW_cpm_9HB2n3YHDDsgKuDnzOewmGIyKrZHGRtiEPHVXzSjHP9vo10RkPZqJCmIiqlQ=w1170-h878-no)

Pix 4
(https://lh3.googleusercontent.com/hKHAnvxVd3Xw7xxaU9b3Xi8k_jpG4BNs0IXwm0IWPaxAixiS7LgEmnY1ncd791XNaMFEiziEQ0J90LvDBVgwkVVwnMa3f6M6LzSuK6JSAZakqg8s_SrxLG0m726A3gB_-367sX9d9a0dtNkvDqSRq2I9pTj7btHCjrm9OeCSjBpNU9EI-9w3lI9-kKdIVa7qbGWi0qL0Xav2hAJuKSW-UhWbBciiF43kgJJaHEX3k4TEXQ-LmHjbdLcedKFrcOJZH-aHp69Y6i2Q96MdSx1JilvzexL_CW3OxX0EHP_SNGu-GKa6Ang5m_NGipiSwyPHxeTg7qHgFPl6y11fdLU0MgFDHR27A8-Xgxy5SdW1FMqwYMUxjVQ_m5Wa8ZO78dghGQhl0b2y9XNUKFPXWnKnv080J4zZCcEvncFOdVhitxCdwPt7Vt3621g_ov-NJFuEjM3rsn3Ybo1makMzuuIS2VfUrtpgjKeVCjAcbAaTlGb7uB5BukikrVNAVjRPjAk6Nl7TI4-NVHrch8dOKsSMkddWb5b9tiEL7scfAM3DTboVA_HGyhJID_CfvxEefeLQpYnbAwdtyhOmhzdO7e-6xc151FpxHdHlwfeuHrwUJrp9zFxCYo-uFmR-LqApymulasHxxsfy8ni9ctybl5HQv_eUYswUfLKJ3F-E3lRm1fGOJilA7OEjbkdneCv-HBhu_G8nEePxW45LRwC-eQ=w1170-h878-no)

I like the appearance of this engine quite a lot so far.  I think the scale model fasteners with the brass washers under each one look good, if not exactly historically correct!  The fasteners in the pix are either 2-56 or 4-40, all from American Model Engineering Supply.

All for this post, standby for post 3!

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on November 25, 2018, 12:13:02 AM
Very nice work Mike. Looking forward to the third post now too.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 25, 2018, 12:14:49 AM
And finally the last post of today's work.  The dreaded cast iron flywheel! 

First of all, thanks again for all the great advise given earlier! 

I chose to follow Mr. S Hart's recommended work process, at least as best I was able to!

I mounted the casting in the 4 jaw with the jaws reversed.  I decided that the one area that would be impossible to machine was the ID of the flywheel between each spoke so I wanted to get that area to run as true as possible.  I got it close by eye and then tried a DTI just moving it in and out with the carriage.  That didn't work so well.  The casting is too rough.
(https://lh3.googleusercontent.com/Cqwkerp0PPPzIX9x7TmmkxDkEDIlTmm9MOOPttZllT4QxcNaPFXXLNJeAB-so_Oo2ObVn7OlXIDbpCpCD8Z2Zr4GBG_IcjnU5ZIc9N_JvYmfekjfIDivUyx1VwuRCc2mUSINoLSR9DLlW-uKMZIHxiG_wMZO0B8DzuSAeypq86gigPx3DmhAkSqU3AFpv2-tllcbcXUITIbVMCwWDq3B_R5AssCpISIXZTFiIGUzWP9T3q98xdvgXWHDqsrArkCVZsL49SHLfOCrTz1IyC4rrOkTTt44aD3DOrM0d4WL8BmAIXhdWBNQ-xEksmHPzFibyMgZ05E8hMQzOJKfGmkkO8Yxn0gh9WThgIbuK8-O0-n5joaGeKoR9iSGE_UKss60L_9S1ATPtwBjT1pMx4m3SXIimyTZL-9ccoPaz7kXogACf0jWindRHAJZUqz56qWG6v2G5VJqSPoLtzmPc6my7F9w_CzxIQ8Jp6ptOuDXcX9aayOWXlwKkJQy-ldUxY0I38o93MKrhowM9j8BfLDM3zHoQtX38rdStRhByuTK-rPxd6bzHHuEwk5Gou24_J0uG0MpZr4kA4O9Dxl5iJd50UTvbJgT7wL2RNiBpxQK3fAg3AQTkt1v2utiyUY9lbPPAuc7QciI7C2Wzh0y4wiEOeHoUZQYT68yM8OuIVggwU2LtdRNVTkuxWxTkmzt8lR2WJBwvosnBNy604-Hcw=w711-h947-no)

Then I tried using a surface gage with the curved tip as a probe.  I set it on the carriage and moved it in out out between the spokes and just judged it by eye.  That seemed to work ok.
(https://lh3.googleusercontent.com/mD4gu_OLAnfSseVY6-6wQOtoqwIOH-nZlfS-vzXntGC-1hxUYt6nC6toPepgdyKnKlpTdmTMy0p_cbPhFT-eAuUavbtikSS8YcsYpwHae_HmDjrkS76lUcl_cnoyp2RBMh7r8u3C_bNG-FV3-x728oPfhf4fCRpaGumj8NnJwbMlROKojHJYJCU_LcPELvWBn8gJec3P4b65y2UwRW9i9mqcitHub9ryd5omQyxenR18NjdjsExyYW5odydbOc__zswqULA-y3cKM8YRneVO9kdrYdk26mQ33t3CItLTtSrSojzG2goC0DaDwXimG6cdMP-TPKc06JhnBHf30BSEqP-DOo3WVYmLsHsL590fUq_L27sH9j4mvtJQRSB7EP5N2mPduIMUqzzSKWeDLoqKikp2TfKgCmc-v_CXMrNVaWZEmKYdTgRl8qD1WrO2vI9BGCH3-LQ2Z3nzFVJSLDiPZnOb697Y9lqnAVKT5_fhjmq2LpNwTBCwa4G0twLfDHrp8MCUkaqvDaDFxIxf0perYNg5LgXZQEy5y3RAXanQRp1RGF7w_LwyERV4FMOaOjy7QANX0TWQVbxC-n7ZY5uczCT0Gd5Gx4lWxJUsyx-QGe0ClaMAdCKNkgTObF6hN-2YtzukD_AN3L8PZF3g6MhcULlrvBQ10_12SFHuh0wdmkpbbVq0L7Jm57BKOBMtQsOH3-ba0jd1jMIKvMUm-w=w711-h947-no)

Closeup of how I used the surface gage pointer tip.
(https://lh3.googleusercontent.com/pHpmwVRov0nsZbS6rTZZkjRqC3doMseDTJLhZgKnOmTqAmjRR2v8Hbn8ntv8t62Bqgm9MQXamZ8vUp-eHbQG9HV33H-oAIQ-5-g5m5TcjZPai4Xr-yxM1SQEVOVbz2k4IQ-3TnszoL7thPTT5dj3N3EhR6sr5ARMH0cs1GBQNyaoDEZOLYeZGbudJMl5X-m9KhX7gbwPSRxWZ8TngJvp870TSy4xEl-WPudl35KNbk5o7QpJ9SxRpDzR1-hMlFKl7QCXSvQ7kFGDWMzRmE-YS_CLrnACe6Iw0552oFHADbCA4XvkEHnYu3BowNaFNoRB-sx_t4b6ZDb7QRuOeolRQl9u_r-G7VYwBGDeUhSqhaIPuWYmuYy8hPhkQUvsW5bbt9iXqvBs8UnOL3raXNHYIY8_o2r9JZwAYcNZehaFHFqIVyPDjxq4vOpXN4oqP0STxonHgU4ILjJCdaQtywcFrg9WRQKKI6Sh9FCqWMN2Ba9_1a4y4uzlS0fmk0MXlG4N2HXxmqtQVyQPMcm9aoHkZXq205xLoqNFebBhQ79zysMXIHzLL--OrYWDrSaMydRYutlbdHL2QeD1IRXbQ6c-QRQbB4TwIlufL6LghwYu-FG6djRv43-Ln48M5s_jrSyRMBXaEIEdzJkeX9nQH_Qm7oHltlqFy0wCalYXUlkAKC2fXEmZ5D1p0uZxvVFCkbkRK4--IPjYMVQ8qUP9yw=w711-h947-no)

Pix after I faced off the outside of the rim and cleaned up most of the center hub.
(https://lh3.googleusercontent.com/W4jakTwtv7BLqcYcKTsT34qsHLS3ykpA8Z3oMHJhw0NB4oV3hAorXB3VuhtSWka_3U0dvBHmOzbe10rhP2-Yyww7TfpyHjEFObU3QK3XALJLqa8_WEpJhUYG9nmetCbhfNzfWrhyOoB1-DVvp-6BUaOLlFoop59cc6odjSDeANnnQ8vBukfcoUplV9OgnXfgIgCHJhsLyoCvrCjxtZ2Vbm4DdxSW8OGg66Rq5KDYBoSdZUpvQRwCdWvQRmIWHnd4Pc_SCwG5CmHYlOB2kMKpaZ4Moip-_HsN8hSyCs9_qqRZxO-7w9ocO5IrxDxbmf9J7-uPhcXwB5DxM-JAk9qM5idKJUYo2qJDG-Zdf234MBJQZ-h0OAs9GSIza_Fo-FbBbXHyrqp7f1n3E-hU7YFeafU8-nGJqoe_v0jYTnTJOnOGHbQ63UCu8BJRl3YvpYM4-M_uB5YuvNtN2b_iiF2vBjCkpgK2GLqG_0bEPYIpGl0soGq8fRc0FCHxJ8shQuibrvVohsXYV7YW0lWzefKOjsO2MBk36OobahFK7FQtuuYPS-PwnB0qRqNs_iIBiC6NptOD0wyOxvl3ctSXAFlXij06WBINct5tSny7xeXJkwpmup19z2zYLT49Ov0-s8SFaNM9qtoPLaqGJg1DBid67deqihLz8eZNLnk49heSu6URDTGYyibF6jEHrjvGoXi9XfQBkitJPe6gESPMdQ=w711-h947-no)

Starting to cut the OD of the rim.  I set the lathe to turn at 260 rpm and was using a CCMG insert.  The casting cut very well, no hard spots and it didn't take all that much to clean it up.
(https://lh3.googleusercontent.com/ShpH0vU3fqkveD0GUw-TSJhEw4Eud9-pbQikW9orzS49XboNEipOAtuIpXCdtuv6Bmlo7RblT_ySAOlDmJbsxn-AHmBoT4dpQ4lKf-ZQlo3j0z2p68v8AoFQNMcDkyu8h79_OhuaNYhhRpH9Z6pfPEcgflxafKfqJPFL5fSBQ-cMrAGKBN-L5ljkHTL7ONcb1N4lmyj2eMngoR-n-D_To7t-MMylwKTJF9LToy9zNvBjNe80ZdtAYxf39PS3_Uzk3-4fOMzPxeGfHlSCWIo3zaEeCMbkXg7Z8CXgpTlA5W44Poh_VyPiTasd5baTlsHU0fig_XPftF9jXPq1IjpEF_W9tP-bKLQEC0WzSIgTA33S5pmFQ7nTqsZ1t4MFDqHG3J2gkWj91s9X9oWe_uON5EZx6LV247VP7uuub1Ji86I6pHq04ye4Sp9t_VAi0zSYpyPs4pvII5QbRhpgEj1ZupXOkDLYZOwOMaV7x9zi5_Z_EFFtH5taOtp_8y-BHPn6ZNVNSZjXl14nRfx8yFrsjgFfqvRB1h36GMPGmQczGDvatMawtzzyeA5rBtQ4-qVNEsNiKWg1azTkbGXyL15_AcerhbFTZHoQqCaL2Ck3G4OxC2_7pbmGQvvJFexfhzHiiQi9vSw7BPbd-5jBF02wgJ97IIuFEjSnQmHWq3gcmm3ca9OAcKFEk4G9hi2E3GSEOsa2Jg667iVvcil7QA=w711-h947-no)

Then I took a 3mm radius tool and started cleaning up the root of the hub.  This actually worked pretty well.  No chatter on the CI.
(https://lh3.googleusercontent.com/X3OtKlTAuZ1c8yv-gL9xlK6yDPiuVZj7Q7VjWgMNTLAbWLHuuoRTLXhim6lf3pVXl3KHxSzd7M0He-0q_25MzqXv0OTsDLvKjyiTjIbgTaGh6-Th7GoFkM0HbB_78oUmMeUDXXw3pELcitb-7gkzdrarKfaM3t8vdC0559biYkrLm7YRzHK117yZvw05bQjmjHj6Y48HV0TuIRE9NAmxo7jz-1SYh0YD0YdmfmGGsLuxdd4vdkKG5FKuwfdYltivLn2DtheD5sVRWMNeLopyOxCA4tTqvuuOi6gx9uUqLCesOHesOCyIe4HvO6cDonQIV1WNrNAz27-0HLyTuWIk3urfQFBzXsqNOiz86fwkvEPOhu73t1xDu8cTlPnej7kAZhK5ruZcCPCJZ06ktPn45vk_puC2oOHkmrTXIwgpHgrA7VfqFCBu3RJfGkg-WD0QOPdyCQmcPFnlsvbi84SWDA4M_MRnhVCW419vKqe-hIoxFs-pICQEAPfLv0dEXG4b76rgdtcrWz7rybPVcM5JLLb2aTCPqZnXAHeyMQpiM_Tqz2YrElHvzUkPK8J_Gy6vWdbvNSCGeRbNGJAmcKcgCz9bVPJgqZ6mEaXyo0Y03A9YMomIUqmwCn-YHbPShjaVko2xF3Jf7mp76zWyTnLXyzeEPMtxvz2dp90ptRK4S9Ltgn0ltOoAJxLUFRrUnPn9dC_vbWrTL5JJ8g5vEA=w711-h947-no)

Then did the same cleanup on the inside of the rim.  I didn't try to get near the spoke webs as i figured disaster was sure to occur if I were to try that. 
(https://lh3.googleusercontent.com/kjIXYVWF2ZAAqphEzrc-2ixsLpzA3ptfxqESon0mzmvL2b_S386_KRV1cM3k1UqohOgBX8bugPLIfJgS5zEmM5NQl-YIV7tN9-4kIZwTr9XrhdBjYIKxXAp6XwtjTepkv1OyzhYgvBsIuSonOj8nnCSS35Z0c1xLHvyc8_K_idgwZGBa2u3j1XFKNrRuurssxkDXDzcR6RApO7GISZHSuQbbqN99aKVweEXCqjpLGziTRJ5hpTRRhyXniSUTwhTLtoawdvtR3WYq7GRUmt-IcuAWgZv0YT3ff4PBUmz_P8Uq6ECwuc4FyswwStZoSCMDx6JtOKF6ffzhnrMMaYwUoT25PqkSPw_rG3n9HUIVrRd5oALh2guu9bZ2KqSyxqskmsgrIecuDZnnAss3_oXTAFx58CIyKw_7sWdi2REnkMkbsDjiHc-mg0GV70alqAwL5esokGdtwTBpChTxo_SMk25Pqm_A2dX0car7_PNeXWlX3DiI1lfA0q85VKYsldKBdA5BoTc_zk1yhdYKGqa8PW7xn5Eu5jXN9PIf6bFFZ2pl4L-DwN8E5MugfKZ-koeyqaiflh_3vQY-jTGZsN94qYnzPIJYLupFcNzbmChvMklPF0i0squjg05IOjvBldkEOyuUbztg_3Kx5c9181B-5pBwJyRdZqhxyMZYTs70Z69OLJ-fncZEujCytD3Kr5GhAWFQjoTHaZhGTsy-Ng=w711-h947-no)

Then I spot drilled the hub, drilled thru 19/64" and reamed to 5/16"   All with no cutting fluid and 260 rpm.
(https://lh3.googleusercontent.com/8VpZZbriA4M8L-3Uktv2T_8Uie31KQiRKsuR7ZpCslUqDIAInY8fXqSP-TOWuHbO9BByMJgU70RZun9sKb-VypPhJEW2iM380Q1Y_SPzWfCAE_3H2OpIt8RG7Z45QUiE638cdCaU0btKjCwmH4eA8XXHZKzWeoJwZN6ZNsf3X-l2m7WSSyJyJxlrcw4N_5yzWbYfRTqMUZ2WQKhgHu7KcNskWg3QwZDs4WTK79qI3kLE2dBuv3Gd2-tbyWrFY5JOBsmw1yXb7ZwZoDjr8S-cLgCfwrcXB2s8kS3Q3LVwca367zUZvZG7RRfSs8IxuQNhIRhQm1UVII1wKH38w6Sj8NgiD7L3mRH5dNdBljYEuXdNIegTtNZJM4lA6X6rdjQGk4pPajGP3484F5bYX3QPR_v3-9nEL-P1pYFH3OLgiXe7jcmduMHTOyQ3D_eMN9ipH883WV7XTp_u7rFNmAPAq7HrGPvTPDkt6zWQXG3xwgpVlyApOXx5vka5ZlhcRplfaF3EYNNX9oGChhdLCN5xlSJ_Ys5EOvyfWb85WoBZwcBmDnL-dfabqRxVOCKaQ8gj_gCLvJl1RBKpBGR2MzDizLgZeNK0KLuUrQBkbnFqUDbQGuQGfXYb5MQxYnNGViV2ItYCjQzFsfRTKMg-wR7TJrMFSdgBNX1dmt0s9cI7ISrQOuy53eTmPM2ghp2LUte0ydXKrDcDJeOJ7tZbBQ=w711-h947-no)

I was able to fit a piece of 5/16" drill rod by hand but it was quite tight so i think it turned out just right.
(https://lh3.googleusercontent.com/V_Ft1F0-tn5YtoN3a51ssB4TpnogO_1JMOi0BRyImDASF_0dTTRjyln34-Xj6kHKDiiAX0YTsnnYeL1E4eQWTlYJD4Fi0Mt-jHTLRSyHzgoWtRptOrA5pCXSHAf2EHsHJ2fEKjBkS7U5D0KlykJM-GBGL_8r5vEzJxIyoOaoL09UGL-t4FvxxuLdcGfmCf4CHL9TC4U2_eQVEsTilwE0Fm1yecoiw_ALLEbWl-1B7mRMtAfXuaTCKA3DnaBajCU_qIhLZzrDBZXkeXhf5N_L1ASoo70O-NJE1KIBtFy7IwCv7Mkma96AQnkF3IVlu8pzRYWk-m1GwkZpZ4CIBYCMnvLDRHJXt7xqnW4-qcdObo-wGrI0Y6r6qB0By_qFLzOfKDCqPoG-SBNaPf-9G6jr5oLhI227cX16-zG1nqGuFzTaVysDlUZKfShwVuHC_7nr8Vefl_WpNOIrIgmhNW0Nm5xL8NuRElP6myFY0le_9IHD0y4m-EkZCMfMvPji8jfykf5yDkMrfvtPzp8UrDsqb8pdRI-y5nqV-hk634j2qrOIMVu0oZxaYs_460nziMI_EdatmituO23wOROzOEVbsqdjOu5g6aMQsMhHOMJn4tr8SVuynJqRMW8KL7bVHdDeTmgftog7IAeR45QTbnRKZ4WH1V2Y8VcB8JD8EcuH9D0XLVoZ07QQN-kEdfMZ3J_XHPFsjzJeDSEUg2vjKw=w711-h947-no)

The 1/2 finished flywheel on the bench.
(https://lh3.googleusercontent.com/AcNTHcjyaidVqnzsd-eUKgZ8_af6OJfYnhR0R6glrlVAwhAN6Je6QlSpMSLDKa0Npnq7P2Zr5zTAYPkDlaD5UEil0CUO7FJQ98Mp1dvUKsaLdK6dSjXwhSMHBWkqyOjVMdIp5nwXfA6yWG9ei9cQWB0-pyOaDzRMeOno9oI8p3jQ2aubaP6igMMzdWa1va0raCCS6VGtd-nkdcMipUbUZeMD7S4V1cY5y8Xujb3UZSCsv0mUzH4yQ-LjxDuPa0Hmz69OV9tRFJww1tQA11cxipGavke7aNBLk5jLhVvbEteCvWSFELp9KWsVmXvUmHXrWYEYcQzXX6M7y8_UG2cythKau1_ZGKgB-kgbiDvmOqq9aJi_VzGPz1cz8AIVUnYFyB8GNkBK3YBRwQOb1MGokZ43vGSGkv8cI6qNjqBod0PT1CoQAmnjZ9opNGdgOlxK7fK_0xdzyNDltYO-XfXDUCdLczrY9wj3ezhPLgmKWtBxjY3F1i8Xiv1DGacJtFx3zs6TBiDwXLSEuBxQJyf3vxuJbl59Glr372z5eq7wvm6cvV42YfFG475V9PdwH1ONSTWiUrUbOENInIBzB0ShKF5ie7IQTIc68J09hlIe7qxJcSHl9UgQiOtDjA9eszaD9wdj6dXCL-Z2DQuAEaleub2tccl8f2zDWcGAU3FHN46mw_dLl15GfZD_RwgoalXWA33-K5Y_sw1HOXz1VA=w711-h947-no)

The unfinished side of the flywheel.
(https://lh3.googleusercontent.com/aBQek0C-cPiT4Wcu3mCs632Z_VX5v5hn0pJ5l47cOmcn6WLXF_qdpjIrU2yaoXoPj3bI7UEZYvoLrjWoVAab4J_vthL2PNgGyB2wP_CwSCeLInr1qeZTRBmmHWnWHAeIlM00G2ozluDxQ4EJU-iFq_CntA5pTspbyocRfASsy9JCdzbmW37r_mIE4dzOP5YFjFybyC_aZAufaRg0oT_MbarBJpmcFA0nN015wxu2gRtkg3PgotxFZVDqKcZirqrQe7FAt7kxd3jGlcM809izG1c3svgCFJSf9laSuWSzf-gSpkDcpTYTRywb9lVxUDrIrF_52EMdxen0lh-ayttotellCENFQgaD2g5MIOkSUBKOTrKhDTEnzzgTZ6ONtdgeju7Kiov1jK00hLr8jAsoatjXj9shtVJSjZMPZeCDAzCUiRSSj_rgEguBKAOhHhiS3M71ixF62rVdz9F-C5htWHiUE6H0tK5nRv-AD3tL1-kuCkmxM_FoagK4UXNldUDHxhnOV0QyPhJPYWYv-IYvqR-2pZguL_30k8KtWb1tKsvsaKzQWpfInjkpId2o1sBPY_t8-wGWK3yGSzCqf8f_ewWVD_klVMo6drwWZvEzHG06YVUPrh8tRvxrJpeCNlvPJF_nrMkztIJ_G93V1QdZtSFcvvgwf3_KRoB00lUhV6BqbCQCbLL5HOLPogkIfeK_mHb2QAaLGv_KLtOX4g=w711-h947-no)

I made a mandrel out of a 4" piece of 5/16" drill rod.  i put a center hole in each end so i could turn it around as needed.  Shown is the mandrel inserted into the flywheel.  I cleaned both pieces with some spray brake cleaner and used some Loctite 603 retaining compound to secure the 2 pieces together.
(https://lh3.googleusercontent.com/7HKBnMcRfn8uQcGEzJuaUP8Ij6gTcLrBpIzW2IWLp9I_7RgxUCSAGOzqE6SRmPF0xW6n9kK41fJDoYrH9W3RfloH8Cw2EQY2V6rO5AABYGHo9RSX4OQtTezarIB8aBTUV7u2_jusV1fbNzJHPdVciQ-0TWVaObyXe5V4LZp_DUzHJSjJ_0USupmCHjk8KDwqeRRB5McHqbYyiYko4H5X0eNA0IBUqE-p86eFRHFGFzMn18bIr4KKmSNhh67utaacJtLJN-Yviw-4zMt3kisluCWmhPZ3hJDfkLSqe_jsewKxDGhzgikmSoTo9jpXsEfEWt0nBA0mQ-uVqYPBxmb1fxve3UvUtPAEY91q812-DW6I1CAkCRL7y-_solZ67if2BalMTw97Cula3Gp3YHYEM7mz2yf7pRLKyM_-UHr3U7eTZtfwE-Ds5kcqBk8qAcPCUPu2YNuQ0jbfqO4AzySr5SWPDZwwANfGckfOGi28pmrwu4MPVwiKuCoOXrx1IcII2nAuU7SR_1jrI9qpaacGs3KeNzBHXfYhn-r1VPsGeWLcHVMB803M0AVIO8HAt1waldaKe62sFFLaJgCfMBznHowHe5ZNFsLU2XKDMZRtLrFwxXZjZC0Lv9Q6dfX3Ujl9weQJKVLQI4xIYWd2WCDox3TjXQmgFw4twewdpxg-PdyZkvbaYMEg_NqvQvOlSksjzEA-Lk1PhmTv3EyilQ=w711-h947-no)

And the last pix of the day shows the flywheel mounted in the lathe, ready for tomorrow's work.  I mounted one end with the 5C collet and the other end using a live center.  I want to let the Loctite cure for a full 24 hours before i try to finish it off.  I think the setup will be sufficient but I'll take light cuts and will see how it goes.  i did check and the flywheel runs quite true on the finished side. 
(https://lh3.googleusercontent.com/HA0XGw3fUaW4gFH6PcJQDLDzjAzpLwaSpNjwD3rZz5BHAN_MYfeWxizkNJkpaRNcaE1u7gQhVt0GfQIvqsyuplt8JPfx1roXRuhC8PrZ1lRxqmFtkZcuZtfcq3CPNOafhLuedLZrRW5i9g0vb6a4bofPMze6_RawJwvrzg1r6LqhIVu2oTNEq-sxqCeNDLsCpWMLfTewHt1-UB7MTc0WnfGDPl_3auoRYfZWHQtrKgb2dA2q74ZNjb4JQeIyzVfJyWGQVEBgaSy7N2OQ5wTMWgo_ZdF2qIhHvopWdUPW3z2XVI-wZcO9OJGP9I_Mb1gO286g9MKdY9g0ulDoEwbruUDIVJ3kV7lgNDNn21OKEMDuE6rsjGdOANnR2Myq6NfBntj09sv5mdAx937rBHhWxrUhpxe0uUUHGNl2zfLLz9s7MiZJcNjOto4XUDbLFDppjtcg6sMiA8EA3r1rV80s-eiZ7FVnQF_0CuBr0jrvIGoo8Q6Mj6FmVhN2d_5eIExpm4RTfy6m6H5u7pe2xkNM0m3qOqS4Sjhm8-f78RjXHl9Gz25fNplBvgvjbK3iNlvi_iySUzgMxhKnEKsE6p4m0i1kVnx3A7bj8jUo_BItAS9fIDt0mvjT3vB_ql6aX0zseeH_qliNedBmE17xI76zMizqfgn8W47WSCVyP3WP59cyYhuSlqLyMOgdW3kyXd5UPjzfBCbCUyD6WLDIQA=w711-h947-no)

That's it for today!  Wish me luck for tomorrow's work on the flywheel! 

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on November 25, 2018, 12:26:45 AM
The flywheel is looking good as well. Nice pictures too btw.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on November 25, 2018, 12:31:57 AM
Looking great!
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Kim on November 25, 2018, 06:11:20 AM
That's a lot of work Mike!  Looking good  :ThumbsUp: :popcorn:
Kim
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on November 25, 2018, 07:46:56 AM
Looking good Mike

I usually use a threaded mandrel with a nut and washer but your way should work fine. One thing to mention don't be surprised if the inside of the rim on the second side runs out worse than first side:- this is one of the pit falls of sand moulded castings, the trick is to have the best side on the out side of the engine  :old: .

Cheers
Stew

PS Stew Hart will be fine (you can call me what you wont but don't call me late for dinner  :LickLips:)
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 25, 2018, 02:57:09 PM

..........................don't be surprised if the inside of the rim on the second side runs out worse than first side:- this is one of the pit falls of sand moulded castings, the trick is to have the best side on the out side of the engine...........................

Excellent tip!!  Too late for this flywheel, although I'll look here in a bit and I guess I still have a 50% chance of being right! 

I should have realized this as I certainly noticed the offset between the 2 halves of the casting as I was filing away on it. 

I shall also endeavour to use Stew Hart!  Although possibly 'Senior Machining Wizard' might be also appropriate! 

I'll post pix of the flywheel when done for everyone's critique.

Thanks!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Ye-Ole Steam Dude on November 25, 2018, 03:12:06 PM
Hello Mike,

Every thing is looking real nice and you are making good progress.

Have a great day,
Thomas
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 25, 2018, 10:50:35 PM
It turned bitterly cold here and so I spent a limited amount of time in the shop today, but I did want to make at least some progress on the flywheel, just to see how the mandrel would work and if I could get it running true.

The first pix is showing turning the OD down to 4.5"  Notice that I hadn't yet got to the OD of 4.6" that I'd done while the flywheel was mounted in the 4 jaw.  The very good news is that this op went well.  No chatter at all and the diameter was brought to 4.5" without issue.
(https://lh3.googleusercontent.com/la3VqH8d7j2UcCtjZIOWvA9bgQIWSv5-jQD9V7wXJCEsbYUJuJBwhMznQ3wrkH8wbAdVDsbsux1EhhwGrAR6Uk41Lg9bJp0le_cRT9CUtsWjEzhgS6ubju9AfGZg7WeesDVl8XApeBpUKj-qQ2lQpcGi8ItDzl0g9R-iiG_a03KMNNih3_g9vhADYZobGaEQhsu-Vb2OAvE4xd2N8yNhDWyggfMz2dL0sO_ZyZMTHJPOQrWs2SXF7p73kk5myVsWkDW9S2o3Ik4Gj8xAeWfS1wVpF_i5c6MddnR2bdzAe19W3rJ9BR5c_tmb--7R0uLG057UMgcypR8do4uvwVCRTGgNSCgrqBmbykLwbso-05mgs99Tr5dNY5MwYxC_D5sNCnlLruVWFdUmsPpzd2oL71Pf57TS4CV_FU7mdzcvamMMLgi8t0WTczpHQwjTr1X34InuKaOyn45aBBdm-0NLLtBsFEage4ILacW28ha0MxPquhSdI817WtZLmxRIUD54yKufNLmpPqwMfraWo120Z3KOHy1syyjuIPNh4hR5qiZIufS3sxclLiyZ53p0uH1HmjO9oS7Ul0P7C1eJNqEwzJ9dCUjX5nwJwVNCq3EGGdCY6tzhoMJgea3z10MsXGO5g6VXGl1Ecx-GsO3dgN9LQHSTzoZAbrox3QJ77ScmZXQcb7PvTnYoC5MqMW5VMWIeu8zHqaaQGxONsf1rdg=w711-h947-no)

Then, I cleaned up the hub using a 3mm radius tool.  RPM remained at 260 and this op went well.  The main issue was just getting access to the area.   I ended up angling the tool post as seen and maneuvering around with the crossslide and compound to get the tool in position. 
(https://lh3.googleusercontent.com/ebFmUE1MAGiYkXsTAkzMH1BM447Ck6nrvY5yBR4NKjxWn--56QFV9u-Vg5lGdi9BRCLRLe3Fh7b0Ld4spg3C8zyqve_kE1y1YjuZsADd7vRJp95PLIK97f31SQvdbAM0hoGUPxXdPM6K-nGkRo97DbbpBsnmoPcyKninIcyIQjx0-_kp-TMUHa26ZGweQpJg15tNpizY_GuBbmP82JtbNiuGX_bK-kKH2ZeBakm9jNnW-b0YQs8B_TqstUBvg0PcaV1LeociDF849NOQxBEcQb_Z4EWycHGLhMhkdhpR1-qI0BFhUEGt7H1Mr5ULJcZX1BWCtUYlXvhofS9yhFOin_sYqiuRhSQv5KTOErfypiIOoBfPRhG4Pj09vqaZp9uAPvd1HeZOLGFBJ7a6bgTiit5nYI18z3LY47b4HDInFqNziXiigC-Iq63hAw_Mwjnx_OsTn-EgO-tu7c99xzOtdJ42T_mZBbIzE25jq5Qhjx20z8MEiW9nWBzkiqoxp9JtVSQRLFOZC6T3hpN-4Opm4cd8dpcrfavAQOBy97dPyZA4JDyC6i7lKFIT-ZwXoFqb3TfNIEMsL06rqrNVGFIeY3ldawcdQkxarx6cuDV5i4R3qbYlK9vyJiFzChX7zd6kDdWvQ6FqXIUENbP78kZLyN-aPZ1Qg4dY9_fFfgDq8_WJ5v1TyL7VrY-mYyhT7LVrsDFdEvIpmAoAYpnlpg=w1263-h947-no)

This pix shows the surfaces that I machined on the face of the flywheel.  I do have a question.  I'm pointing to an area that is sort of a step to the surface where the spokes are cast in.  Should I attempt to clean this up?  I'm a bit scared to and I'm not sure it would buy that much in terms of further truing up.  What does everyone think?   What's common practice for this area?
(https://lh3.googleusercontent.com/8b1lk033_Odvf08bq-rdhEsmPb3YAXj8zG7Jztta5WAqUnFwYAFzzQX50KHZQ3pnY4fXDCi2Zc30yd7wc5L5hMLi0VBy_MLPJ0gukHPK8k1ARioitGCsQZkj2N1jPxa4KqdRb_UD8ilGVPxgaw9AOa0j15IqheCgg9KOtJJXknoWta1Yz-zVl34H_DwD6BJi_p0o_dWdKfIDJWbjLx7Vd5-Z4tFy37K0Z6w5el97jqcZt0Tpd3BZtjhEwDub7csjWck3Vskr0MIZESiOKueUWbQuOovwTUiGCjI2XAEY3QjmyH8eFURTqNuFdHWtgQJ_mpE_vPpCK4imhSDIVblK2ih6cz244ePvOVL52xBHdDxSZ3SyJePzfdtl2LonjpgVWQz43lns5xOcJkaPeWcpdQWv_bNeR0Fi_Y3dNryBusD0gd24V6WgG2P2qW3LQDMl1F0wljPJz8r3HbrdEh7zwOARY2IJXzdb3ndyJXB5En7FzMLiuPHd67zixvRXrjd9mTOjaEtAfyQAMjMiJUxt19B5ffd2rquq7AoQsxu1w0DVIGHm4sk1FQCzBhd2VxB-1UcTGFyzkmT1tnkde0_PyUI1HzXtsjTwnFdgO7tEkNuEuGGJGOOvTeorKSRP1ixNjEsN8D7vFb4lqFnNFYYuDw5bP4OgQPEPYe2_4jqFVgoATcIE2B2i5n9Spn70OU3tGkcHj0OltH7dgB2YoA=w711-h947-no)

Finally here a very short video of the flywheel being turned at 90 rpm in my lathe.  You can see that the OD and the faces right near the OD are running pretty true, but there remains a bit of wobble and runout in the spoke area, although IMO it's not too bad.  Certain old equipment that I've seen run has plenty of runout in the same area, so I'm tempted to be satisfied with things as they are.  What's everyone's opinion? 

https://www.youtube.com/watch?v=79jDUhXsbpo

I need to cleanup the areas just inside the rim.  I tried doing so today but the tailstock was in the way and I couldn't figure out how to my tool in there.  I tried to machine it without the tailstock and live center in place and that simply didn't work.  The chatter was horrific.  I'm thinking about re-installed the 4 jaw and mounting the flywheel in it and then finishing off the rim face details that way.  Since I've got the hub and OD true now, mounting it up in the 4 jaw should work fine, I think.  Is that an OK way to approach the issue? 

Anyway, all for today.  It's supposed to warm up a bit tomorrow and be sunny so hopefully I'll be able to get back in the shop tomorrow afternoon and finish the flywheel off and maybe even get a start on the crankshaft.

Enjoy!

Mike.

Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Johnmcc69 on November 25, 2018, 11:24:22 PM
 :ThumbsUp:
 Very nice work you've done Mike! It's looking very good.
 IMHO....I think the flywheel is fine. The mis-match & casting irregularities are just character of "the period" & add a beautiful contrast to your already finely machined parts.

 John
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on November 26, 2018, 06:44:22 AM

I need to cleanup the areas just inside the rim.  I tried doing so today but the tailstock was in the way and I couldn't figure out how to my tool in there.  I tried to machine it without the tailstock and live center in place and that simply didn't work.  The chatter was horrific.  I'm thinking about re-installed the 4 jaw and mounting the flywheel in it and then finishing off the rim face details that way.  Since I've got the hub and OD true now, mounting it up in the 4 jaw should work fine, I think.  Is that an OK way to approach the issue? 

Anyway, all for today.  It's supposed to warm up a bit tomorrow and be sunny so hopefully I'll be able to get back in the shop tomorrow afternoon and finish the flywheel off and maybe even get a start on the crankshaft.

Enjoy!

Mike.

The nut and bolt mandrel doesn't get in the way of the tail stock, I wouldn't worry too much about that area it won't be noticed on the finished engine.

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on November 26, 2018, 02:44:00 PM
Another vote for leaving it just as it is Mike.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on November 26, 2018, 03:16:21 PM
Sometimes its just better to get it close with a dremel and sanding drum or bur than risk ruining the part, the inner sections will be sanded and filed filed at most anyway.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 27, 2018, 12:54:36 AM

Quote
The nut and bolt mandrel doesn't get in the way of the tail stock, I wouldn't worry too much about that area it won't be noticed on the finished engine.

Stew

Stew, I do indeed see the wisdom of your approach as the tailstock certainly proved to be a problem to work on the unfinished side of the rim.  I do have a question though.  If you use the nut and bolt type mandrel, how do you finish off the end of the hub as it would be covered by the nut?  Or do you also secure it with Loctite and do that op and then screw down the nut for added holding power? 

Just curious as I'm thinking about how to improve the process for the next time.

Thanks very much for your input!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: toolznthings on November 27, 2018, 12:55:55 AM
I think you are good on your flywheel. A little bench work and paint and it will look great.  :)
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 27, 2018, 01:14:53 AM
I did managed to finish up the flywheel today.  I did end up remounting it in the 4 jaw to cleanup some of the area on one of the sides.  I didn't bother to document that as it's no different than what I'd previously done, except a bit discouraging (doing it twice)!

I'd decided to secure the flywheel to the crankshaft using a set screw.   What i ended up doing was to take the flywheel out of the lathe and install the mandrel in a collet block and set it in the mill vise at about a 30 degree angle to give clearance to get to the area to be drilled/tapped.  This pix shows me 'cheating' a bit by using a 3/16" end mill in  the drill chuck to spot face a flat area so the drill didn't go skating off the intended point and then spot drilling
(https://lh3.googleusercontent.com/Ceq1DhAcuN6vmB8GP86sW0_x0Pakl5JeGpqKv1J2xf-VNhCjBZCJx695Rq_mMzMFGADDXNV76fuHvjv2Ne4gcs-06PmeAF9k0CKsiJcUMpJNvANFRPMyiXde8Ul9bTbNlfDtyHxILPasbaU0KtnPbUhKBfPamK95a_We6hGZBDVp2Iix_eRr4tymsiJkHlxOzbeCUpbf6UhxHlsNTYM9vjYEF4Fo6-6-ldHKi-H0mQLA06mqVMJOcQv3l3Uph4lz3XoLoqhJ9KlOyG7iferom-MlLfqbSrC17dLG5VJfjUwnNUgYUlC2QMgJCOfCJdUCxI5so9YT9L_q9gyavbeFGVfaz27KCvHb0qDBkVqshJN0AAu-n3a2A0RqLBHGo7Dkg1f_mv1fwNGDKWgrqDYOueheQNgH2W3Lyi-at8IqSkZkZcYm1hfiT543BWR4MRrIKtg7c21cHuqtEDazLwi2C6_d4nD4XoF6TOtl-ViQd5EQccUdJX6Ur9NhPRbDk6k4ZnMVvS11MCjt-77G-dfWNHEETaXKXjV94UV18nL4fR0JSh2ga40aWLf9KahF8vAQjiY3CFgVi5OS20eWZVw2wkATbJPmkakZju3IzE7D-VH8HpLYYXnBumCmfhB6J3LF2n2klpvZVsZFaizwh1bOlQ8RupkH2YJd3uaVSnr3wfgmd8OQPyuY-eg177a2RHngkxFWs_NJdQpBrlwQZg=w711-h947-no)

Tapped the hole 10-32 by kicking the mill out of gear and rotating the chuck by hand.
(https://lh3.googleusercontent.com/mr0kwusvkZHWaUQwSKI0JE7kUoQ7DCiWak9e8w82v0UY24FV6EcwLT7vkJUJbBSXeuU-HGmuxcVXKt-LnujB_pfNFC33gWsVja9cYWvMEbvOQLf1S-xtqyOF7NKi_zYuBJmtbmPer-7lmFxF8m-b3uH_Hzw_CVyLm3Q3vMgxaz9U7jTISU_TDCQZdT5hsQpljPTBpu-BQHe2e32ik82esS4FDmxdx4Gr7-5KHy5djCjnG8Qt4pvxVtWtEF-cnt31o5EZiwCMczfTEdDMOu4Y0tXczB5UE6SbAwQPg6EiiUe0oRY8LvEyPVKeuWh6aTBpxMovEPXAS4UUiafLvxqD_CqHd0igCDo5x9YLTK7nqHfyhuwtSspuJJDP7ZS5TNfX02aDRmqsNb_8K0ZlMAr8nzHfx9d5xcHKR8zrIFNC5a4L_kWxvhU2Zl0heuZYElw0O-l2fPJQXJYcmeUwHBxceHMirIDXV1l7-nLtqx9oYwOUB1Pwif-FRKdb5bvGFlJHZuTXY0sO3Hnp1Tdf7XI51tQvvxrbKNRI9VBPy0Wa4Zv9rm8oVnUJ1nMl5qhZjMISZ5PRhR9vwOva9IH6p0SoPLf0egwQ6uBcxT4a-EwHWtscK4oAICsn98PsoNRN1LgdhVoLoxqGF31VN1sbIeVDM-fhqu_A_5YiFLCGtMlpFFOuGasdf99H9a9Ee2fcQU8aLwfk9c5v-1HnTe5kuA=w711-h947-no)

Rigged up on my welding table to heat and drive the mandrel out of the flywheel.  The welding table is a bit near and dear to me.  My father built his first welding table in 1953 with that piece of cast iron that is the current top of my welding table.  That piece of cast iron was originally the top of an old very large gear box, possibly from an old Case steam engine tractor that my grandfather owned.  After my dad passed away, I got the table and made a new base for it and put it on mobile base to make it easier to use my very small shop.  Cast iron makes a wonderful welding table and I do appreciate the history of it.
(https://lh3.googleusercontent.com/NbGjJKX7UHWOHwsdQlrCBiuxA6LC2wd5bxESZp-LxiE7g4VoNEWDhulN68ScvlV75W6AHBHKdHSw8jvI2ZecajWYwkL7d6M4cPtRAZchz6pxYSd2pGf7lCzpYTxY3NH2PgjzsISG8jqCsDqCc7QjC-8NqqP5grrcZEitDTZY-TlPgUj-x2hkoqkuYU6Ani3HJ-auGsvYONpnJfpehmK5o6gjCfCxOHiREjvo_f0IMa0TneIEg-qZvr7YSYWInNypNiZKGhpTyHqef8M-P1k8sOT_8265WS3KyylKDvaWLb62JbMlQ8Qmb2wLkMx-LANu9aazFzdVXF83O1lvlmDPFRYgAUIsf0S5uffjS6O0262bDlKyLcsN46EGRWGnBYW8oIsud48iNCu_9R0FN-BaPfF1qtb_Uhy4dFc7S4FXGAW0rRNzBk3e48dVGad4NaOqd0qnoK45XHzuCHcgxKFnvXAhpalIPQohgBj6b7B2y1_VLMfhXLElw47Kw4WwbPB2N4Mbv91lkefOwiaki-Kj_WrRaNpRk0hF2bOvU7UggjCTZT61pyumVe0Y0yZMx6VhT11W2gXOzu-dqxNYJG0gcMt4fr3JX8rg4rNP9q3jXQd6BbHbcHvqFML0FNvmvy_JayR8JwjRTLRXCGKlDM6vWX6r6FfeQweOURK8EXLjUdFYkEjEMxZdciUpPHZ0294xLvzyTdqYSBFGW3MHsg=w711-h947-no)

Finally after all that, the finished flywheel!
Side that will go toward the engine with the set-screw hole.
(https://lh3.googleusercontent.com/DQL1YSxyFc7IpPJfxSSEf9pByteZGGmBvbbmy2E-rdUgSTSTfBNuY9ASJu98ajjUKJSvUv4fe7Inw2xFL9z450Cz1X3Vg3_YsAsJ9mT1pqO6Wv7Vzhw4b4-mMiVawudxrAPXWvTSDdOyc4swznv_wyAJPFYpsrWGKesvIMwlzw9QpY30V0__Lq7uLlGaoWVwbo3wo_0BSf30ctSSoo6lBVbrxzQ5w08_Yefh9mhzoyE2sWnp5gE0ocV9rclJd2nXWDJXQQd6bc8btkZsRSMIFSiYvOpq6KxSAg_Uw_G4kh7R9qbp0wHIOjfl3f52AAHxR8k0V47DLob6QJBoXV72WT-lBAy9gb5uC9KlI0-di-hmvRDyuWzMt20uh0TUd6y8EOqV-XUOBLAc3bOSIHlPIYYDv4fQ2m1UAe6Z9ueKD2fuGecYa5Sm4qvkMCee3LXrPcSOzI_sqc1Gnif4prj06hm0BE3MVJaKJ1z4mDIZkepjandRjz6HP8kNGDET514m33F7gLlo6GEhpK5W2txcUctBtyxGZmT8GKTLsOe60PYPJciMkb7GfAVyjjuuEkmAhk7LRX4Acjs1kJwJPqn2QeBulbKpwrqkOB6FXjIuQvFtKlEeCYMVt86pzbcAuhch97WSV2OwsygaKeFxnNuoiHvYt51jREnm6XGRgA6dGf3PlMvmjRQB0RnH3wk3pDoEFLBwc_qBI8eBaydLcQ=w711-h947-no)

Side 2 that will go to the 'outside' of the engine.
(https://lh3.googleusercontent.com/3lfXRI606LrkrBdhvu6_mZl1_vY6Y77RenM2nOPCYvH44VOrgg2DRX5qwX0QEGd_L_Ud-nhCcVuOUqbgXuA8NQ6MtoGIMpdjxaN90PHw2c_lELyVp_3YecL_1at2u2Lke6h9TNpA61L1lh62U1mLISQGiCaeggOvdfVM40Zb8884VKcL_4DiElmObGz9JXOcJDVWYqk6TLMPWnrhUHuZVwM1ysrUjiuUxw8A-i9aPEQPGrEryx4rE-_tBnUU929DT_DT8b_87cZHU1FGLF6xoX0vMzKEw-AYsvrboh0iwUdWG7dBjO1IDpEgX6Il_YJXRSCSqeoJLSgYS-e6YNAoHq5Fjm2-Lug8dfO17u0HLhwV732s9Uie565dIe0f_OJbeo-O62HJPvTbcyMALBraEJK0mBDp0sXfn9Qo4cmNMGvSFZPq8ZwhevJweMNRCQdzN7mjndXekU5T9bNnzgPUO67Jj7TradE03ov1Uj1dTQWS77UDJ2ZGkZtGZpcvFxwtD2EUKLZBz1bGu_CNXtmdolDc1QOfTpy4xyLV932Fi5AhBPbprJttQhmC18HHXy5q0Md_qTbKyjSokQ7x-yA-ry9-hEGMKgzyxNcM4vD9NgaOEViBwMzcekcR9o6zonuTpGnKsa___csBNxHLa4dknkBtVafwS3WlLMgqySia5GDDI3T9tGAKSSNpIrQL0IgYt08og1C-1EnTSeK5EQ=w711-h947-no)

So, one last question.  What color should I paint it?  I'm going to leave the rest of the engine polished with the brass accents.  I was thinking either satin or matt black or dark green, something like that Hunter Green that's commonly sold here in the US. 

I did make a start on the crankshaft but no pix of that work until tomorrow.

Enjoy!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: AOG on November 27, 2018, 02:34:21 AM
I like a dark hammertone green on castings. I think it goes well with the texture of the casting.

Tony
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on November 27, 2018, 07:34:39 AM

Quote
The nut and bolt mandrel doesn't get in the way of the tail stock, I wouldn't worry too much about that area it won't be noticed on the finished engine.

Stew

Stew, I do indeed see the wisdom of your approach as the tailstock certainly proved to be a problem to work on the unfinished side of the rim.  I do have a question though.  If you use the nut and bolt type mandrel, how do you finish off the end of the hub as it would be covered by the nut?  Or do you also secure it with Loctite and do that op and then screw down the nut for added holding power? 

Just curious as I'm thinking about how to improve the process for the next time.

Thanks very much for your input!

Mike

I just roughly set it up in the four jaw:- it doesn't have to run true, and face it up, then make the mandrel .

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on November 27, 2018, 04:49:38 PM
Quote
I just roughly set it up in the four jaw:- it doesn't have to run true, and face it up, then make the mandrel .

Stew


Stew, thanks very much!  That makes perfect sense.

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 01, 2018, 12:51:15 AM
I managed to get a pretty good start on the crankshaft, and I thought I'd document the progress on it so far.

First i cut the crank webs to rough dimension on the bandsaw and cut the to-be crankshaft and crank pin out of drill rod.  I then trued up the crank webs on the mill and turn the round stock to the exact spec'd length and drilled center holes on each end of the crankshaft, just because I like the way that looks, there's no functional reason for the center holes at this point (at least I don't think so!).  I'm not showing these ops as they are pretty straightforward.
Pix of the parts ready for the next op.
(https://lh3.googleusercontent.com/uEliM_SlsJ_mt13L_zHe1vdh0nMtkJPU5r5ARTHXuXNm2TyzWo9byfbnyQ-6Y9Afx8pBnPDBa_dO56UIgniesmfpn9AKIz92quS2zh8V8s4HjOyGYV1hq_1Fm96LxI-a0RmtzMq0Q7GqoD_MkVr0zAmpGQI5Fx8nWpDk7F7xVcCKEVLoNKMFTjjXD4-9lCSOGziHFL7g73XeWCg1O-1-B8RUigsd3f-LzxDM637jZeWbM393Ce3OhgNOCALi2HW7HOMrm4FAOWrQ-CyM1SCqYEA21X0flMxMKcUwXoges38jdRCLFYhiR3R_kWaaZYhac9HJHe4ak3kRI-M5hvuubun_8Vyeuqp0prFUee2CzkrwJQg6VwkPDSbH_t041AiEpbr5PQd3Up1FUpvaNvmDqMSvKXSlK_4XM6Wdfk6PL1qIQQno1DWI4pIUPYJXMbeT7_2dlpDATNCdP_1SzBw8Q2DYKAlZ-4p4G0zJFSl_-dIrFfJeH04Fu4eT0gM747xz_PlltOix6mjeIkc-Ak4_n6HZoDtqu71stBlAx5Fi5fUfSik1y309RYZ3vOpwBoOFkw34gAqdRv_-nqXx9mzCgDs28RQA6h4DJlBvqMkx6BFyE31rF1V2x0aBT_uXGR348YjEv4R05GF5v-uVa7oNq9oa9qjxpL6DGt3dMiPWHERmGeMj-vEt1E7Zred9DmdRMESwVBdv0rKpkplANA=w711-h947-no)

On the crank webs, I was very careful to get them to the same width and length by machining them together in the vise.  To make sure that the crank would run true, I stacked the 2 crank webs together in the vise and spotted/drilled/reamed both holes simultaneously. 
Setup in the mill vise using a square to make sure the webs are aligned in width.
(https://lh3.googleusercontent.com/vvUQ3YKaO3S5iZJOpTVrzq8z4uYDtGhCf690czL3A1ITAONF5gdcqKC0Rqy_IwVxNn2hb8dWaO6ExlV2CcykKRObvX6Wp3m2IRk-MyPL6mdh3sjAYu2OyXEYz9HAbZgBx8vyLJHL8_z5VVfiTCFo82aYkOQsDRZYpAybYFfS81Ni4yfX2Uk11E3V6F-zky34FOgaiE86OlPQ9zvFYFzSvoPZnIOZYvisLzcd7kt6of4umy7Mr_RGFknvsFppgnnw9jkNUiX_xpfie9EB0UCxgDOtUOrNKN1jcYHG_I2VTgbpDk6ZAcseCqGfML4LdeBRi_IAwj9tm6cQoAy8Rnesv4VUXlPbXoBv-Y8uFwQbIaQ8OlXE_RSwuJSRz5lSPihuAGsJQf_wdf5wBkOVyzFvf8CbMMpqAhmDjdg984DMgsYty8v0ODPf2WF7xraWB7f1dM13ryF8xur-h45BlCWYPi433zxgpm_bvxCrxFh5DUvCiD_gz91nZCHqcndwnvtrPU3RQpgFmkYz1hElj-aFYnV5eRRq7Iy0kIhp9KqWaWYV7J_o9wPEes-dxVU--2rKM5XjMnKixRiL3ZGm2RqO6I7ZzIelbEML2uxeO3ZtRvEI4jY2Oxgs6JeJRaRNymYgUakMaXOlJwDGGCkwwwAGZbPClyvhWkZvFVkqsyS2lZMGFbgb57JAEbV8A3ojVVU1by9N26zZwi-1FSV18g=w711-h947-no)

Spot drilling the locations for the holes in the webs.
(https://lh3.googleusercontent.com/-Rhf-TL6ZZeuImRz3-nKhVDpkYRf0c49vgDIfp9co6TjaOGYr2UjuV4Mg4L8PAVLZ5VASe0K4GkZRIn5V-6ttSXhd83EBXLDT7-qWJnfLQkzqMI0oyLxX32J8bP_YhhZuK_igI56S7FcZZosv9hrURQGVyjY3xJncNUyfcmT3ZrsK0j9f6c8bjjtbS7Kp0kVDaRGlPZWZ8qdfnW_5UxblyVlLk6DM7aO_sqhP3Icz-stZgyVmIy9iiXSFkeXD2ls-ZD_23_b1ZlJRQgOjXRNDV5kYHp3rY5bQGBMo0lxiC5y4q8WUOfPxiXwpiFxin0-JmdvnNXTB7f5dUePI6tCDzEJX8lcbIxKGwVTIFJ9vq-ttaw87Q-iHYlA3dT23Dts03Fb6jZ_gjj9Kb_AZo6ruGVWOst6hldacad6o9oc9kqJnUwDFhL0VHgT_FYsZjxKrjNt8hNkyMzq1jnuIP1TymQ5Boa27jOnXJL6THv5tMmgtN8M2Y22wtlgsK9aCqDqn6dmYhNEpmYopV8YKVJi3KMm7xuNxlN9IBlMm9U2nWHIOoCUYQYZKxK3Dlvh3f0Y7DLPDEVuFdNHjR0Cj7ENxlkTf_V5XyjBRnK9cJR76jgvSvtpWoZivXahKdFRDfTlworXTn0ny1Ia2fGfK25iETacWX18wbMDkWoAaIw1U-13ZGYYzgUmHyPXI_uJt8DABO2QLfB7lRPyno9vUQ=w711-h947-no)

Drilling thru both locations.  For the crank pin hole, i drilled 1/64" under .25" and for the crankshaft I drilled 1/64" under 5/16". 
(https://lh3.googleusercontent.com/z4VoaaqzbX49lyCrY1cvC0WmSpcjoo8A5HpHU8-9bUFv1VxLPMgzvRySmLZyZHz-M9mYE0nn8PX44RRh4VIEcJzc4VxxQTXCYEczRPJfqutYFL6jvfhtM8wcIQ9Shfg3f1xjHz96ReYrtogzOwYt04nPk0sLQalsbuyypPYI6QgK6Yzg5l2Fg70krdZom08vmbRWyVzPfgvrSngSC75MA0KyygtVj1068xjox1Hd3KnLcJxdLGLTp5myso1a_hxPq0tMSfn24WfqW7OQ7gP_qHqILegMjS4cRvNAUC7awV3ck9DUWIQgLzh4lu3cWNJ_EifJAaybAC3H4E5pUSb_KQ_aoIC04kwOSAjl3cAyM21nwLn2UJcyvrSwsksdNPNgBwJ4cMqxm2omLwyGqDZBACNiJNncOvh5e41IbnTLht8LlQA7FKWVbcksPT2uNoec1-opVByAtw9E6ex-TvlUvPV2eXjOy42q0qjlqtcsdGqQbVYmPwE_fNycC0tpd9eTL5ElS3KDtJsgIEAZUa42_fvbXM2F7n_zT-JRS_1H9vDayuzP1mM7d1yQhEObZ30eTUETxl7yYCM3u5Xw3F4Ld7WxGWq0BnndDEuvsI2sIuSMCe3lVS93lH5oJIsg7nqRT1NESjmpuN0BfZ2NJpBKEIq4MzHzsQw9nmg4E2gOPXfP2e5xgFT77yOgva_qebCBQ5NSdufKLZPXmn8zVA=w711-h947-no)

Reaming the hole for the pin and the crankshaft to .250" and .3125" respectively.  I slowed the mill down to 150 rpm and liberally applied lube for the reaming op.
(https://lh3.googleusercontent.com/h9MO-m1zXTtdq6q197Sq_f5sJdO84UcV_T4KdaNWXyJXclnCbYVyrypAyNAgqdqSRAwhWsAGisLGTeyH1Ev4PGQaM3UftAm58jZkGrhqTvhNtpns2GZ_pXwUfBdrqWob9xnRUHX1CD9KX8YhPQSBZfqsYB32PBiVhf1AYl4Sem2tLJdTUe8lOrSZc4MgtTXlTHLTHtLI2PAYeysaMRYi08qzou_KZUmQpAxB8lCBQ9kGTsFQb2i0MhHgfOLSHuaPAf09WamO-BOKtMQbRJ9UCnw439jv19Qr1RHuB26JyaCI2sBh4hqzfqZfpRJOrf95PpVkmi5Rbs5ynP1iB7a_bd28RztQ6xRw4K6QAx2OboRKWgQvUD3-pZZ8rdOHspE9LYPSFUGZ4g9Wzjp1YiWY_kUSUr34mot9G26AmpEbdb6i7pJlLYHE0blCs-hh8Co8N8CUmj3Dl53QmRkuwhFqa10bV4GVEQy9lN7MslbF0ZYaaZESfYZ5dIcEnRbDt6urJIEvdSiwj-w1CYiMKU9ldttBhPGBHxAzVuRbJRQMsfIfRECCASpo4n-1pRq2FlfVN47GI80KuvntiWi2bfHi1m5q_lwFwKEVjXfSb5qG9FB5V38uvdn8HeXleYsDPP6d52XXt1wPYa1v0RCldp8diz_XQMxS6nAZYQhAuIwM0kLn65QuZy8DWgEe15Nk-g4hxEbrNfrvEyTAHGiFWA=w711-h947-no)

The pieces hand assembled on the print.  The fit was very snug.  I could hand assemble the parts but it took some pressure.  I ended up polishing the round bits in the lathe with a bit of Scotch Brite just to ease the fit a bit.  Rightly or wrongly, I decided that the fit was ok.  Quick question.  Does everyone try to get a really 'firm' or 'tight' fit or is it better to open it up to maybe a thousand over?  I'd say the clearance I had was about .0002 to .0004 as best as I could measure.
(https://lh3.googleusercontent.com/rf68qun8PNZIOqePECg0Ed_XxKr5eHUWK3h-x3nOeSxYAnAg304qg5OWgKgQbKJzWiFwAQbfoIqrPAZ43Tvx8zdY-7GV1roZVGSt_ES-GDDh8Y_avAVnD5FMZFCs9fAXzD9N2pPXqxH7gTToBTcCO3PkN9I75E9HWDht0oWtZZzD3v3zVsMePNLZ_bJyRFqoZpabGISvG4myOqC3nz9RlK6qmkVFjKjhh5EXxlGAK1jlMLPgzqFzFa0rO7THHRu3Fh_Fs3Op6Hax_ivUO0mna1xc_x6tDwwzeHLRZ-tw265K9FdFHIS-W7mq5IiXwS9FsFa3JAQgbzACm7fiYD3xtLeRxODF29H6BPMCFJHEgHdELKCZJ6wX0aRK4PDbAPjwUqKc4L-6_ROoQGlf5ck0gV8W9XA7ygJuGxvSkhvcYCR-YL8-cmxDwpw2Sp1Czx-i389EB4A5dlCUXgKGh8LvRaeoTyf-8AmQ8aZMK-prIxB-F9fg6DprExqNwih0Qr8UUpjBAQhcaUj4rh4rsKy9y165vYgMXGTVFi0CkMlBEIYhoG4u3j1qOu5iH2dzPBjZLr2DRmg85zBXczgmyhHhR2rv1OJ_bbWZhNXerin6X7nNaMienYbeqeuhss1YMULBjyMtj1pKw120SNq9MzHgufDX8fImDxHqQSzIw8avOfluVZig0g3nnI_CuXnnvlxuDWHUSxCCDxfdcw7XyQ=w711-h947-no)

Related to the crankshaft is of course the main bearings.  I assembled them on the base plate and then made sure they were aligned with a rod that was about .001 under the bearing size, so i could slip it though.  The pix shows this alignment.
(https://lh3.googleusercontent.com/AtA7dlFxaWvkL2mcjWC3dxRQJIghSUC5fufhF3wauJLm8_2n8U0YWb7qJES-rEB3fLMxe0YDBNUVvXX19Mkg9NpyB1Gw_Dku4tKQb5lxiMRPICW7kCPOLRlgf6gFusmhuvwU95hECYwm9DoQn5LPgVTI-nax8IxsHHidTACYVHHPfAAEuIO8Zs238EqsERUx8w02URF7FPewJAwtgnFLujL0E8jgM95hwVO_EAtngVS6i8BvYe4UhxXMFSJGT3EiIH7tZFslsWG3J_Gi654CNOAWNy7eY0LzonUT6Og-s9Ws95uCOx-JECyxWoKp-y1FZWs0Y8Cr5MEiAEWT5uFK1DOvfuy-KrOYQ6R6ota-EEt-IvVRYXJKlSjo3St5Yj6aoQ0mWTU98YbvvGoh8SOosSh6mUTsAmUqQDQ2ib_h2f63uUWIOAwQTlY0HIhC1LpccZho9jfDWibcxJFKgbK2LbBkgZtXzklVkj-br3hTCLqMxksHJP8bAX6l9u4bBjsCYJzglEWumQ4WoTx_XfkBjVzMkzVbMXhuX0SN_eIsUBilmR9-xGDka5akFPtIt7PCUIrMri-9C_lS0Vse_3Qi4qGk8mz4FTCAeomExQuMl5aXD3Kv-TOK0bmiWsE2Ni8ucPyzGsmoX4fwQzYdulxvUHXdFtTrT4cY0Vre7uEoevc7UBeDHbRPL3rJ1U1cZnHuHUgrzWiX0L-kr1axuQ=w711-h947-no)

The crankshaft would not go thru yet as I'd left the bearings just undersize.  This pix shows reaming thru the bearing with an on-size (.3125) reamer.  I put the reamer in a drill chuck and simply rotated it by hand and passed it through both main bearings.  At this point the crankshaft would pass thru the bearing but was quite tight.  It was certainly not freely rotatable.
(https://lh3.googleusercontent.com/GHJ0xIo0_cccc3e7owdFXv2ykOK9iU0w3nL-kAfgg53eAgA3DQsttcZYSSoNLYXsH9IXzlFxeQTce397UQx6NnOqdjniRW8lCkspH05Xw0K2iKbyDy_poubJWSGeCXD2AJrG6rt8MWJX1EhObfJF06c1GITgIU-cxhwZ1teYQrq43lZ864ak7hrByt60gyROH98RXyDFjZKN3FNc-PUoGkbbgfmFoFPpTQjyoi7HWN0B-y8gX1_EZNEPDSL_g3dR8B6mGHPQSq8Tfbz3t1F94mJCezwWxN7uB4eWeN3hC3ZUxQaEXQ4Jme2lsBpxPicW7A8mFZqhXaxCA7i9m1dGUJqiFMCevKmonXiBT0Jgpt5Fq7kOpMag3rzSTTx75xBTogkURZO1OtY681WAWl_Q92m_tjusjDoJfHE8UEzp3Jzb-2g3ZYveDUm2WtY9tAVnoi7Mp81nyYdQtaVz8r0hchLLesIh2Fkuq1saex1wN4_eVWwizYR_zy1tmkdL48F9PKGO1keKFR8Oz3mc2pXkigQbgDxzpWgDB1SpwiR_zIZQTcVK4UDccz6zpG6DHbj_xaunQmcMsXaH3ESAK9xD_33ls9UB-XrQwQ0_zaYk5ZZqtHEHgQpb7fl7KyYgD8QedXRNp84ydJDt7NScLmE-ImSNJLHvKEk9eGGYcBNns0PFUJcEP97JoAx3tHYQtP8DH8iuFuhCkn1SmVII4Q=w711-h947-no)

Closeup of the reaming op.  In this pix, i used a .001" over 5/16" reamer, again rotating it by hand.
(https://lh3.googleusercontent.com/YnSwJU3bTHM3vMz-nwWBF3b1iBNLUx8NkyN3HAPePl6hL053Ar0sxtDDpKa_MFFBSlhLTgNlE4YTFdgy22ZM_lNhenfWiA5o6FxBdWmrcrexI8OzJa1CamWkYSDtIT5kg9dPrhl2mvQ-DMYV73ITugwlyb1fpsuLJzQ7bAk-ykUptc3xEAxK2ibSy0x0pIHTjfARq5BwHfUX_kDEVb7SV5_DpgN3FmYo3LxX2l136oM42BRezmH9H3HZbG1d7KYr5xcdTlt_kahjikOsDjQG7odcR1NPVXdLs6G0n1HK1UnL-oBdkN8C5ZyxIt3opsgURWKWDb2ZT_-9I7Dsi0vEiWEmHCD0NcxVAi31pfD9b4EzTYIn9uL3LmAooXPus9yYElG98x0LCcks-Raz6LXERIm5b_DzsYSCTE8bZfuBDMcd4gWh8dEFZQajwSunA5SLe6jZeF5PJ1bG5YWaYPUSSzZz2wj10iTI-sT5QmpsraJ1tuXyr2HTpRRj7hVi0ph0aB4vBzCbeiDELvDh3BIAFIP05sACgi6u0ujdFCf4oK4aABje1PDueIoGuMFxi_oa0gww5XXM_iAq08AvznxPPWruHxIiDIDz02VLEnUeBchY0zfcYTsl9Ewm--jCuY-RcfVQ6bVqx8w13Bk2e_Y5SvXQcqNWcLxlDkcsWujZzrbIi13gqDYIYjoHueZUPQV7Nrnh-0FXw8UJvGv7uw=w711-h947-no)

Then checking the fit again with the actual crankshaft rod.  Now the fit felt good to me.  I could detect almost no slop or play but the shaft rotated freely in the bearings.  The bearing material is SAE 660 bronze.
(https://lh3.googleusercontent.com/5vbKF880DZ8jfMhg3j5Ja1uF8tK5zs9uN-Cd8EJeEXtLZmtMfPfJii_miQg_TDnkex81OdemNqOfq7L07wOJshJDVlcEegv6P486xpG3s3Tut8946L1rWA57r8gYyl-9vSLTbxGlX7ze6cbFDfIQesAQJtyYnPmu1g6-9BxNe9gb1DDoYmnXpgqeMkNf3gxck2HF7RLHaJY_ZBsuY-Nf2jgP6eNxfYP24nvRNKXFzXo-PAfNtdHWF9DLWkajDpYuSplXtJsi8L8iOcWSMqGkqDem1X7kaxgR3e_dUdE2BjVFp1Ve7lv_aYHNkfF7XaEJpmJgxoT7sYc5IBT2wOXWgVsA8-DrBUEO6JsVlJIlSUVJxOnbha_kz4w1-IH-WtkhtzKTAPjekKy-ZGdUG53t9H_72yA9YHUP_KBEOIaPHXQANQdK7v6ND2bM46rc2qEZFwsTOJ5ni1mSD0btBQ5HSYUaNo-Mymu_nGMuSSq9McoOI5YVEzZfIFeFE3a4ngWifbdTBe2LI3XWxIpHnj4Ny1rhiHP_VNgjOUpHWP5D_tv7IGokGixv8jWo_-LN4AdkivpF5Pc721vg_gpy0Atg7ihCKkdiqY2RkpgBwBd7gyQ-E1Dg2bwsq-9tMaDpieZbuQye0fG_w-Q_y7u0_5sOkyhLIUhsMTyUlsTl6Vhqw-Q9mH83OMEk6JlcaDm10Q3FZlwnERoxKRIzoACUow=w711-h947-no)

Just as a comment, in the future I don't think I'll try to ream thru both bearings like this again.  With the small size of everything, there's quite a bit of flex as you try to insert and rotate the reamer, even being quite gentle.  For a built-up engine like this, I think in the future I'll just ream the bearings .001" over and then assemble.  There's enough play in the fastening arrangement to take out any small misalignment that may result.  A cast engine assembly, I suppose would be different as you'd have to do the reaming in place.

I didn't show the Loctite being applied and the parts being assembled.  Things were happening fast and i didn't have time to take any pix.  What i did end up doing was finding a .30" block and clamping it between the webs to establish the spacing after applying Loctite to the crank pin.  Then I applied Loctite just ahead of where the crank webs would go on the shaft and slid it into place, checking the position with a dial caliper.   

This process worked, but I used Loctite 603 and it sets up VERY fast so I started feeling the parts getting very hard to move.  After looking closely at the specification sheets and looking thru other build logs, it seems most people use Loctite 638, which is stated to more viscous with a much longer cure time.  The strengths of both are almost equivalent.  So, I'll for sure get a bottle of 638 to have on hand and depending on the circumstance use the appropriate product.  I can tell you that I almost didn't get the parts in place before they locked up solid! 

After curing overnight, and based on the wisdom of other builders, I went ahead and pinned the crank parts together as sort of a 'belt and braces' approach.  The first pix shows 4 holes drilled in the crank assembled.  I did not drill all the way thru the webs.  I went to about .050" short of the opposite side. That way I will only have to clean up one side!  I used a #49 drill (.073") and went and bought a small box of 4D finish nails.  I mic'd a number of nails and selected 4 that were just under .073", say nominal .0735".  That size could be easily pressed into each hole.  I clipped off the points and ground a small bevel on each nail so they were pretty flat but still had a feature to ease the start into each hole. 
(https://lh3.googleusercontent.com/64ADKxRKsWSMGv8cgWzV-T1w_6FfAw9rGi2THa-EtOEHj2pr9Cg3fOTyftC0Kii8ouK7bPNZYHcFQlMCkaKeS6mn3sWDnSiUPT0PVUVG9BlKTED1aE76t2lzOdzIAhjlLahvHlaZFgYXQ0d7rFq7hbNQdKZXyt0HmXitAWKdm2Rw5SzMpYsf8-N8X1nvNhPnp0YpC4bCmW0eipeOzkE8Lv-NYxSiJ9I5COHIAgN0I3zXL8_Tr_fp0y8ClRcHyu1KvAwuCxHMnkPERbiWqbYaaWmiGAFhS0Y3S45AEBMIvBPDHh4bx8HJ2h1KkjlKpjsWz4eiIksrBSCItDLQ38NrQB4peK7NGICIWzw4nfIERWe9sfNlG3axncS5pkQFa2snuSCBkd7Hh6BWMyOZNW6BdFcL00rPvmQBz5529YXVjd3PMzkcwVuw-i82gQtpvhCJZo7PXLm-ahgBxazNtocz5Pdq26t5l5HD9NVTLoRwmhKwtqzdk1DBxItHgoZwHmEpfGq2FAerJzQGeRwQeoI38y-Pb-IhhlSb6K6eKHBsqnpc8l-Lxe90NQjfVvN4oWSCWxh8tWcDJn0bZ2MQyNsRDHlwiIdtfiLA1bPymsV3uPkQOVGKYuUHyFMkajUJ3GfvlA752uX8T652bxirE5K0v-DaSJB8t0Hi1LhIp1NCNPZYiFx4bE1GmNq5KXPnVH9qLPF7Wh09lmSmQULJgw=w711-h947-no)

Then I applied Loctite 603 to each hole and to each pin and pressed each one into place and lightly drove each pin in with a small hammer.  You can see the Loctite that was displaced as the pins were driven in.
(https://lh3.googleusercontent.com/bYJJrXic1NWUhkADwr0bUY1z54jWCwJIey2jUIFLncU9OITuE3vK_VQ6BHPqOpXAOt9UIK6s9po0j6Wkv7baT6hbMxdvjXU-R8K4BaAXGKCQcvbI-YgV3b_5eZD-MzWR07nhY6TUNpt4gZHMpwnxjg2rLbRs2aIgnf5hL4ezMtHF9S0yaC3QiZ0SjWJN2eBu6fNSATKyGcjrvR_nd9qmYXDDUzpZMjf9jD9YKfIEYDuBjn1BT7AxAxf21FcVpCedlx0AlciA4UsXcLSLxC8TR58Hx2zya8GmZOUX23zDoWxodbKw-UOz0loloXd2jlDlwSSZTDzGJmDpi2WBq6RuUnPf-R1kYfHhxvtGZQnchGtq5VJbj9JoDk41DH5lAFF7xUBKyZHppy4comjECcWN2Y1x19_TcI0yB1P4ZbZiOU_slWLNNchJE4D5BdnzZsooV3_wG81NtnW7tjDYvQ62U-MP9BB2mLIJuooYAlTk314A4-hoQMd24GRb-WnBJOuQ0u8qv0P_PH0JJzXz8GFmnTVPdhY1B0aFUZ7C3z65cxmKykAF6Qcnydbp05BnmW-tykFMJdoVEj_EcnunpyLL_EFdt_xpRWsUr0MhX1QaaES4njUJb5JVdxznJrnarT-mhh7QEAR6aLW_zuxA_otTwUmcXHH4N4k3R6Uu-1l9565Ldx8-6FHDaFBBpN_t3u3fS0TMm6p30IOTs6Uyhg=w711-h947-no)

Then I clipped most of the exposed length off of each pin and peened each one a bit just to make sure they fit completely and tightly in each hole.
(https://lh3.googleusercontent.com/arsmvLRnFuJX6II_98o5ecLOHo_uS3wYzpQic_oeRMhcq9WKPOTHGpxExfRpvM7MQlggujBf5b47xKvovbr8qUpo8nT2NBXK_Es_570MZUdv1st6LnPxelaxzJ-HDGJK_2kNqOtfVxcoH62XhNR6Uux5Ikdx1TiH8H-_5oYfjE7l4rnY1HJ3iIdTMlhe93bdaFN9OUGhOsJQLUa544p6SOpyWPznbiV40QjaS5-KCNWN4j4g8B8OAlqdF-1iUk8fMrxUXQbq_qmhhuvwXrPWAAk3565wq7gUgONMFWseY2jaZ6ARZ-2SqAVFXVLS-fXzR_QLRiLrIcP0RwQOEsteYpzRZ4wmuKr-zhH2E7bsYTF8P5jlBDnr4RAk6xKKFgUsBbP7q8Nb4PPka9k608j2F3y2xnorCK0VVvy56qKvB8PhYoVCkbHrke0hNuBS9KdIz6DSASiUSdH1y8pyaiT7lSpTF8kr68oyYUSqogzxidhqGFz56O8gE5SRmdkGxi-75qOrujslgARXoH2jwB1OnU7m8gj1NQughmE3xGF2QzTn43jzeXP-kj4zVO5n8-Q3ouC_2QgLElpQcGPkDwtgHigL6pO41LUDTQbh2AVBjHZ13epEoLv1B50uAJiBAvZlUe8RBsPAc9C8sErY3euKOhfCNmKAtM4G1bD9BGAa2kYOaABLD9rew2DR0YxI-4AZpHvH-LBRGeTGxkuybQ=w711-h947-no)

Right now I'm letting this assembly cure overnight and in the am, will file/grind/sand off the remainder of the pins and will see how well I can blend them into the crank webs.   Then I'll mill out the center portion of the shaft and that should complete the crankshaft.

This crankshaft has been quite a learning experience so far.  I'm not sure that I did everything correctly, but I think it will work out.  My main question(s) is regarding the clearances that are best for the fit between the shafts and the webs and also the best clearance for the pins.  Is is best to have have a hand fit on the pin or should they be tighter so as to have to be driven in firmly?  Also I used soft iron nails but would it be better to use something like hardened dowel pins?   Taper pins would probably be the ultimate but I didn't want to purchase a reamer as they seem to be around $40 for a 7/0 or 6/0 reamer.  Opinions on the above?

All for today!

Enjoy!

Mike

Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on December 01, 2018, 08:21:21 AM
Hi Mike

Great looking crank shaft  :) . As for your fit ? I’d probably say you’ve made the fits too good, drilled holes with a little bit of shake would have worked out ok all round as for the soft iron pins I use nail the same as you they to can be lose they are soft enough to tighten up when you rivet them over .

Hope this helps
Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 01, 2018, 02:41:46 PM
Mike the flywheel turned out beautifully!!  The crankshaft is coming along quite well too. I am enjoying following along on your build  :whoohoo:

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 01, 2018, 02:42:58 PM
Hi Mike

Great looking crank shaft  :) . As for your fit ? I’d probably say you’ve made the fits too good, drilled holes with a little bit of shake would have worked out ok all round as for the soft iron pins I use nail the same as you they to can be lose they are soft enough to tighten up when you rivet them over .

Hope this helps
Stew

Stew, thanks for the tips!  I'm glad I used the nails now and I'll for sure open up the fit a bit on the shafts/webs interface on the next project.  I'm also going to definitely go to the Loctite 638 on the next one due to the curing time and viscosity. 

Again, thanks for your help!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 01, 2018, 08:07:39 PM
This morning I managed to complete the crankshaft and even got to try fitting it to the rest of the assembly. 

Here we go..............

First pix shows how I got rid of the remaining protrusions from the clipped off pins that I used to further secure the shafts to the webs.  I used my belt sander with a 150 grit belt installed.  I carefully checked to make sure the table was square to the platen.
(https://lh3.googleusercontent.com/z1FhoDjoBwRzUJCJCWefViyRlNG8muyRgeF7upMc5oe5A4ZGVglD0YBgfKB2IU2qbaw5EGBgz8FFcT3vDtSO2RFdDd5KgANcE5lwDsJmzwVkGhyUMTGWLEMzIap9CM5PjpAG9Khc48CkVxD-H0nrzJSV-5RG3b6CoQHk6UxV01CZOb6P7TT3p3djF9yqqwGetkOaLlzi5jwOQHEGS1qm45VUQ0cB2PYuJSRJkH1d2FfnZTJ4P96xxko6GqLRFEu1NbZvC8GlS4fpSRdJuvq3vsxDyZ2N1YYxxjtypNWikD1SPNn-ZdlrPjynA9mORzLiCY6z1Oo8JJvxqfYs9xj7PQzt6qRfYgQoB_p4z9GfyuOKFdu0h3QJ4GypnFtVt3Ou6bpIBSfhPuL2RAKptQn75viCdiDoZtt1jQaSwj_RfqlSBM8PoanUmcWDO1Y6-i1JgdeCcnXvdcQ_lXm4UZQvFHehTGfM7QFkYYab76REV8vfLmYzX3PrtJV5mUD_pdE4JzOyVNlesMTQFSou9SctBKKAGejx5G2pGKQ1nRawg__dpADzx3OP45plVTSz1f5CyvKsLJKTQpAuRo8TTCsWEzj9gxn5jkRpae5CHnb13MZ0z5uLM_eLb4ayaUvSGH-zDFyJAN6QGY5B7_XMmzdetwR5yowsnoc3AazqDspx__c1XGvwpI94KufoRtVa-Lb1oO9ryb6kpwVyL6Af2A=w711-h947-no)

Here's the crank assembly after the work on the belt sander followed by a little hand sanding on some 220 grit paper laid on top of the belt sander table.  The pins remain visible, but barely so. 
(https://lh3.googleusercontent.com/5tYkWtl0ehrS1tb6GuLy9MQA9gB8jBj23DCkZLWqCP0xWA3lAKrugOnJjwKMW1pFNilQgcwc_ryulzNCy8psFl0ZXT3Smgo5J-n_k0cdRVOkQJh-bxkD2HAhe5I1UkOrQIVluY_t8tJ32jTunXLsNkQkb5PcdTrs57Zcre9-Ee6KjiFmCiWM4jqHNGZdW4qh09-HL3Xw1B-9gkTmI4gWSeUKisv882RrfRJ2umtBh2Ur28dNajCzQCURJrpotlHD7yV5wVPX550RQo4gUGP1rmtzpUoI4h81_Qb_lNQQz7DpmPBvsACP78o823KbDBlxpnVx7_P5EDvVfJBTXnaHSnlLEc_qHkGv8W_r26sxOwPEbMmUy636bPXdVCe0rtfrtSbgfUCix_N76mSUuBe6NkxND2WWkvnj1uCnExvLl9fAPljOF0WIfNVZgdjelPEhMR6VvE3Pu2iANX9q9YVrfwTLErJ6GirYck3nffEYMyNmgXhjm83GBUsnzSIPQBHKGgOj2j25ygHY85MBD-ZQaXrtgI9b0W0LI79LPqYeTT-y2yITbVi0uShac-1erOna5Wd3-n4TAcI_vzZQARCUPlKBwrajwT2XAo4-uQumCbbTU7TtR5lSvB9kHHsJ_1JVr6Sax2q2F107s3fbNVqyWDBmPa-V5tg9XdmyNRlwjgAn0fkU0l5xtIhfCwlSpS5dznIVA4WzTEHv-LvxUA=w711-h947-no)

Then I setup the crankshaft in the milling vise and carefully found the edge of one of the webs in the x axis and moved the cutter to center.   Cutter is a 1/4" 4 flute carbide end mill that I ran at about 1600 rpm.  i took about .050" deep cuts until the cutter was all the way thru the center portion of the crankshaft, then moved over about .025" from center to each side until the remaining shaft material was cleaned up and the cutter just barely started to touch the webs on the inside.  This worked out well as the inside of the crank is quite smooth.
(https://lh3.googleusercontent.com/qaTXbkqZiQkAToL7-eee1YHNxdD292fwhYCtXcLaYM8aHjXtnBsroAFrFTDYkDdei1W3ebdIJhNGvTCBm9poTr4bZxbgS-SWVgpYXZKjZpjPHEX_fHut8on1YuQ75ix_2xbivj6UL1AfWembMyKhvcw8vRZKtZv9IJYlRj0riGCjzYoh3Oi7p2SNEtcCGejMtXHDzfeCYkY7pWSLGO4FwnSk00Qn2rl1oAOWlk2IAcLWFAXzmkg8IQmF4N_OXpyEajpGSt8Sv4MAN3e0ht_C622gTcBVnHwnICNNZCXEQckWKEpXD6Jz4pdCl0WSZuMhIlyuzaWeYSp49FsRNBRus0QoCx9xEJmxsQKKjzOHrmp1z2cdvuaw44HqYN0rmqXUTTyRWHs7ZSvjRkO-LyncbYFDlAPijrGpbmvJsIlRcqC9q3ok0ILzOX_3TbwR80q8PBofcf4D73QFUKDJPLDf9P2EF9NqzknGD7jc-ohwRyVso2lvpmXCWygEfNoXm3biMq7RYNpGf5adzfC8keadiHKGRXVVAUPtust8JNwudEmxsgcAowwgJridqembVMkpToK07jRWtgIWhzANuAWtkHjWN5BPXWOq23lt_I5MHoUChvRn4xhiQ0ePOR91ucubK5sBQxoSl6z3DOGRPLREN4pySqKE_Bzrw9GzDCPXLsX2pLC93Xg99KMzrSek3XvFP5dD2RaCMr9Z18JzfQ=w711-h947-no)

I put the finished crankshaft in the lathe in a collet and spun it over by hand and measured the runout on each end of the shaft.  Runout was at a max of .0015" on either end so I think that turned out pretty well!
(https://lh3.googleusercontent.com/Qr2uj-xawwabJi4Tr6KErU__GK_IzsUV_hM7-K_kksTfTW0v0OXrzJxCr9OePAl_NossOX8BUB19p_6SFaCLfdBSLj1vp8sEIMvhG2pJMJHS7XpIktOGD6GhBuDMDRPKxttAB5crF0Xhad_vkRRdwrJQyGDf94cy06sLY2UOkbMQJGQoXTyp9FhWKVAo_HlSaUGO9dxrxifmu9b1jlSF_6EIB5K1T9TTqLDO8oDYHDzkBCgwPylcf7ERwwLTLbtcleHqu0wFqGSZxuDKDUAx87kFJlE9Ji1XIKrDXoFyrZRLTRWvaKBjHfw1BilX-33U-nOTZ7lnfGEU6f8lRP-BiKjf50gx3zEA3WhiokKEYOCH9KKwBd3xZDBQ6O59nIjUmN2C4WvhSrp-8eVUIlT9ZcbKLJ7owGbWRyDPCeiGRIA3wyMnj5Vl6Rw9MTTlwHsQjpr49vAsUUGYqMqg9bVamIEN1Maymtet3P1_NuW4Lpe0YPg4WVdRk437BuV0uV5mw0UoVg9cWHeDuLO95V0n0_Ng4iVc1vPF55cdabXFvTC5WTc4ItD3FHIx8R8xiqFrH5MIm2EzuXsqoCqXXgltQg7fBeUnhGHx_jmTyJHeXTeyjiONQmu4IXpk1PEoHMQ2H9iwq6idH0BEm63dvkCOKNCtIpWZvDTufl8wW_ZRlYAYGoRNHWuzcNzsbUpj4EK_0li85qA2-VBI7UTyow=w711-h947-no)

Pix of the finished crankshaft on top of the print.
(https://lh3.googleusercontent.com/wbvXAP48V5C3kFv6GTJnc0wI3D02QBhKXRmVvadJBDPjI9HQjgzf8S0qccQ91jypP3TVtRXu9LYI7dqRg7Uc9TONkTVrqO3BPfdg6D2Gfc5V_jzs8TNfwT6Y9LE6eOLbF84hcKpc3MNtiaH-3F9CvR1TL6eZ-2MC_WnJlyV5Colm32y4E5Y_Jaq8QrDcKQE4x6P73MDYkR6yMTpWru65yvGabEy6M0qtQ-AY9IsdSwYsen4fC0gsPs0b4RujvDtlL66PWs1188VEE6UQntauuOr4wcGQwA2qiiB9uTl2VVyuxYJ3PfiU4J4oSiW-et3vGraKu3yF7jpGNdLEkDTSwckNE4Da9xk_mEhLjQ2hW4IKIdM75LTbqUfpsO4w3lb1i69aiEKY0-FaHn9q37ZvCGpEBd600YOyy6rCIdiTesUPlvmH4JoI_UVUfeZu8nTrRIDPnR-HP_twDKharuhJEQFobp9-FaI6ee6qgfrsEgeJP1c1RXQQWo9HHeysCL42NgF4q22UKg-NVBusBzW1HI3rkIwmfNRqaCZyHpbnd7d92Q8HbnjyvoNchpQX_9IP-6YcDh3GUG_A0ADqVSwp6tuozGf9qbSlm5KZdhE2QpgAikH38GFUKsyMJRKPVoenvd8Tj2eMYRatUPfOmE6xR5xnchonPW8H1qbggpzxt2Vezev6ihVa4J9_dWqcUJwWcVWtSJb0NWfk7yApTA=w1263-h947-no)

Another pix of the finished crankshaft on top of the print.
(https://lh3.googleusercontent.com/DkmcmiNAOaYRbT74yif6b_8r6vCkvw2PnbuU13AfKY2Bk3DIXh1EeQ4RxjkCR1ObEhclfjpdoa55AERREhypvAHl1ZH2QVXPDCByEWhM_eu_R0IKe4q9TOGDUAMFWy7hqehmQTQqqAXuAsBeL4-q7jfxh37YNsS7ejkXJal7JDodA64x1bK8jqb8F4yBwphvVBL7jZueo67lj-hUGClCJXuZ7ZfC-XkeUTNnf6n7xR7no67IbCOVq6BiUZlZXroBpS_W5uyrFM0ViP9tSrs71Csux4p7SS8m4Gq9TllAfcIxn2gLlEWJCK9omRjvx_-pj8PbTQiKiijTuRWUzDp2LMCkYlaF-qlYvu7Ke7UUDFsHqGRnSq5Ng2KQgbacYazOHETI5jKJ6r_5mLHmGdEwTFquocuZ1ugRtSRpRnJrXQ5YZ9jCSU3l-ClRj0sKULqBfFGi-CXsHOVhfKB-xGpIrd_36hJpNZxchYELhaTuyBuOJcAq-YF_B4DdM-ZQZvNRNdxU_IsOsdaFud9OrZdDfjZKEMRHNi81LB0bNVZWKAM_bGehZZNfnAOIai_5UD6JwpBC7Eikn5BulHZWTrAPOGbgZEoDEFmAcvOQEW5g4ECmBhQ5rHqbeT6KAszLsiF2k_eb9z16sE5Gv72VLuc1P34Rh57VArtYz4Tfm0PdmMvtdNFcIKNq6b8pKkYNtYfOFC36V_6rCKC41kOxHQ=w711-h947-no)

Pix of the crankshaft installed in the engine assembly.  The crank turns freely and will rotate from the weight of the webs with almost no perceptible radial play.
(https://lh3.googleusercontent.com/XXo-tn0L3wlafMh74Z3co4gvvSKdDyGY7JV57xwdEOHk2pFMp8aisygtG_eKnf1t-EYlzSYmzI3q6feud5KB_edDzC1G1TaVzWYbGG7aaKqEqqZBle9SONkh6vZ0hrZiTYoPoZvmAJLT1lKp1rIASi8sAFc2lvmqM0Ej0PYiIrLYlciQjTedwxvkJR9f-4hgS0GgwjRb_tV4gkOQ4yXVrcT2ELKSLbUPM3ybfcF6Wt-2DNj2qFAFnD-nSBJs-W9Jp14HICCW3urYGiQ0RGTdXvsmeeaQT3jB1bef5stp-iHl3UkawfM8jrprklRmQa9oyknXoRPeharDYdQMrRvYzZr5wD4VvmbJDRJtktrg7LnR9KvYrZZdJRtLhyKJE50_lMNQVtcpjov2R18Cht6WhKmtlWwK__8KaUuqbLFtM82gwwAkgyTUfRYPh4AQDQdmpbbhwZTLGykM4ns0GnrSqHnXIh9MzW4KLSRNHLdVF8cXtDKWG2lQ7u8dQCfVtWo6NSXSJcvtG0FlYAHXMdoLPxNToem6qkeJHpbdNHA3FFqdkMaII12Rcp8WBw0s-9YQXsP8Qb68aBC8BU4tWaCpqdPGcEZBDKHlKIWT4mymlpLoF792s4VqbNmBmwm7jpeUAA37jABwmO6-rG4oI6eoz0qgU0x0nJpGr8kwWMKW8zkL4GCzvvfWUSK1rBxzrtzqBvTo-42Cihc12Uj9Eg=w711-h947-no)

Finally 3 pix of the assembled engine with all the parts that I've completed to date.  If I spin the flywheel by hand, it turns freely and without detectable radial or axial runout on at the rim.  There is some wobble on the unmachined surfaces but I don't think it's objectionable and i can't think of any way to get it better.  If I spin it by hand it takes about 5 or 6 seconds to spin down to rest.
Pix 1
(https://lh3.googleusercontent.com/lF0jtRWn5y5aBSACeR9qVZQ2yZVyjzxM0NTU7b3UUM9CptuT4HGYmKfaTL0Tu6sCBxgRKBIMuvLZO2jlrbP0SAO-vJmuHBJ6qwtYgsavcoMBNw8eMyL0jhz11U2ubFVqogaNyeeMe8ru6DsuH3rcjdhI6YtF0tMZ1OupiPzqTSHkeFKBD_9oifzjMBNyTcW_Y4YmCAoTSbJuOLGfzJE1kDdjkBADQros-_pHcjKXUoMBUUvj-Q2uqqwdqxA_PdC-H6QASdjqm4KX7faAe5ts4kAdrGkvmPgRybEHHztxJFmSrRGzeioTytGaCpbSKSzALjfGcWno-UUI13FqkAQ2incAuf1Iz3vdlhTEyyAG9dEWXa1vTwvCK4085Mgju9Ul2aAQ6p1FphwHBqMbUKIFHWgJ7AFHhx-0sZ33YqqfONbUo9BsX9je2-kRvTdVElzffA_7dsszVAnXrc1puHcGTlO4apchEv-Lt35-GFIb4ajuW1krm5QPtjUx7UWx8TMCcxQ9O0-tzjsZlwmnDfh3m7_1DK9xVJ11H5hl2yqJ9cK4ex4Zk3lUnBBFoJzOgI9fd9Kdec2XfxpDU9kr92GLjVploGxJ7E1kUle2R7ZRiBjFMASWWd4xJNBhT0nvxf_kW367EHHhvEPyoZOHaKMEYVAp7HvUBdc3yKPz3r0k_SCojlpHPkzD6_TWqzCc1l0kl2L1diBSN4KbFNWXtg=w1263-h947-no)

Pix 2
(https://lh3.googleusercontent.com/FOYTsNtmWQWfjgEzTjBAB_7cg7V-J4GJ9Pt33SLvdO4FRnyVa9f75TeNdRgz2OpU01nKz9c2vzlGRDEemaBTFK2MA73h_R0LsKs2czbjsRKWaNCCxz6n17hrWGk3C9k2jE5Vj_V6UI5c43f00iMm1_gFU7hgbjkSBfYaY-hdUcPVT_ybvEdP78wSJEe7ZgZBz3vvoCdIR8f9JkRwoLTxtdGqtGkNgt90k43__f6LAhrZueqhr0iQo9yzXXPBJogFgHJCAWxY5-QOcRrzfIUitjjkq9bMI5j2kkoS-AZcqUiBoPISyZg4mIuzj0IbEj20U1iDaT7LQGQnVpCzPUfHO9CyrEBUhu8_d9AzoxxWP1JVYtYe0oJdIv7vJ5hxgv0lYPwH3cRNXcrz8rXVy1FFlLm8vW2dIJO-KOnpJ1LPivU1QfcGRICkr_p_xDdPfgp5uIxPIVa1bqMwayrh_uSbLjp0vfXsARQAgREOej89EGhL4Le-eyyWUho-IINgimVmIY0UaadefHpsQvoJygwl8KIItpy3O5DTQI-8_WQi3kZjq85Shejle29JF8MHJIEACVUSQvVnbJzCoOG5fO69lEIuS1YlV0JZvo9dj82Q6sbLPWUTSiRTaZNwCVe_XNtdqs_CPCXitltlI9MuXw9jBcxRm_GNdspR5nSm53aFopVDS0ae2hAHVjmDuuRCkjyLfBH-s2QHeowQVan0IQ=w1263-h947-no)

Pix 3
(https://lh3.googleusercontent.com/hvsNqZ75YxhRcUDG8eM00LNvMvfoiCJr3dpqmCF8xnBVimY8Kj-_ESX6F_4bKoX8YUyGnrTZI0_3H_vPhtoI2eyxngES3-gCajQF0dzLpZdAYaagakENVKZt13TUBgfaHrryak-bvBf1wrywDIzWPFsSHCfboADBFUN5AJnMJ8nr6nNoJhnb5AGRfVaAEB3T8EfJzVxmBxYvweu-4IKEt7MAR_hFy10baDii_mFyYtn-E06FWETx2vP8bqpGSgH34MIl8OSFkU-cFFrWFc0wIbp23HVaR1glWoPQvHH1AONwyd2q1Uqj27NQ4JWrSW9DYtdCxENEIzHVE-UTLv6iwqG2qwmK0p5jN3HBDkb7vJykMN-zpBEoZWrpwtCtPPXqVGW42MV9menw2aHoL_KS13joWFJXROGaOFenBfXJljn3D95wL-vnFsFaZQ4sX_86HvLRVUc_G4L_ADKwjIVwF4LZLUgrZ3MRL3NAIMICQrr4Cc1NR7BjDfhxXTTV0h2uXbiZkaudpY4pY2bU_XJNQrcs_dyQocSLkM-AnnOP4exugUTG_B7Gqnd6Vwm_Bf1n09xR1NmedW7CzO61GEsIlFSscvHs0DL7Fw11IoGsILDMWj8G-7xnnx8RpC0TI0YrFuF2m4h7vXddOBvIJdYZjUEcgC5HsKEywbtj84yWdOoz5C3nmmTw_roCE6RL8--low-jn5hs5BnxTuGw8w=w1263-h947-no)

I'm pretty happy to get to this stage!  Next to do are all the remaining smaller components.  Hopefully I'll get at least a start on these various parts later today.

All for now.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Johnmcc69 on December 01, 2018, 08:43:31 PM
 :ThumbsUp:
Great looking parts Mike!
 :popcorn:
John
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: zeeprogrammer on December 01, 2018, 09:20:05 PM
Looks great Mike  :ThumbsUp:

Nice progress photos too!
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on December 01, 2018, 09:21:14 PM
Very well done!
 :popcorn: :popcorn: :popcorn:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 02, 2018, 01:02:10 AM
Very nice Mike. Won't be long now!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 12, 2018, 01:06:22 AM
It's been several days since I've posted on this build, but today's the day!.  I've had all sort of interruptions that have kept me out of the shop but I have managed to sneak in a bit each day and so some of the remaining parts but having just short periods in the shop seems to slow progress down too much!

Anyway, on to making more parts!

First part up is making the piston rod packing nut.  First pix is turning a piece of 1/2" brass hex to diameter to thread 5/16-24.  I'm lucky to have hex collets for this sort of part.  Makes things much easier!
(https://lh3.googleusercontent.com/FnCEmL-KPFA4rM_yf5fNZ6-Z_EquVxQJuiwE5Rfc3cobRsAuYa-eULICidtRmS6YaKtqN6uQ3qsK0dKbRtOfEhmtprUxrASIK2nSAgSG9YXGRUcMWWkRUAqXnuxzawLEKhvBHZo5TlHfBqw09vkuVIKD0ZrR7LsHQkQGu8J3WBrl2ink_LPX3mnJ0Ge1b4ZOJhMd47eQL49zMAZmkEB-T3xNuY5aP_YnVCSDRqnY5dyv72a1JYBd95Sd3jaDsUD3TJ_e05xIr4C86Y346Xexq-6cblzCZtOBFsc_cQGG0KvoOQipq-5da93wGfwZU_volorUeqZu_QPg8q0zGm5H3nCESa2HPiIUs84W86R81wiuVZULXVYMS5EIWVErLV_VggcpicF1pB3moygo0uX0p8DHuzgmtKj33g5OQNX_riJr90TgtIzQL058IVESVQdXdNWgdALGUQ7461L-Qk5fdVS-QOTXXE67wgx5DUbV82oI2pXtqSXNTXQ5V6RaFLLhy34WABLdXBtoh_LfCByYMIxAVxUY9U8EEmm7eW4PhswXxkLOrzs42ePNTh7sUMnokcsW8bzLDCsAQUnRWlvIx83P_W_5jiC8Fa-ykPNFQMTyK6HlkmPqe1J85wEiFixhtWGVrZgae8ze6tS506uagslNe4Yqopd3MOHDP2L8jU-tTVJirIbw1xH2_IX1inoLSvUuYJNrdDUAgAgv1g=w674-h898-no)

The finished valve rod guide packing nut on the print.
(https://lh3.googleusercontent.com/uOdUWjMjVWB7RQ3WqmCUL1u1w2veMEx87i840dvr4GyVu68pvJfW-G6qkAu_-T-WJ3UnPbFwkHkWMc-FrYB4iK4FRRHd3W5H1oCCyD4NNOEv9IsLsCfykGSLcMO9CWgfeGvH3XPykNyQ8-XQQaaweNYuGhBjfpaCtiLDxq9i75P2tdOCvbEUcc7gEHo5TDMdpJOC7qrWWa2xg7VUO9S12DvRwO9Pot3Uw8gl1A68wlRXtCa2yWBX_7gvxsP67sZ1tboxpjVxze30favatBViYJo2ifhSI5kvWnwEqJsaD5XGW9zqBaorsBvK_Jra3siXODKs-u_rtXsa5ErLKgfwL6BQARxjlb4jQjtJtGDxMWFpESBwCP7P3gN5EXo-eJgt9VkKljFQFxrk9XG4KH8wteotxDEZJad8DFP4nvdy8xzSOwC40NWuKRPNjJZRJYmTcL6Qghy3s9WonN3jQuXqIRIjwVEh-dHmIv-3XRpPdjIlcI52SnlYT7PtPbr0l44SaqJ0QNcPhupOLCXqM89aXBn6UVyUx-l7j3FblB8gbieeXf5YVTLUHWs8rhOhwCVBuSZJ8akdQvFkUPuZnD2o9QK_hs-g0ENrcW840F8pe1_gk81SQNKAlKNbHlbzEOSIMajUGQDYFoy3k2BLpaKXj_LyuGHlKThZ4g9DpJOuYTDXRku4W_uw0L9fFidKXoldkeqmbmlcFbFE5HbDTQ=w674-h898-no)

I didn't take any pix of the operations on this part as it's very straightforward.  Shown is the finished piston rod laid on the print.
(https://lh3.googleusercontent.com/AyIjE_ezBcxVu5d9_8wKn52aVp-3gFpRMmJg4_qDoAF-a0txVmikZ-c3JgA2Drwb0yQhvSO-E7yGmVq0yOyDcQ5LGvBjstqIO3Sxx4jgvq-mLO65ZrwY4nv10MsDLLEg4y6CyD5QzZfYPxzbQ5uODn976Nb4-Ew8zsGeHmrUkGDl5mgey1Q1zCbkQbsat5ritSaquhQpBQk_D7Q8-qIrbh5KsfdjVqbzO9YAdcY6EWcVJzY8izUQ-bs9A1BbXOjuH60x87G8oOHsgCK2ijyyMNKjtaKSFvH_LjWpJ6dT5kdMCaaMcoCbnvuG09qD8-sMtlp2waQHhrpl4fE7J0UMepmkWa86tEZY4RwNMHqOKelV5IYb7Bp_9YIaDNksM53-l3ocuMvUrrUzU2Wy5Rk5a2LLsH9WxeLtz9RX5M_a3Z6byfI7xzyymnAXD6tnjumsFsQVnizkXPRyYsDdcqOFAAHGn5IMnj2gUlnAOjAHALsVNVpbnXvtRGcVyV_n3gj_EhYzJhjNucUurGZHeyW2O0WT6w9rc0gKCbfTIMHafZXkg_t1Ju39zX4BMCHmI2v0bpQE27iymMjqIqxH2Io4IhyRMrtjedBKX7ApOpF0ijCWqIRRoIOfRvQeA2GBXBHLVWToSzKsDFSdo-_uyrWZmlY-XgJxanfe1pVE4mh85Oynq51cE2fhxJzwFwy3eVS9Vj_ZHAN28pDqH4PsMw=w1198-h898-no)

Then on to making the crosshead pin.  I cut a piece of 1/4" drill rod to length and turned down each end to thread 8-32.  Shown in the pix is putting a bevel on the end of the part to ease starting the die.  This also seems to help eliminate burrs and overly sharp starting threads.
(https://lh3.googleusercontent.com/pNGiqVLFjyuRweaORrcbJazVEbftH3_IbSySDGt09YyQO8w4XXq1G8DpXya9cDEsjnC-XuP7cbeQvGtbSrBT3YYs5pHzIvd5KC4JCZwjCd_yew6sgqpnWZt6G2kQB1H2qmj-YYdxaVnn8Z6aKpxjzV2d0R0BjQXgGxQ2z3cDklPvd54hpK1Fxz3BcDq4yr2Q_g8ZgGH9HSMllRU945PVWAfGAVLHO36DNWgVy9vpZyXBdDzLIx29azvurcVsHJ7p4w0VD27bupdwtzCqPh9lci9Sz7_ov0vCnnpDBr0-07-o5Kw-uTbMnEbwtamBg-C7dFaIfliVWyBkr5YvDEFoAdBWY3u7g3fp5bXvo0B91bff7BYxlPQ49oj49pCBZwge8jKDH-e2fra_cN7ZRFtlBY0TpdFvsIZn2vNTIlv_VXn3x0IRPdFCbuXCwJxEMTnk6QbqkFHSn4ulreqwsENDX427GgcQl_QYGha9p3PZVFBZ3bVbLOEubdLRVpbaENTdXMfcmP97IicBhxFoi3G0rA8WDMUjmXGsaNrKwGgPMyj3BLiAbsFCEDDwaRkpODhhZ-G7OeP1-nlBywnmD35qxbmt9TsFbiRd1KxkLQMWIUsmZRUaN4mKFJU-G5l-y5BhvLKO4CByzEAoNR5eTvnONLAavbmL6SvAtW7mQ9B9N1rb-rKiTLqJ5vLIVs2iUR0iiuISmECzSxFwPvzFdg=w674-h898-no)

Cutting thread relief with a .040" parting tool so that this pin can be threaded all the way onto the  crosshead slides.
(https://lh3.googleusercontent.com/xqbvIxdQsqNXKhXqbeW783pgqYGQiUk5k4L4fBAlQ4MpDn3LqJU8AICe_vwZifSZOkemeX_BN9yMDmFV-FJy3jQC_tEncGSF86zumAQ2d_0_8wzRXxsaasoF2h6SGM44Ia-PYENshtE_ChIYh2ZMJqwfJydCuk3GcghAl2UfuAD54v6n1-imSlKoseb771LI84Pt-zlQwYK_uC9B5XDqDTYWCqJMMlXRFMyG9RzDB8ginNwF56upXn0yRq6VEkN1AE4vrob6ZETs9pMSR_FoxDEMOVKv8qnS33GbZ2_ZqhqlAQjIzx0kOK_T-l7lrNaH7Bkb3soDdc64T1PGqA3w9u0IW2Qqkf6Y_bpVj_rvHA52CuizuiUP5Yo_p6u6XuxR_EKKt1uw_XMy4MVl7AZ3HuopWou9l-oSTc5Q_3Eelz_3liPSxIthdvXeLGG9W86bD1fMvFWXNXSsLOxtQ4WSZBByzok1Pykn9k-TfloLnP4D8IXGN_y6PYnM9MWVtHUjg0bJIeKbvv2tvbPd6airGVCeUyBQJWcaEJapbOifR3Sm_BMIdRK0EJmJo-69n_l8Sqgo2IKo5SerfkFwokl2Ao9TF16jIv90KbgXJBl6qMVmo0MfVOx23JoaQZrdXkPr68COzSj0KWz1RXWjabJcPjunjlATcVq8kEESYGzgumEs-OWUtA8bzLiWwFFqsQEU-znewf9N6afNHMDMZg=w1198-h898-no)

The finished crosshead pin on top of the print.
(https://lh3.googleusercontent.com/Ej_ieec2dmcQY0631MZQaOr_1SJxPqB90oOHUSVyxCaQbyenJ2Lz9rzP0q_N1oiKtNeL2z3zRK6BcfylJscDV3Bhl57MmeLR7LadFYWRNBIpqU5kQQ0fqqNesdMEo6zaTl-RCBCQQCJAWOWpAz9RRK9QNfwrKwbJcv_Cqo1PyqgBuP_3b1skArLUusF_qMj2sZ0ywyN2vPDzmigmMKkIkxhkXZtofMCY6732adv6Y90dUQ_5HWUYQ7BLrE2xJEqY1nQ83HfApoaYEa2FctMcrHqW2mNdQSo7Qcjl6hFH8ak9QC4f6NKj6EgHfGE7uifOsz0UTggO3Vvk3O1zphhbwwd8JGhNUPN5OMnCVF7h26CVx6LitONlyW-nA_LPvOZkB4_ZklN2pqMcr--gM94CIUgEpO4hFsDdcH0r34Cl5z7gqgZLy7mU3UEqcv4k5IexSPGQ8m0vz5GcWoHufShObLQm8UqzYS1cSCAcJfhAzFsLju6bROZUq5QW9TxzVqnbWxZQldPN5NqURDjU8r24HJIfvcTtysQ5jNXLPjMmFvgJjBO9NkacWn19E7gNYTKZu59WrA7t1q_OdlejiejEilqMnNG37RQl75wxlYOexOZFwPYnvZ9vxXqxwOenSO4w_1c9gxKn4Qxz9by9_hVT5Q4w9G0dq_MHjpMH4QYlQAkj2isBExdGaLEyUDgNZNXR0qo2KeG9s0qSC1CRpA=w674-h898-no)

I'm going to break this into several posts in order to make the editing of each one a bit easier. 

More to come shortly.

Enjoy!

MIke
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 12, 2018, 01:20:34 AM
Next parts up are the piston valve rod guide and the slides for the crosshead.  I made these our of aluminum bronze as I could get a piece of it from Hobby Metal Kits at a pretty good piece.  I bought a flat bar that was just under 1/2" x 1" x 12" so I cut a bit off and further cut 3 pieces out of that and then brought each piece to dimension in the mill.  I was able to hold all 3 pieces at the same time in the vise and then just took passes on all 3 to get to the required size.
(https://lh3.googleusercontent.com/7mrQVhpBDa9-roAuCFpHkfEBA_ONLNj6vlfghHryB89OgZHU3-KVaeWFttsKxcSj37dyR6iytcZ-mzsWSB8k3XKLAKaCV53CTa2BAOmwLo3SXg4FBCPaimlfnqN5fTqUUWRS427jJiNV-67C94rccWj0haiUCXBtA59yZ6GSP5g3T9ppBLczAqVAqV1aUpa2zKm8c8T_xGe7U97KDqYz205AX57vkhJR1KwQ7DOUJ4z4n8FHCcBFq4eMwYrjSKA-PhytAh6KOqL_drajt4iXtY0iRH9cYADe-SM28T3AF9br52l4f_N8_8sg878q8wnj5mQvchcelqsdp_fkQBmS9exnA4tc2O5hPGwgdVX9RpxafSNh35cc2UyFPpXwMTc9QThrJJx1EQ4YeGtk84Y4wQwRxyvW_G41BSe8fNX1iv9PQp9iKkeLinXNkH-15RoZ4aCkxevxlArR0HqgsumMC6KnNBoIKhrf31ai2V6taT5QAMY836mXFTDinkbCQjEfiIGMsnu8SPCjOwlvoq6rzotwFYHPqxBzTFHqt7i3MdqzmqQeo0LChiv-mmsn1G0p5J4TsmeSHS1ua4aUcOGF72sSSVaRPms0WhnhFvmwJMDuewlQHQPcNP6qOp8r6fLJodL7RDmTIBpCED7fS0T73Ei2=w674-h898-no)

Since I had repeated operations, I used a 1-2-3 block to set the end of each piece flush with the end of the vise jaws.  That way once to did the edge finding I could do all 3 pieces without redoing that step.
(https://lh3.googleusercontent.com/COSt-ukciDwZRp0PQ05mRiJMVjIH6-4Lrxj-lhjLoTd-iUYIEKatqx_6oa4PWI5of9G-Taequ9n43-mnGW4ZrcpG4PNQZjD_ckSyglRLh7H4qWSoVyZJpUz1QL5q-yC9z4si2zriSWK1xgVr8_uFyBVrETdysNTXqMrvUCdHW1Um0GVfNUObiwGS9mduzrSYydglNb_8LtFoFEITal4qY-QTLTik8er_eBGwyxfSTMe7_eo1vIzuwqtqgG1P2hQjJD3jC1RU9lIOwphXRcs9-cViLS0ShvY6Gb5f6Hoh2_1YJRMd56Suzii5GT5srqjnqpgdFbgWpc9cFpS-gmsdPoHK7_Eh9OyvPIWX9VGFpHDS6r4Df5pjqP-ynG2_B0RdBR-IkHqFg-WIu-wCK9morGkkTi6DFKeN_uYPnu4L3kOTWJCEBhk4jCVl4WCE0X_vqQfOQbIhd33Cd8Onh9Wo2dQqmwt109Je0IHenXp5BiEFvypytTihrWcJZYPJpqzbA7mG75eoMiw1ROr1LEVtzOt4wh557CP3VVbcMChbfSPRrXrIruAIgk6JODxbGXB8CemfxD4DVVJe9rJa5OwXBqg2yKlCby-O0lxdh2UrDpF8ereIK8KPketaaAPEah3pDYTsxe4775t4TIMI7yB2l0ps=w674-h898-no)

Drilling the holes for the piston valve rod guide.  Having the piece flush with the jaws was handy as 2 holes have to be drilled on different faces.
(https://lh3.googleusercontent.com/jSfmkehLL-AKqRirgNC-IOmRyFj3nSWiIxwaAeKeAB2b9bmx1aI0WpiyAtr48e_2xN15lmnnooxslFngTCuqJRzwH5UW5myWmsUDMwoCcE5Y8HV0a3CA8I0Cm_UxyExbgxaqw_of_VMz0DATX6GER2cXkg2PzuQ8_TpQaMGI1tCx1nfIDIaAFTVBbrXLkpZBA721PkoivXAVmg1aCR1Jic1W2mgfhEKsBFeuRtiG4QpklUssRRY5ZmT5UiHaf7XZpxLp4C1HQiAOcAUJW-Zj-XwDcCW8B-SbWdAZnWgtnILSfrRxDfWtX81kOTSWeSnLg7Owo_8OU7FRkkxJkK-Ri-NjAa7RO1tMd14Oz4Qj1ybBn1Fs0KppNaWTGpbf_DgF8v-GBwgSWF8HuHGzHThqmpKngxW6dPAJcHspUMTqZsZo0q1U85MenVtMvVph9T4DLkMmZq9SjWhQapOi2jU3eNp3PHU-zug0RA-h72FD-Shdv0qLt_17w7K933hIoD5GsF9EgTV1D84gJrVv1bA7xfGKja6dCza24BKcIAmm-klcH_-5XvU3Ss_BFkNhlzpFMpJtFuGP1gtPILhi_7ABD2h9_BG4vDDnlsB31BF4AOtc5m5jhI9ks32TMTUQihJttz6G-A91wc5UANuJA4SZm9Vq=w674-h898-no)

The finished piston valve rod guide/crosshead guide bar spacer made from AL bronze.
(https://lh3.googleusercontent.com/l19p126ApBgds5E5b_bBvDf9JY-QhKsKCTZYe2lHTNMyBSxOvQteuHLhZ7ElhFJ3uhZwqgxdjZUGmPIhcFSeqoHsSgYoWihDT7WV5V_AEzaYGGjVf6mAal5RadmSwLBtmf_IwvXfKqTxd-v7Dly2VMAFTudiZ7vnRwx0Ot7t8LgsoacUmwCb2cdiUGjudRpR6a2-DQN5ZB7hrPxxwoxds_88-i0uYFgS6befGBeqwBdSdWhoPRIekvOMdtM2ivB740UpdiqK6TNgHTCG4bU8m-7GdywdLxh5FqjF0bfcJF58HSGWJiRyuGfDhmKj-4gc5PR67-26grPiISWnMZI6ezn_Ug-_Tje3zmZ879Q2WnkoPeJFR7BTVQAs6gruHldO7_xFm1_wsi3QGqvt41NlZpCsSFt29HnviTc2QRReN6S4ZHPGBQK1qTOUj-vKLwGzuFF8rgc7st35OQhp0YStL4DoyoDVcQOVLMztJArXXCB5ZUdy6JHk-DfMzewXl3-DVpXuRGWIpmTmwHxdZ-LvtiSmMgIqZHXcm_FlwgWaDMhIexvn-7vESNl4wnBwe9TLa_CAZbOiGwOdZE-wjOT5PLjjV4QgLDfLG6C-fSgCZowue1CwhANSh-olGcbbiSqGgOeELez_w-lOTJriYhZMoWXCGorTJi4QDTGTxgnbUgd09jkC1t7URql-4Xb5Ad_8VgGj5gRxIB1H-ArCfw=w674-h898-no)

I didn't show the specific operations, but here are the finished slide bars also from the AL bronze.  These just required a precise thickness so has to fit inside the guide bars and have a 8-32 hole drilled/tapped thru the center of one side.
(https://lh3.googleusercontent.com/20N-Bqqu3nTKRsu7WbIDVZaR0IjAUb7cW9Xga1LyxMNmWmwaOCoCELMY9fmF89sc8CyCKv85XyIO2Z_IVUf-rdbhHurMKHxt0aP3Yo-CPGBOkxYoh4CB6mxlavqhLT86DH7xyhb0PAGI3lxHS45xBWvqSg9mZix7rOsCMdoYUIEdDNfjxSwk2DeEuIOWArm6Ttwmuce01iO7oInNIykFUfwom94izT0cnablO8cHoCGOravrMuKW4YfGbwGq1hU9X6h4I2YjTSM070_BXyZH_sK6pnX2Nbk673jk_VxNPRKmOrgnbsyFGnbLH9FQInpuQc_ThbMOEK7p0TeYkGtJvvKbb5Lnz4stEk61RtU-cja0wMcqQr-Vv1LPP9hh3qNLCdHvfM-LmCx9exI7t-pdPA7xJeCxtNVf9Co8bF5mfqbtAndrIb3NgSDvSIHkDRwoj0ODmodgaUf7NWllO8Kz1d7zrtsR2EezavhisFeQ88_Jrxo2JH-ht6vk5pCh-9bYtOgfcrLzn08c-BiBk48kho09QnGJXgVPWXK3pQaMrZInxM6birUNSYreP8BWDEmCK9AwiGQuScSsDMfkxawMYM2AvkRVPR0RT69InuV3_qcTLu1Nq8ebS-iVPymYZicTt-TfypXIR3p5_hYx1YDDYNOk7kR19umZroG1fksu6cIyp2Ck61nZawJjfQ2vkshuiZRlUWQeLM9t-4TtfQ=w674-h898-no)

Then the final pix in this reply is the assembled slide bars and crosshead pin.  Miraculously the screwed together!
(https://lh3.googleusercontent.com/_dhV6ejDwGDkKvzktQzJmHbtm02qHO0Q5KJQFdu26RkRBtxAEWsPar1YsMsY0_3oCmt_BqH2M0-V914mYTF2RVGBnA7db-YYHydDn5t15ZJ3bZHc4aQL25ecfjuH5sHGa7uxwdqKwHyblZIfBVlmVtWjN2XNs8J_G-dFXkumuKw9KArMYTdhZS6j4eFPW-Ql_I_U9cWbtk9Woq2UWT9K4GtRqUOxab3z3fBlCRPZvGJZv_4BwdV1Yi-ueldMOqoS6izhEH3rEl0aDP-pJMZMFFEdkwtePYW_s_W6n7fdvx20ztXMLBjz6I6oIyj-6vz8XbWF61bkZrUOFHofEbGLIsa9o_8aPLFltkLIp_VbLwiWP-4cZZQnKV7GZh-roXbfO873RZnGoMNnGUy35pU1eCatuOQUWTZC_5-O1ZeBaHwxprHPS-aGuPHinrMjGangKg4s89hHnSGKER1DYu5p4piKppjke9uifUyQu-QU_Q_V9QZqYTme-vBbpUgBtIwK2pGX6Em7YMI3bj-pM9NPxJ57mlWyvlETHIcDeGqdzOrFO2e7bymDoAMvpG6prxaQ6M0PpsRS60a9yJThNQscU3X2RcprM5FEhfXjw8-rKcAKX7Skd1hKp9FXKSUDsVRhYF7S2sE-IvGo029dsHLSN41GrSsGllMv0aWl2oEoFIlc3BDTkAElIXBhIrEVyQkVf6I8wdgvHaRp08uGaQ=w674-h898-no)

More to come in the next post.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 12, 2018, 02:21:56 AM
Next parts are up.

First is lapping the cylinder.  Previously I had bored and reamed it to .625.  As closely as I could measure, it was slightly over 5/8" at .6258".  So that 5/8" reamer turned out to make a slightly larger hole than expected.  But in any case I'm going to fit the piston to the bore, so no big deal. 

First pix shows my setup for lapping.  I chucked up a 5/8" Acro lap in a collet on my lathe and used Timesavers 'green' lapping compound since this cylinder is made of cast iron.  I just mixed a small amount of the Timesavers powder in a bit of motor oil and applied it to the lap.  I also put some shop towels on the lathe ways below the lapping area.
(https://lh3.googleusercontent.com/ZS-Mc3jAlN2OpYoQuFhDn1Z1xjDqjEITwjegS7i1dM9eXAHOzOmpJ2lEazG2JqxnjT4RYmaq8pPKkgp-wCDLJezKzfZSGisFvWIOEdrIvE27MqNIPoetypLpd4sbMvqHDemdpQqOmsgLzIgqaPpRfTMrmYzKYlra7xkUeWqt_ke-ezrMSxb688ldFcprURNPIOiwUXMbl-q0jHexrM4RQ9C80bBfImoQ7FUbUWr70jMeXfre51ZspdTbZ98Sqqq6pidcZQ1zsiG6mLvYE5FyDlyMlDmF1iio_1jrGvF6Wf9AszbCMnEIEfJ6pB8XI8hy0ZLkWVCpZEw1TU6YRzfBE4ZhN5u01kwR7zrFkoZFb-Cc6jrdqykeaIdbO1EGkGAZ1BhGQ_F8_ggTJC0wswIZOruAt7W3QDJqqGjO-_cdPEybaWYzM51Er126_OahPEanM9UenddzI3gvPpoG5Sa2vwMUW5l8POInw9CFRETitdic3AkcOp_ZXQmxgu6uwQ9z2UZIlNk6JMftpSvL8aWpzBPXCWNNi2wtPzmpqtlJUL-7zeudA6a7iV_P9LPQ4fhR5RMZ8A5AI7hcQMjomrKv0s5cmHoyTZIgX4e_PnhfzVLdFnQv3h4xlL1MgbScMYqGw39jDaE_l5gFLpFGm73Dp-zdZzwAexeelTK_fL67P2eDBhSfb5bdBtPMS_0zpZ16Ap8FfUUBgIzMIpH5tQ=w674-h898-no)

Another pix of the setup for lapping with the cylinder shown on the lap.  I was turning the lathe at 90 rpm and holding the cylinder with one hand and holding the lathe jog button down with the other.  That way the lathe would stop the instant I took my hand from the jog button.  I  went thru 2 different grits, ending up at fine and kept going until the cylinder's tooling marks were gone.  I never got to a 'polished' appearance though.
(https://lh3.googleusercontent.com/6PbJYiwllhLbjpoRh2t1KsTRql1aCzyVXv7dc2ge1Ele0YruQFG28n-c_hgh0CGjO90u6r7VvDLItybv19b1GIp623aSMqAVFx0DabbC6bSmm0GXFJMMYFwQtJUMXEBRAwh2-klxs4d6SvkxsFQzNNDIWcMWVmHHqdko0FTz8ZAHSZlDLgeh_zwf7ZDzZAGNnqQbPr654dh2MpVLZvTRu0ipWHI6oknSL3fqutARsiAeucG6ITaLoQhJMnMgNVh9wPsWExOl80GEeqwjcKRlGoLcjJVB-z106Wv-ut0f_kBROSQJmMBdWAlZ5ubfAoPRx0s0dez5vXYSQ-L7AeHl34xWu8kdTLP9drrnfHewLAo4XmymfB2g2U1L4MD8nfAQRWTKrijGZtTcld15JgJOUWEyMP48_GEmXGBPBHddXKxdh7jHX9WdoBIhUCYA1i6PbZQdfKXny6K4kh_AvzWgzE7fiEXhs0Fv1OMsfRuBUB_lW48ohknkXCRYveoXa3yx8QXHUzkLNQQ6rgyZEsc5-H_bc4jGJg4TuDIKEUh2Dilax8Q-tu46xORzaMbGZ0YIMYAf4i70YhonMoDYAIqzeZqmTuN02-R-kJSF8r3yK_tRLhYz9AwBVHD3YnnNz6zTz7XuKgnZloTol8QCcTd9eNhxBe90yGAaNh-gv1xGDRmxW9QUZo6TXUZC6UTyvD147TYfpof-AoUCi4BjIA=w674-h898-no)

Then I lapped the piston valve body.  Shown is the 'yellow' Timesavers lapping paste, again the powder was mixed with a bit of motor oil and applied to a 1/4" Acro lap.  You can easily see the yellow color so its hard to mix up the 2 different products.  I just used the 'fine' grit as I didn't think I needed to take much out of the ID of the valve body but did need to clean it up as drill rod that I plan to use for the valve wouldn't go thru the bore and the bore had a fair number of burrs inside from all the cross-drilled holes.
(https://lh3.googleusercontent.com/mlrKNdQKClsPPKp7ceH1Nvtawxcwu2q5vF8R80GKtPbil3DjSfuGRe-4PNHFpxrfjNn8-_IV7HUujITRlE0do3JAd0TejKHBgtlRBfjlabXG9-G9ndKqVJ-N7z3roqa77gjXmadtoqvTUEzKU8UPAIyt7eGS4Gn8y9HjizhZx9rPAcUNNDmIXjKp29BlLDx4Vsf1WmpqpH_0p2wjF3Ywm6AdZGPZWreGKiBRpFuh2IwZB5zKYNWaQyYsjlRgiWUVTyuMoSUP76zxGVqOkYTgSyERt5pp0lXlFGfPNF2js13LvdxbJEj3-jgX3LGC2nokLB-_bmEamDVZEM54DvyygroW9L4yG6movdJ4Gh_utdrAgGCVZ_-gicqkFtW1d2lr_0OK7fFcAwpkFTm4Vs8ZWfZzXnjlHTcI2IosZ24oAUq-q9QFixGAwgEmvNmmvNm4BbvXsMHrEz72VheAjaJkm2dXDwyYfhPOYybLOJ6BTpW0nuGv3f_dMe1TNkHFqi6iw3WrP-R8EghPtIJSY3j4h408W4GryJuT4yDuWVKZXnD-Qu25IkXa2HXO0T7IX8y5ijbNjBMYjmDVf-efbCii8ChFc-vowtZTYyBF09FFoljtElbxEUjLZ7PeOHBvrKUn_B2q3vZXzRfbdIM5XJG3xIpQZlApSYr2ycXP-sEgkCyiRw83TAPwyU49x980YhMmXk6H6Fcqa_wVmXokDQ=w674-h898-no)

Lapping the piston valve body.  Same process as the cylinder but with a different lap and different compound. 
(https://lh3.googleusercontent.com/R89VGYblEDHBpADV-00YVaewgmB7nD14ulBk3VcWvRWeUmse6S6XAyIfD6XxQnLALv3e08OVyrUC0fuwoOIk7Ax9d4uU9VLTrAWLXnX2WDrqla58DKxXsYMxHkET66GH9h3kjg9tVTUNmB0jXRKnWal-8D4Or_B1mYVQWKhJg4MmJCJ3k0L9_RF2Fl8OvRbfsnAAQenCIhxbnQS4VAhKNIodD96Q6fHrC-ez74xzginVCCc0IYfTp1Op0zHjLiHsQ9F8T8qTQ-vIIeiJmIWoxJQpM91qBYgfZ5l4lDLJDPXAoSdPLAI0uxKyn8TFp4ASTkSa0P0oQ1fwzc8VOlM2L-BIggi6-HSEdHCr7k1N46oKP0OwR9h6Ew-BDQRuulT26B9Ya3woQF_JaRhwku6ubYiBaUV7YIFNw8WLPhKNEByQTVFxfDHCyb-TG3gd0kU0wvNJoIUBzkF1QxiLJGBqMaBFQp4jB1SLDLyZIf5rtBxYMImm9aF0wDOBYxwHcDAj0QqYvXhje1GMTnHeXGN-URonbZ-5htPeBo0ZK755q6HMDgYGW771zWPslFSYbKaAxiZ7VSyZ5X7Q2pbMTK-7Q84oOwQWQTqW0Pw5IFSys3ahkpQ59C_pQCzctaqLn1IhhWAWauGH0FtAyCC0H-7uVLEihysrBJfQ9jJMTQouc8yLG_VAOhlF6eO-4c0a4QW2y4MTV4QNdtShCgEVyQ=w674-h898-no)

I'd made up a 'gage' pin from drill rod to judge when I had the ID lapped sufficiently.  At this point the pin would slide thru with just a bit of pressure applied to it so I called it good.
(https://lh3.googleusercontent.com/GT4N0ormMhFFq5Llmr_Aif3mWQpkzzjSBZ1SgcArsUJvXPLennshIzWiaRk0S1QV0ADuFA_BFCAzzp_rTsgWvbNNO6cJQZvWLSWJBjIJvPrNEnyfzUP3w0R8RV0BvrfwYhSU1eD23lh85COwl53SSirUHWsEQ0u6FwPiWbXVSIDQI3Y5N8VlQlTLkf2ACgHJO0BLgfpY4AAdfpUKRJaQtjixySPs6jZFGGf6xFbU04PMoZgZRgh5L5TVqFKD83-ARXyCFOfyQNmBV46Qs5f-Z02eZgdRbThLLxPtH7rE0NFKDqNpvGBvt2eVAgg_3SD8JItmTmLlZpJ2h-OooPLsjA4tDWX6k2GDJCMW9K4dqDF4SPkdiYoN-xW83Kb4uYhdufw0d0dTTD2y8tvh6quT20bhxvdw0srQxQtJcm4v4I6mf5tQzWMH5QqF46R0SLwyUipYAoYgE4Ao4K65qtUkdaQ4fhN9O9MdY5kcyYURvL6Q5Pf_HTtQkiMLdGz0hI8uJufRMLIiyBb2MRl1n9KepSF30PjVGX3jn2lfvKRkL17q8G3IKU2gqF7cBJcuC2uyZYeJXqVjeNgq6yumC0jkA7vlJRhZYzVX0SYAhEnPW9sHOtuykZEP_tpb43T-1AnmH6Q-hDM7fzrYB60AnDSMa3de1Nhg8uQAc08tM_bj5QweSVJB0GespJQHK8kRbmYwz0qb9ypbe5sluGqc5Q=w674-h898-no)

I will say that the Timesavers lapping compound is interesting stuff. It does exactly what they claim, that is it stops cutting fairly quickly so it has to reapplied fairly often during the lapping process.  At least with this stuff, changing grits isn't that much of a problem and it's hard to overdo it.

Next up is the piston.  I made this out of cast iron.  Shown is a piece of nominal 3/4" CI being turned to the required OD.
(https://lh3.googleusercontent.com/rwEZWvCD0ZQuyWqqZPF9ldG5stP7FCX2cj1yVTf759SMMzFjzcTXGPnuypK6sx-2ZnbxfkKkmXTZO2a9ueorN7o9_kat3VRmvC5Gbm237Fot8kIK5LwPMzDXRv-Ov7JvNlQTBTiqASJPwZWVpHlur6z6ZGAzlCUasFkXsi3vZTleeZ3mppUAQVKraOI1uS45ELwvZPQmhFbY7PTQJ75w7lhoLy6-Mex3Lahs8HazMZwAWLagM6IcAXTdywdIEOcOJHkT9pnzoMvQ-9X7ZkIZYU4T8dc_V5kQGSOBnH4zoKJPVgcn3_LLpoPg-M3k8zpEAKq38kn4Bu53GQNfQ3q4UYmIj6IOQL2M-PJ_0ZVKojN_ibWDjQNqz90yivP_PEOzKEI12VtupGJlMJ6f1P35X5Q5hROLeySPuYqKsDP7WnR2B1I8Wq_6irtt9WCTQv932zHbsuqIIoMY98Bi1_IslsmNMSgsMLULGN0Svhy0BtL6BUWSFF7JUP5FW_x0oNYrcXrq5XqseOfNXAwGkT4FL2QgZOBlrjJYofxTamcVC79HeLIlvcPyP5Gjo6udCJfV8dolF4ycBfzcfLPyS9rpEts93HFQtibRc1FIJ64ByrG16bH-yzRw1hPXOkCbfNXRQuzP8T7q6PRp0ZeVkfQJkoOfgbNpaPcLsXWxjotcu4BAEw4s8JuZj8LRRhCrb_akbUbRxfimJOR2MZ0b5g=w674-h898-no)

Checking the fit in the cylinder.  I ended up going about .0015" under the cylinder OD.  More on this in a bit.
(https://lh3.googleusercontent.com/VVF-srS2tNDW_1a9c-1LmdEmZjutVtAyu2JNPc2AOawMKHUs6xuTfQTD28ZIkHamw1Gqb0eSlAMnWT7ieU4VHbwItN-YUSTPPK6PqKNXBMjvifRS534fw2KCbuLoYjlIqXd9zkQk8sqvWf71bHQXgPupxvv3GY09gHZUVGPEaPyQOzhX2XGo-GPCe2KqvN6nvfNKdV-ST9IlimAL8B14q0nB4BwDWy-Cziq0cpfatzqqOIrdP49jKCPEcXwv2lfqFLvAhoNBwdbePuqgjDOwjtdXtdQvSsuqENsT8ZVyDQR72KKlBQFnz9QA_MOUdKaeaqjtUJeYLK-oGoDvh2kePGW9Y9ols2VQl_XZZwgNvdOpBRRnwRW3KP0Q3I-XEpV76YMemF_y55eDC0zCl208X70IIia8zYbX8KmxdC5dxKyceqStdCIzxDPOBQbMzs4Ksp967Z_psjQmdCxScq4SGFaH4UoaDA7v47TAaqL-xIObuOI9GnamQ-7_3z0fK3buQPjKyCrON9m8VnhQTdW2722w9x3mlCBb7RH1Iku_icslKh6UJ-LWx9MuygxTz2pKeyGgNVrfD7XftUi2u0STNTUv8QzloYp92t9qypZJfWT7NeONfj4YVJ4K598V_2FM6L7BR9Q1kH5aGx6OV8mi7iV7rCd-DJlMR_bU0mI6V8SzV9MonB383-dthGj96P02I4L9Lo2jAQlMqi3PWw=w674-h898-no)

Tapping 4-40 for the piston rod.  Piston rod is 5/32" drill rod.  I didn't show the op but I also put in a short counterbore to accept the diameter of the piston rod and to hopefully then keep the piston rod straight with the bore.
(https://lh3.googleusercontent.com/aHmlNyxM1A7Hr0bcZASMGUk_3nDVqGAaLaTd-7yFbfG2wEJ8onuCokVw2g2eufWV5Zw99yGrJNHREXIycsDwQWtN-w5P69M8wjE3ahG0QX3HJUztH1JQUdUbqmlj4xeF8RsKb2j7EssFFDD7PrrChoENa-o3l2pO3pywutUBLZ_tbOvMuD8ndvd9p_ekpOi2WZpGrLhpRJbLC2O2b147-wDeeIenaXOfVtuh-FdD0VeFIqsTBylhL3-J1L1MAJRa5-K9u1D4ndDFW-WygXaAb-fUOf85vlmzQZXccYz4FsNfQMmcAjV8k5qRxTYQdehVkHxZ2toTO1tXg6CTPdOzAvNcNCQLOFqB9Sc5chWg2z5fVG2D00IEqh6zsjy43Q-DAjYdXqvUR6yh13y9nFpaX8zZb4eEzvLIS1LHLjdugQbkzjlfVG7IVpspKUIPfACu96ordJBR1CFnEOCLf9eoasrATK487jDmmDrT3Z_mGyEF0xl2hpVfkGbGiNVcnu8Snzh3Dfos9BDhN7RiKAbQ5AWeJklnGJ2RPklllejNgqil193_tqlLZis8lgSKExrZS0l_pMdkYbZ8zSJGWuiKYUBf_AJqPblZEYCPdBCPASgIsSXoiH0B0gk7Ny4G6Tjf_qM4gjp9k_ROHa66nN2--ynyjiu8qF8271O9kKny7TfETJ9FRgQ7ZT3t9l0gsQnXQ20kzbVqWPmKoXtbhw=w674-h898-no)

The completed piston rod / piston shown on top of the print.  Note the oring.
(https://lh3.googleusercontent.com/qKdnMw6cmZAT6q58Jua_biSqientL9ZZAhIXlYDzd3nDqmGV4Gr1boH1KCfLyqoMlyAAbh7QRkfMjeNhd8ioEC9IqMMSbpUJkmQh0kicRELa0eO4K6x6NCcszDTT_pp7FI13WWPqkGiBn1hvNZLYEa445JRAacFDjCFIiJl3os2EN593wVWZEMmOCJtN_HtZfE21nlu2D_BG1RslpFY6k_hpFgx992vB4t8G5y7cL_b9hkOGjN_I7ydEl-sjYWMan3Ba5uz1tUs-P9ETyRYfKhascxv67ZX9AG5amHvGzD9exLNlGIYdpOFe718yv7iOBfBzvzPNB16Hp_ZvAzviNYI2zb5BXLIkBIBv_lemG1NCZFHspzBxD2MxgOx1FPO3laxOdeNZ-kffBx84z451rh68WEBe6uVEw_9YbnBXj9moZUFqrsNr72u2VRSDZaSZBXo2bJYaem-HUWEejQAuKA4NswEel6bKOGKrG3B-QqoeYu9Etx7xPFUKXcdU8rs1khJrcyzn1TU8gVep5Ux1jHvGo6jsTzNxi2K7-uWH17nrrOb4a5tQh_rgCyPIG1w8FXdaor815XMFgVFZbbj-YKpQi_JNtvXZ03eNc8b-f2e4TR_t2NWys5Plx0rrNKE_g-GpWt7K7lG3kkgBAAT_iuk8qZ-jEOGL46qeOyNd8epZqc3TlIN1C8_3qCTN3YsTzhitVjBDKcX13YQA8A=w674-h898-no)

The piston / piston rod assembled into the cylinder with the cylinder cover and piston rod gland all assembled.  The piston assembly does move up and down in the cylinder bore with what I THINK is about the right resistance.  I can feel and hear air being displaced as I move the assembly by hand and i don't feel any sticky points.
(https://lh3.googleusercontent.com/Gz1UQtINwRhNBdGED5xLRN4xl7jRezaSbq4ofF9vP_R-jg2cAZNfXB8p0eJzU29tnPkPgBdUzppa3DSqnqVw2DCvcrULU5QDO3DuznMI9eeBOgam5xGZdwpV92rX0qNJbxk8cS2C-9MnIU8s-110aCKu0v6KrODCCJS9XSaq_bhX16IXf3CEwcX9DNjflCx_1S-yYNsnPpCPzoA9pj4A4391NjBrmMHcpyzLLelGUKhSwr-tBp6nInV3sreho9-VyxU_QmAg1FwNjf68KTCopc-2c54JX_lirY-6L0QjYwS68-9oQiJ3gvEQDlp3XD_782dHHq5N2hGdsVXUqkIBg04x1SxV6tmZmjHv7vxn3b1uOHGaEsWO4FpkNv4ZvcP5AvTCCkfj2ebJmXaFVGpPPy8Cl_m29P78J5u8Ca-AA5SCqGuBbXQiA7T7wXlMde0RMdxJ1Uyzf1uU0MC-PJY1PQn6i0eMYUth_DBcyo4EeLZ1tz_8KR-N46r6TAm8PqSr6VhsfYZJmuzm4PvFbMvWsRUPeKlsa8JVJooyZ_1lkjl6YqNjkQ-gR1vzDohF7pKdVqryTpwqaNc7pIZP92iunrso0OZUmAQxDIEgKWYYYoTPlFtQqi2-Aih0gEKkH6kiFnCj2qYh1EaIHZSjWvTPyb3S=w674-h898-no)

Soooo, about that oring and sizing...........

I decided to try an oring as I'd read a lot about using them in model engines and many report good success.  I have a fair bit of experience with oring seals as used in high pressure applications but this is a different kettle of fish as they say.  Two points seem relevant to me.  First this is a dynamic seal and second, friction is ultra important (that is, friction needs to be as low as possible while still sealing).   Standard o'ring design guides (Parker, National et al) recommend a degree of compression on the ring that IMO results in much too high level of friction for model engines.  A lot of searching brought me to a post from a gent known as 'BobsModels'.  I followed his method and it seems to work.  His method results in a around .002" to .0025" squeeze on the oring per side or about .004 to .005 squeeze on diameter. 

For my particular situation, I calculated what I needed to make the oring groove diameter.
My cylinder ID - .6268"
O'ring is a -014 nominal dims 5/8" x 1/2" x .0625"  Actual dims .629" x .489" x .070.
Desired squeeze on diameter is then:
.6268 -(.070 x 2) -.005 = .4918" 
So I made the oring groove .4918" diameter x .094" width (width was from standard oring practice, see Parker et al)

And as far as I can tell, this works, at least as judged by the hand pressure it takes to move the piston thru the bore.  We'll see whenever I actually get it assembled and on air pressure.

More to come.

Enjoy!

Mike.

Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on December 12, 2018, 02:31:58 AM
Excellent sequences, great work!!


 :popcorn:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 12, 2018, 02:36:18 AM
From your description Mike, it sound like you nailed the size. Nice updates!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 12, 2018, 02:40:17 AM
Another post showing the remaining parts that I've done so far.

First is the piston valve.  I turned the piston valve from .25" drill rod.  I used a 2mm carbide turn/grooving tool for the entire part.  This sort of insert is nice for this type of op as you can cut to the side rather than just plunging straight in, although admittedly the inserts cuts more easily when being plunged straight in.  What I find is the best way to use this sort of insert is to plunge in at multiple points until you're close to the final OD and move sideways across the part bring it to the required OD. 
(https://lh3.googleusercontent.com/NeTX9-MzDn10ZHTFIhaGzRoOstz8cthDV9yC8nwHDDjgthtD9UZrlcwEcSQgnAwSuIm2cBYRJbEV782rL8GY-q1_wPg5_OH-nPYFOe6fKxWPjX0bO9BZG_cn1nCQSfLjgnzSh7Nwe-BvMXVopaKksyLJO4NFiH80MP_ko2-LBJAFvy4ybjkGHVlDzoV38GI7RwXbruTGb8xh96uTVdtjAR5QPfTb3BgyA6NqFRknRPZfOdia_J7dgbVn75hxs94nwvloX3YrKuoKiauMobE2vODd9LMVkP4Ws4_ENBDZ7403enp70B6qg3bD_UPDAqUfbBiCfux1SlsuYV6qL9i32GDne8AmxiaCiD63gu_myUJ1521LOCxG4M_ZR8K4bAl8x5Ss78xMjGBtrpgtGtScI03Lx0ibLvBKsY17oaBopDq8wsWlBSrZSQ8kZoN3RbqstzC1nYxsSD7hUcItA00bLOzRNK5ZpVqkADpCORvZijeTzGTJgTFFUJ5YBazeFzSD7sXPVuFDFoiZk5pgDPMs57jdQB5lfDKW6eNKYlViyeS1QHHFa5u8ZDs1kmX9Jhmmf34OSuEExIHaDH-rG1pD2sxhYoeMaAMQ0yT0HOOzcSjxQ9oPPpK4Scx_Sm73M3lih_Kfu1CLIYKDA-cyLXoF299-atkupkvzQkiDnt2DqT64UTZjkQNakdEPnN8IQp4s2EwFO7vvohKIjuVAGw=w711-h947-no)

Reaming a very shallow 1/8" counterbore in the end of the valve.
(https://lh3.googleusercontent.com/yf72zFTplZ3G4chF3Yww4PMr_AT7yqMYDbeOzZPXvtJtbEExbVoEfAroY-Xop4xV03Os-d2jQ86bRTesj549-YQiI_WNTqmxAfOYK2vBSwxkEiay1eZMOch7g6af0jdCKez2uQ9bVmq-yY1LeYUIhW0Koh1Oex5RFAeVE0VqqiZXpQxm3dZowGyA8-2K6kKUO3GUOD-3NPESLouaq8lqEjaUt05hyy3UYzBkzzfFBJPTAsKwi9-t8WVccgd6f39felGAqk-qKuxu0mlhgLuzIhRwa1zX2HrZG0swBXnRthfBzhYmsZEFVaGLcPcWuZ26QGlrIH1GKFJWdJkYnGPSzxpV4qIe-_ynumh_VzSsZ0MkAS_pws_jgORNOqYrFHvL_a2DvWCKwOYoitXH0kbHtcpU-uLfIbaiab6vOfNBSFLRUQNGHd8-aVprBq2FX_pWg7kaeo01sWhh0W3gUk03sr2MJ2Z1yrkRCzqrBUynQuWQS8YNf4mMO6dc1b7aNNd7LB-QZMlOb_mWWXXSq_XQkVo3ZztEfLxv3lBL9hAnrBPhR3y1oHZu-d7c9Clr8nxfbgbKeJIKouY_qBphLLb3Y76UgjblpTXOUl6lHspMEsqpvFSfF4TBdLmtTPNQ7A2zZXDwmxNl6lR3iT7Q_8furMkuoHsvaixmQNryfHwbLXeY3h9YY9SWbgBify7kzG569OBtVMWx-zJiSUFEVA=w1263-h947-no)

Tapping 2-56 for the valve rod.  I had to use a bottoming tap as there is very little length available for the threads.
(https://lh3.googleusercontent.com/TpQCZJHwlVpA8y5srMyFnGChKgxZ8nCi5HX3Fx64T0Q4x8BcE4oNN1-zBpaOXVLCfnvTy4mHQqRcQa9eJ3oqWrz6aqEazWKRm2s8SUNzvNdszl3E8xyPxsYQnkEQGPhN7PWWNEEZpWtwuvD2NoBe_9y3yC8B1Q9tGN6RI8v5zHrpEm0PY3Oiqfy2XzRBmy9pD6gfhUSvHppOha-BUs0sDUodbNYeM9y5Kl8xeaQXQ9CuW0b5qeg9SGhU-bl84VjqxpzJkZUXSOZHlQdxdnET89u7e4mfChXv4N7ijt9ohIhehEi9NBForVmyfI7abc27hSxr4-JnQ84HiFwMH-WyGdlULoo5V_UUhURsi7p-l6LGtP2B6mD2fGfBJTGIw1kghNLD1wvfWkTbcF5xiNIoCUiO9NmudlcZhfwR8gZQdB6Fa6b-oVeKgVxgnHqKyghqJkq7a5l8z_AereINcWE5e2ekDRPSC0gXvcLJ6CkzvYgRwiX4m5jvzMu92A1y9jVEsNzzBOsYBCXe2rfOaXA4Qvsdns850VdsLhW3mcvyNqc8mrA6lcFsEx8zzFhrseMM9XfB8kg6318TzwOPtObiuc84Fc-ojRUsHbF9uaQmQ_rtUXRp0e7N1BOL-NCG8OwtvoNC22fsmxU9IFjY0v5CecBBo4M0n3ZWU-wqQ4rnnBKCbwcRnqW3eODNCLQF78UefUsKO8ahAaFNOme3Fg=w711-h947-no)

Finishing piston valve on print.
(https://lh3.googleusercontent.com/1Jud7d59jNWHRbwKzfvoax7vl1FATH-9PXbABYI6EBX6ALZOSwiY98Ef03xATiUV2Nhd11Qu-0sLK0_I5TM69fOidOrcp12IU9dIqdyyD5Q9Hfy22k1VnSUHyWfe5oF4LcmC5A2wzW3W3vJ5Xc2fgb0S6-wBU7Z4oiyyQ2ws_N8l5d0l-ycBKfuanQIzLDfcGKBFOakw_fOFD4dkqX4Hm-XJ5d-pZDmyV8UC8nw7A8xQ-12WHndPsuWCMCFpbY_WR8XtYhgP95aBBi2EC3OiEuQRKAItsu632cmsTq2m4o6OSzTRDgTMZDZNI54wGBPa3zYHRj3huZQRJkrQgGnJBik1xgStkQ5srfQpRGuPOQelWzi9GEv8oGIiugcxRwqZkvxqjwcwocZsRpHSLpxBfTSn4btz44YFpSq4_Md_mM2nHz2d4xJ6oH3qrOayWlD7lFhFUXjiCKG3SQp80YWAMTo8z3fQHdn4GZGwBMTsKMlgJZxypYL4-aTt3jqHkUgXbw2B0VxMKOgYRSR3cQNdCcEv6ny0QZroj399yhK6LRWglKDVZC-jJPBUFhgQuUkHOBoLIbcQ8rA9gflu9PO5evSEyYClDb1BJFst7Po9RBzPgXMsMh7gLryzcm0CxEMc3UoEnpp8u_FtP4EDbCHO73Z4I9qV9N75k0GpJAMJJXjRYSkFAHjqLMRJDjcdCkAWnx8D4boa6BXTbhaFvA=w711-h947-no)

Turned the valve body end closure from a piece of brass stock.  Very straightforward so I didn't show the op.  This is the finished part on the print.
(https://lh3.googleusercontent.com/N7FFbi-nvmtV06f3392Te8HTx22F53FaQyFmXZHV64j9EK8FElszkKuzGXr9jD-y_rNL59APp5oawSzk_Wq2AKs5u9iexGVevz3QUhjBnGzy0a8TQxQ1DGKmjK5-oK0T2sXgPHUz3Pvt0Y21HGwHp6yVkAfbMFLYnWp-FyRIko96wIUQ2kfjOnFd-lRVs56zyv5f9BgQUOT4fECltd0TmcHKWF6g3qcxEXZ-IOhRtg92f0ED8RTJql-FvrPKWpr561GZ1jw7G4uRa4eRFFqT6fSD_TjD8gtnQQl68kdI3nEgVEBFyzH1OwgiSTbbJ5FfdtCBMZ72eQsHIAtOgpLfkF2n3_lwR7ezVzrCElt8GHrjyOAa2a56l5H7vkRzhQP75mO4dxcZrAnr1_UGVf26rIKtV1IwTMlby07Mxo5W1OgXRmfHRvPBZpwIBoVG6Qz109LyjTOMzlab4iaMoASth8ShJTVSo1GqZTZurD7boNYGLIPXwz4a5AbwXfgB4ks730SNbJDGiH1kDEW_yqV07x_ce-2s8EbfJGzTfkMXdK5rQwRIFPjeL8WCdttPZztb7Du8XvzUzES2TtS9C7vNJ_8WCInNn65O4SkAoceAI4QFyr-0n3MvSUBiMjSN90S7RBtK9dYicXa6rrcAjZoLCGcyb8FK3_BfzjW36tvCfTQR3ngVeiBNNo3Idu5AQKV2rQpgqJKjmTbAEdfv7g=w1263-h947-no)

Shown assembled on the valve body.  The fit is pretty tight but I'll go ahead and put just a bit of Loctite on it whenever i do the final assembly.
(https://lh3.googleusercontent.com/FP1CpuRkJvyfitq4fhih6e-7GPPcKf-PdHh0EESh732nRnDLWMtLU1MjsX_TkB1gg_az-7veqYxsyzyiPiK-W1smolULkXZL6tDj88CXO06yFoI2iXnP_ofKUEUsUN_Idu1LxCO0KTWX7GMb3AoZ4tiHBWvhnKeukINlK_KeZcwyWw4FdXeivWpvZ0AG6ZL5TS2bxrm9kHqD45tOZ49z0V9pZY9-T_xltvwHh13MwJ3INpXGHPiafedPyQJ-ST0MMZLnKmNjEfXvTveq9DsSRzcp0oNGo6r0sJRM03o2QxcDtUHN8r7H3-Sm5RZnUKMsUt7iE3jjnuiku4tds69dL8jnipjnfAL4_O1oeEegm1Ch050FNnnGZti4dmZExWlVU4_umRCg-VDj1gY-wbvbi_nSb65r4zOIki2X1fAbjbIuOkOUQZyr2YC4X1tflWMXEPy9ZKqX9IThdzmUMXnM-qDVjQ_VeUNWL8B7YXSB3k8BSe8Yl2oH_P25cOjcA_L8i-EIql2G5dwpuhlOSrAypQp6KHkN1DGINgpai8WJDcSwLODZkAd_y8wTnWr1G1X0RnXQCxnQDwf8bXClF1teilCU0vHCrb1qbINywGNvDaqXo-8M_zs0VxsxXr1xlzXrSeH7Xc12AP6qZOQKuRIyi15G0w0oFNdFcJivC9CzV65tbrX26NEW9Vu5kGE1vHk24l_6729DIf_v19bNLQ=w1263-h947-no)

Shown is the valve guide stuffing box.  I didn't show the ops.  Here's the finished part assembled in the valve body.
(https://lh3.googleusercontent.com/G6s7AUZkD1IfA4htmY3VJcn0Qgz5WTFqzlr-o8TMZHWzetnoa_hzdJLSU7y4j9l4h426iPq7XXp0AKp2-Iu9u3X8Uo7yMNnV_bdj-FJxRD1UaUmRMqrz8IIvJjRM3sDRjW0G7HcPadmK9OGpVWUPFQ5NsUAGvqufe5yZz3NacwQqV3eCNsEn2-bkm1S8aw72wqSGPaQ3wrk3uWVdttp_fDSqlJYDC7ZuwCEWG2V5yR2YCm3Rq5MjwCHCuz5TJyXnp3w8bVFbLPeOGTq5eSICNPcpp7l4GQBTwmC8k6LIyT43KXF7sv6wqFCO3zyejg_7IsMlnAm73CmIgI_hNK4dOMs_nlNveXLYtnIDKYeRPhBa0mxMBfNhMda1Oy787nlnsJHKdJ2ns4YtRnRaPNgYl-oSYi8fCzAto1bMVnOiTb5eoxR2lDSzsfuQ-4_B4bvQdgcddRzrR0lnCcmPEhKL13KEj2D0PRBx8hxqliHkxXs8p5V1_p_qQWbPROtxRZZcsz-w9Z__JXuoxdAaszx7-6JvI_SMvmYjXqZIbv-0hDvomNZaMQVLmqvmuhrWOgZ76ApZuF77c9SI36JfoBCYgwtAZlceX5bMojZdmkFHSX-5zRWgSdi-5ecGdFC3cs7GyNgb1mZwnrWQjrOmqJep59mn_4lMIBwk3Df0P1ZAPhso9MzTZmKV2UesSplPvu27LK1DN7P3TFVVQL1wHg=w711-h947-no)

And the final parts so far, the thrust washers for the cross slide assembly.  Again, no ops shown, just the finished parts on the print.
(https://lh3.googleusercontent.com/xvNXQrS6mWyVt_FZG1oARECBuFH4bxeLb-T2v13bPFsX96QtAwJ1TteCZpwoF2Fzzc2_Yao1dyQglvw8mGrm7D8eoG6A2GHM2mOf8NKBGi_uHHma8vLHYhHiloCXR9oY8pd6FHlT56VRRDRbWdg7Fi3-1uYAgFCX17kO5WrqSvq6ihUSOAbsZcudEWqLe8g_JsuJgN4AywoX34ha-z-aYMTrQLvOraFnK75AL_8Uj6pn7nCzd8OHrls3hCBduEk7l0WqUvszj-6E6hTATKtSS4AzxRCkaXzl3L7HnCSPftmd2KvRfyDVmwaN7g8Uxab6Ml42q9h65v9xcB0LJ6r2ww889T32oiZWF89uqLabFq1M0Go_hh37667n3wVWUAaSa_XwOFE-LjkPlP10IGwbDcdpoLqwl5T3IYK21p_cf3sJ8UNnfihtB_YPyYE1Mmptp_8TSnGwAyILx0El2WfDzHPiCKEz3RomRLGcCk6-ig4TQtJjyXXF7VS0vNmYo15rHk75amQgXP6UX3AgW8mb5cgGSfpSyQOBIWSu2oP6qQl7GiZAJGZLRz8RlSbY6KMBAqJIwpfASULnfMA-46zyMS6HscmqziOTiwJ8GnBZKkPFKv-YQDNmbZxc5kWThrUwx_t4T11-JgwkU8Jy4j_XiPRGGtqJq4XGO7Ge26ZUCfHz0YwiYVVXXYWezae0exSzJqjZ7Du03MJeB_PzIw=w711-h947-no)

Hopefully I'll have a good amount of time in the shop tomorrow.  I'd like to get this engine finished in the next few days and see if I can get it running!

All for now.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 13, 2018, 01:32:13 AM
I had  a fair bit of time in the shop today so I decided to get started on the air inlet connection and the valve rod guide.  Both are brass so some easy turning!

First was the valve rod guide.  I had a piece of 3/4" brass rod and this pix shows it being turned down to 5/8" and then a small spigot turned down to .25".  Nothing fancy here.  I used the AL specific CCGT insert for this and it cuts brass like cutter.  I didn't push the speed up too high, I think I ran all ops at 460 rpm. 
(https://lh3.googleusercontent.com/qRnVBeFfVytFAmNS5ygotsCY0fZbiNzk7Anv2MN5oZNL5mAnUOedgfjTGS7xOGK-KT72yN2uFGv6pskJzaJl-V_5Mrn95yZ1EaYKOinGQCYWQxbZ__slh3Yx3qjkqzpzjNdee5p-RY2_c1qVl0s6aEQdwVQu8LILOKvEpvyb_M__w76-TQsmdvT6QVnoJjKhqCkDhGWTkOye83ub3d1z8P8DA9XFMAU_FG567cQf7fkE3dFazmgYqpPwyedr8wDwYzObgdIuP-GaLT_D1ubu0Xv_Y_CPtsKyZGr0HdTzmI71EOVb5QDd3U1spM4qb-xdVwN3zi5nlXl8A0Hi6Xez5QXKz_YSdyVNzvXHlgwsOjmoqPAPk2nREd9pvcMWK067BfHkxQqEdDcR_lrxdv37AcaJQff-CGlNGvh-zCONZpKmL6nYgF-L9y-u8ZlOhtj8a4Nmlan9gnWHeThEHldEojFdN31RgrVBDuNA2eUjHvaH-Wuca3TbP7m9xs0gdnwtp8j8SmSiEH5X2_BndLKj9plBKFbADu_3TGNDzRmbhCIRzMcV3lbZTnQ_CMtyALn6PnBWJOVCG3PJyelo7460B9mb3qbgur2nDb63i4VPPKGXeXPIluE5bQ2FwQywv6V-Dk4Tcmx1wrab4tqpEcF33Neij30smTS8F8vWmRC5Q_VusOAJRMIX2Ntzm_dSNCV47Mc2s4iz2N-3IDAgEA=w711-h947-no)

Spot drilled and drilled thru for the valve rod.
(https://lh3.googleusercontent.com/IpKYNh5_YZnZmMPw66tq4yDjJsnBwBORhsAyjbYs1hNtPu752qHIC0QzppgB3NYDHONuUkyyuzaymM5plc1nIlUSFXipcIOQP13umqaS-nhxfH0Gn-CknyjpKbNpFZ8yuzUZf-xSpc3_HcIOdPcfFK6HfIBPtl6_iTXBDyoDZCqBaS7JQedMoL1VMcRGT05Kf_eE0RB--dve8H_ep8gHnuoP14OwWYi4zqZJ6eBaXP79qlrD0p0KsdF0pEkZh8egBTipxS_Z4mgqumIziT5Vh0vEqjU-f37MXtmBePTRAwcJZrrFCtBSvLetilEuGQcr1f3e7RxY8S2dsMIPhNxmzpCLZHJ_u_cJUWLnIkPO9jT_klihrH-Iqp8Utq15MOHQKSiVA2wKsxEMzAarw8pVI2gN94HMX-2gdqs3V2ZAvBPl9AqCCD0zDin3JBkmCOlXZr908YL5OpdRd5RnL9hiazGi2P66hq3pq23EGqJw7pMnmFAXUTz6S8U9zal6tRaYhaU4qhYMeIy9u_Vtg6gYDn_Kk7AV1aLPjUAlKe5KU8T5W_Nqxi-0nPWRXb4Zp8B221gV1vdaAOQnQWqGWp0gr3nKZbsG8P_aULFNG5GoGnMdjHSsZtYEpkhc1FSh8x7-IElktQ6u70CXpRiUn3tVKr_v6DBMg53VzlEvDnO9TuhdXyE59ecWOd3kdnD-0P-50KL4pnwy9oTV_nOICQ=w711-h947-no)

Parted off using a 2mm wide carbide insert tool.
(https://lh3.googleusercontent.com/xddqZ4OIaPDITllu4_zxfCC8NbUXd2gOHDR5wHM5qoyz5PZ_UAq7CFb4m0wYyNYm1FtuM-GWpTGUphsouqXtsyzJGzlOQz_D-suQjJEWNvg8eJeHcOLM-Boz5UTonW-YYaUQNoT50_cp-2psJcSUujafyubuuUbtMpMAATiKVlzga8C_GmfiMxkMIe7bByY5Tz1l8-iCQAYIkTBzB_xiA3gcXlkQGBXXcGW6mxNs0PhVSoxIMNzqa3G-Sp9lyBMotrq-jYDreckpFJu1RLRD4Sl6x8Sv5UKLR6fh8Ryt8vjwTcwnOCd36AyF0LTECxAJBuXwMM43DaL8clTfEf-MitGPU45eYF8Ifv2J2bDRRAcdolF4foyspZHnycCEy09lkNo4BEeXxyXUffIAWHP-al2gGFiaEIL_CMymLTSN0dKWdXNmzWj7GDmxHw-_2iu5y-jBHhs2HJ43VirHUc6rCNcIw-7TmbpglTXXA9YfS0VbXKFfrvlHVc3TOQmyUM17ho8VPQajRQnDGr6seRSw2BEp7W4R4MmKtCshGzP5oazI5ShiT3olVyqsQZL7nvQ9UgKV_Tew5Sg4Sw9NED_RpzPXXh7EaxnyLAQ17ROZXOEFwkMra6RJlQ4JqupkOy7OvzKyMDZqIHzGIl1qx4hv79LhGhSgcvEwZuJDl-brQoVVSnULsPYV2j0zY4j3_-YcJ64RRf0sh-b4FQ4E5A=w711-h947-no)

On to the air intake connection.  This is a 1" OD piece of brass I had and the largest dimension needs to be 1" for this part.  I'd turned down the top spigot and am threading it 10-32 to take either a barb fitting or maybe a push to connect air tubing fitting.  I just held the tap in the tailstock chuck, kicked the lathe out of gear and rotated the collet by hand.
(https://lh3.googleusercontent.com/EFPOBR53hyKny3VurE4MApwMdC2Yt2BAI16ZXBEdURFotZXJvG_7xtSZbLMPjgAViJtuPoRQlneC__UZR4YFhQllGZBYVYBkl9KS0kYVemw5p-KyyvFC5CgQ1b7pBRAwf1lF_d89QomcxG6ymeXHougXLSbVd9600HOvPp1e-hzSeT6yENprGh4u-7h4Rdj9QPP74ORpk5b999Kk60gS4E1AHbVfGajgVkZBTXVMiOjVQXGBIC7KITsqxcsiLEzEOca3WyjJySBQoQpAv1hltpU7GsuKSDLEo3TRfzUgn9uec5CJUMhbe06uR6rZDRq0vKw1q9hUPeNGF0ocMzfmBaeaNuWyohpOEL9J5hSZdsJgdbCwlfT0d0dEE2I3duJ5kBBQQK1zDR90oB8CehXnct_2hKUSGEAi4NJgmchrc-MLOoJvAUW8Ok1eajwcsXJcDK0TbjJ1DWdC3lVkehSh1zxaEAtSnNXhQQylLx0qoWzji9-YchHJ706OnLO5azFK8xAf4K7XKjtJitoFwzgG3Kk1iOioWTFInluVbjD_APcDhtPqNQw0hBWuzsxfF_CGHHzQnaKOSS3XNrYl0UDX7nITg8MM0ExQ0blMwn8Gek9jSX-uI3PIWT4GSPEbQPL5kTlwI0yhGWKQX20dKK_iHEx2suvuhOClJfYBd_u_dpyuT4HNBQ969YsXyXHT6m_fxk3bF7lktIv48ThFpw=w711-h947-no)

I did follow up with a 10-32 bottoming tap, just turning it by hand with a tap wrench, to make sure I had full depth threads for whatever will provide the air connection.  Brass sure taps easy!
(https://lh3.googleusercontent.com/yr3aDZ5i19uotH04zY6LNeiBaom6mph9jNmVs0LGcZxe_UyauK6LzSbZ167AN0V3gxe0qzT1eHWZSaerUiBOEVKeqczqDsYaR-tDDTX5l5IgIc8wMHtVdXWuHgJk-d9G17ExfLUylWKomV3EKYfcEEIYKhB5A3tajsUCd2KpzTOqKDFze79Z0DW8Dm8kh039hMUCTKr2XtSpU2i6Kim0T1J6qJxpu1lGS6XOc-gNSeaYoLAymoO-Rcg60x5cSSn0PW22ZbFIo9gvLssyWZDJOZVS825esVlBkWAjBLOKfGbbKzLzWQOdifGpGvHWk_jS3cX-_REw8qGq9ENI3v4Q7GYJI_pZ590dBzmB6junuHngHBAXaYGmEIcRsbxyAekU6-A2LERSxw23C_PdRUhV9X9eJWlrQgSo1lNJtTpwsU2bJuBgVbuW0Z-9cppAbSSTcPfUUJhqWklwwnukXLdoezjyNHKPUXpluxTtYTXRHDeaLGo-RaQuBV3zLUXpHsy0k9DxvYIsq7y3Oit-XF0vtoVD0zhkViOWvBY5G9HQn13pHCslTL61KB0wtFOF87BrIV3qzsbz-GtZLKIhTfgUhpf0Hm3qZQAPgDqEez4zmL3n7o79dMMD8QMsLYMx5LHuP8t5Rc9Sv2nGLaJGIBW3joxBuYim8YtcWGB_BLnmROrwMWG2P328Df_oJS_15j-miKz-EwB1tVPDnQjYBA=w711-h947-no)

Here I've turned the part around and am holding it with a 5C collet on the previously turned spigot.  I needed to create a spigot on this end that was only .156" OD and 1/8" long.  It's perhaps not clear, but I simply plunged from the OD to the required dimension on the spigot with the CCGT tool.  This worked fine and I took about .062" depth of cut so this was done in 2 passes plus a very light clean up pass on the spigot and on the face of the air connection.
(https://lh3.googleusercontent.com/4tLEHPMA9k-HbDg0VcHLQKuAJQXIqRQhyvxaU7Kxa6R5ZMnl9HTc0iCIVIofDI08CmbW9x-i1SdkDzUUZi7kfzjvd0o9S5QNFr6I3m7jITmbOPB7MX5N2VemO5u-Uio6Q9cHcxeIDaaBmMy9ok5bz3fFPuXEtaNujmtIgFopQux3X9bEoanevAXjVITNGbchi3QczQAkpHAiJdS2Sh4q4yJbyBeSIzbyHv_UY0xm6TXMXmeokAIxImsw61UXgjcCfqJHDePvWwCs8jmgxLIaXHEWrFtb0PaC1iHUkN3_ktk4vjuqNeZKHCPcejxArOmvX_aGBCKDJaWc_90scwyTZ3GnyJqi54tb8GVNI4kxWsnf5AHbNzU-IHpx8jetvag0XmnuzyZxhqWm6fnzoN-laoo0OB7hfaK5jmcIFuYi6rEeCdZ9TglQd04Di_R8DgmNNMVSGx7JJkM8pmu7plC22PnUFj70ulA8S79JyF3NBq4mBeH_K-kOBiER0skPRyNsy_B8LJGWAfOhlbpc1l_8V_v7SiRGYtly8njHdD4tlyS_dgSF6dEKL5V4nJjFYeSDQA11Hz-TSds9dSGNmWLlmSWtn3XiMm8oZUFPClEKjBAvjomvfVQO5J-XgBSAY1muxHGi0b9yS4OCD38HnpbrLQqriieVqXTUYLVrRWOtY4REeP9gDkQNTfByINjzCTClwYrJTcueKr6AX_M9IQ=w711-h947-no)

The 2 parts are shown where they are to be installed.  There are obviously more ops to come but at least the spigots fit properly!
(https://lh3.googleusercontent.com/RsAPDsJVk9d0ZDt6NTFzBZfbTTZBe5JydYTFF5D3ITM1u4T7x1UCxH5wQfX-vY3frZx5Uatiink76dqn80Z6eVEG6rZzGp6DX4uuBpetCelOEUgC3ISpOA0FxaiUTk1xZDfISSveTS-fRZS0YkOZyHmOeSosW1z1aERM-kfdkoHk8rrlIuB7_FkGQO7TjF4N1bZKYa1tC14f0Jk4Y2bW1HkLEqpADOY4myNPWM1uP2prA9pbhirGgKc549QhPrwYhGMyDmV_PfhP3trm5lhpeXWOggxQfQOCkyW4QuNCDGMso3hZljP7V_lCTFL_szCXFlTaDrZD9GwYrJubyWg52k1ly_qIPPPAmSY9h6a23hlpitt_Swlb1_dkvTRZCXUEvcxve-wmUMK4QhnMV9YtuHXA8y8aYGnch43YJrDflUrq4BpYdH4lH65j2XJhv8PVdTA2RDwrYakKTBtgkY5HfIgrCG2ZD4PB7sNY61b081cdgxbQwu6nwmSTncIwxk7B4bRgFe2lPnf9chqkc0tp1ppgJfWgOWD318mJWuEBGhxxLBz6Ltb2cBluzCYkzipu35qq-rpLYp5v0qjvZCrN-32khy0gNtrTkI0C_JNmbQyyJgytHc-RFerod6UW9HaacRxXQqExOd2aKcoS2usZdd-u0ZR5uFBZN1w4oirqyGv7UYqL3n2IDrED8h3Sh6jg3xR0bxysNC6GWOwb-g=w711-h947-no)

I started making the necessary filing buttons since I had the 5C collet setup installed.  This pix shows the general arrangement for one of the parts and the filing buttons.
(https://lh3.googleusercontent.com/KtOs977VbiyKNsaAr01PuhgZzdXPmbebb9fZCDPH9cH2Vu09JSftpH2dNr7vhpGFtktUvNCHw9ZKEy6l3mXBlRgzzSA35pNCgbzvfOw8O_4yQoxvVJl5uY9A3oi749nH_p8mjIORX2veeo1ElETyWNzvFD31PyWUmVM-GnKtG9fvKoNAx9ciLhVHmdw03-LyboQUVj2pRvs3bb_2t6TVhjvhPh8mRGeEsIB_px_7OCFXX74_U9jMffuxsVu1-YxVa9enhzezJXQmP0N7O7UiGPnSj_hermkf0TtvI7FveYMp6c-r4eWRxY0L8UC3zKUtmDKKYN0qk2VxLxANVmw-tQeGzHnBHqiv1O_Xmhd2JaPLdm6bKMRZRoBPCCP6EwahDaZsP6TYEbV4SiP5Z4zQweKBGlJneRSOCV6LoaoHHuyF13PzQHKclqWL-uyOEGauu8UVbFGeDwlgpz3y5htQTOtZBp8pm60yMNasYCyjxCzfCu3WYaq7P_BasuQ0t38gj-nIYd_sy74I-3zP4HV3_1dqI6_OQmaHikW6bJhub0Zf58IXjY1cZC_kQdBHw0KxbrJZOGL40nGJ1lQkE-yS48xlAD5NAUqZsiirg9G_tQCh3pW5UlxX0goZRoy-vCMHHgd6haj6jfXYx7ZSo0c5kripAKi6YSCk9U_Y361LNNTHYZXe0aNHPHXjOzzbU5teYOC5Wgrf5dj-VyolVw=w711-h947-no)

This pix shows both parts along with all the filing buttons needed to finish the parts. 
(https://lh3.googleusercontent.com/fUeQUWbk6rLFxGPPLF3CSdtNHf2mZeSJNKaC3GgqNjcHEY1ZNb-zYxrdSyfuixewwOpCqUZrPvrwIlMFtkThTvGKt7tuatTzaJSyMVVkEf1UUBm-64aJwJs4_VUy2Hg38hgIx3-F0Frd3-hBK7idn4m0PpQ__JLplbqww21UtaLrZuFO8dmpCzA_-WJmhkZy5lAlaJicxkzrb2qzaUa4BXwr4q1gv2LdzGhzFw8rsM8o825Dnq4XjXiYWkMtoezlTX1V7jvD6DGQTkmKEDWbt4dlk2lPrKpgL2KtsX1Z27S85V2Dv1SmbKLut0iDn-qQI0g9XdRhjCQ5sRI1NSV-AAtRYdgM2v6-LefVG5y2wl-Lfe5ozKgvag9SEmBSkNBeLmShO094xPKOkTAXVpLnXHaaClL_j3gSBFIoaOIqRhT2auVOn901KQG8gG0FMfIb-Vnusm2XKvGKBKfLTEABsGY_K4G9dQ2FhtBJ7MTp6PJh2fekKI1BCK993O2nve0Bnl-EbI6ktcdVKjBw3AUsM9SHdWtQu9GzbHZocx1bH4y6N-EjXnwwQepFbbmrL5pEZTonY1RELwDrEDVFeCeg2rFKH5pbKxItbG_MHdmL7lmEvcs4il4a9U3Ob1-ieeVUWwy2qCnZrVhoSghNG3y9JYteAaoZAunOKXO8X6z2il3D5_0DIyM4x33OmaEsOhLtOQrFVd1s6KIU_yxvrg=w711-h947-no)

I made each filing button at least .20" thick or a bit more as needed to cover the spigots on the parts.  Is that usually about how wide these filing buttons need to be or should they be wider yet?  I don't plan to harden these, although I could as they are made from either W1 or O1 drill rod, depending on the size.  I figure with brass, since it files so easily, I won't tend to chew up the buttons if I'm a bit careful.  Is that ok, or should I go ahead and harden 'em? 

That seemed to take a long time!  I didn't really attempt to figure out a way to make those buttons faster so I took much longer at that task than I should have.

All for today.

Enjoy!

Mike.

Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on December 14, 2018, 10:53:47 AM
Great thread, with a good-looking engine nearing completion.

I have started my trajectory with a boiler, and haven't yet built an engine. The Potty Mill (metric, possibly to x1.5 scale) is on my list for when I do (after cutting my teeth on an oscillator or two). Your thread here will be an excellent resource for me when I get to that point.

Looking forward to your next steps and the finished engine!

 :popcorn:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 15, 2018, 12:48:41 AM
Gary, thanks for the kind words!  I'm making slow but steady progress on the last few parts.  I'd really like to get this engine done in the next few days unless something really gets in the way.  I will continue to document the build as best I can but I'm pretty much a beginner to model engineering.  There are many on this forum that have loads more experience than I do and do some fantastic work! 

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 15, 2018, 12:51:32 AM
Mike, this is all looking pretty fantastic to me. You are doing a wonderful job on this!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 15, 2018, 01:39:54 AM
I ended up spending almost 2 full days working on these 2 small brass parts, the valve rod guide and the air inlet.  I'll describe my problems in this thread as it was certainly a learning experience!

Two days back I had turned the 2 parts from brass round stock and get the overall dimensions done.  To drill the clearances holes for the 2-56 bolts that secure both parts onto the valve body, I held each one in a collet block and then put it in the mill vise.  First pix shows making sure that the block is square with the table and vise in the X axis. 
(https://lh3.googleusercontent.com/xONt1YvSVyyiONW6s-xBSIx1nJXX6JYw6rMUxA3CwrW1l6qEylEWOUVNDynKltWk6Qx8B-808tu0Yfq0b9iJAOT8EJyCke3rI2xZiGSKiBt7HHhpuCegQs36N09mjRyCulX0Nnc0RKdKPsXJqKrtxW6RZ4hjfB6UbzYxoCNWC2ImJFb9nnJEiFXNhtIH2K2izNiZgR1b7yRch30vcW_CN9uulcpQMAwv5hDUZTVECUeROCSnHQfEiYyF7g0-GiQXpvGldPUl752jvQb9VSO24MtJfhWVW4jb3JC0t7u740O1QRY43oqGQyzKC3NwGtPfIt5IL31OI4LjdVBhg7s8DKUlMx1BLiLSz_wLxeWex3EX0s8EG9_AUlN9dm10d3WQJLzx-JhxhfUV_aZkJawhnKBf0WXsqUGA0acqTQfXyQYmOl1reEyoyy7oS28zSYo8EeYnlrhsfUX_j4Qfg2I_mBqLx1CdyZq7kyFl-B5ulJDvgU9dVlnDvEa_Kx_IjrdK0jaSDe7DO8pEqTwBuQrpiVaHWgezLoLshMGCsQ8ARXkkHN0sjPI1EwFTheJURaPTwYyTq3ydwNkLP92jqBDfkQK18mj--RiFY44qaowKgfBEo7dGvrC-03hGBZgDJVSciPxVR1RvS3tp_qX20Ot4JuisvwZpJrmx6-c4mNd9pnKBc6jillcBw1LRnD1L0hlYQx4UBZJiLfoMswv4yw=w711-h947-no)

Then used a DTI to center the part under the spindle.  I did this for each part but I'm only showing on pix of each as the op is exactly the same in each case.
(https://lh3.googleusercontent.com/FC8AzQs_sxbsFCHTKJXXdL5Oczr0LM4VSOfyXeERXWaP21iuwjrO2C88Qyu7GpSJwrueTgY9UpSN75eTWij2PvC1g5gTJRhekodq_y9-89nSlg7gcQ4_kZux4KK04SdKob41aqkCMtpkVTqiw3zTT0gB7uP8JlsW_MHe-CnkMV9vwH45HnJiOnxLIGwUHNf56hrBeVAi5ZE6EOmpvZmuJQYLlgdsmB9SHvGTlIW4cQ-QrrZDExqjVbJHJARd0NlWZviVu47FaciHsyBiXwMr0Xsj3G6fUi6xLN6Rd-RwOrKbA7AkMwPIh9TIHsIu-pBSNgZuxP0MScFwoF7N-bQMNlH6hDhRxuPvd04ADtAhEipYyi_wQhkK229QGeF6DeRGMmiW-HIv6nAzAm0Ko1VLgn6vA0dy5YRnC20-zn3jJuV0jM4IELgheLiyIWAujA87dHwO0B9f9XUFa_hIkCjeRt7wYgD9eY5MDRR13PlnNumBBbyBpzbTf6wg48FvSpar1zForM9PDBIdB2oitFhWtALkNkcWDuJRfCfNgsjieQqOeU8uHAgt2hRT1e5VB5A_7v9cwFZfrLIn0Mxd-3YeoBsKkvKHpSVe_OIpcafUriWp91P4a7YBsT1pJEgBWHeqyWNBzSruOOp_VhdLNY783Y2l-SvvXBu4Xg5mVKRAOjbhKjVO3OKQtgB2er4Nm0-gTqgd3BLBUOMAUj5DNA=w711-h947-no)

Then spotted and drilled thru each part with a #43 for the clearance holes for the 2-56 bolts.
(https://lh3.googleusercontent.com/aZ708rxgSxcGIRt9evLVSI-ObW7ajqXJHNumWjGbni913bpfWXz--V29DORQsZWa7vtlKnqT7wiTPVB71N_IhfKQGQOGwhdAJRyu6y86XMSvnYTrDsWJmPiazuaGwz7JcOf1Q6E3--6cnUJN8K6RMV2mDjUH1I6qVXbH8aecdupgZa2Smz5M9kAw8oJPsZRZ5DFNHeSFHjmRFE-i84yQIv1qPZjx8JMkBwioacDl4aC7a3A2jvpeqMnY3t3DbT3RyI-BvREq9WatE7Ju4R6eyxr7Z_rqWjVK9Iywb78_KTFp5YQr8B1Wln7W_dWkMK2atcpMR4sm7PIb_Jom6W9CDqvufpFs7vQKKbz99uRis7qL0iuJ1dUdFgmp9fWi0Gfb0E4Owjjbrdx2i09o6pt7SGM2Ot9_Z6PU2-M_PXI7irPmhuqe6-yWcRvMoPL1Ou_a29ulgk7DWNDc52bwwA4xbWsVUmWDRGAr7yVZtiJU4OBWlLRuFjQ_YzWU8YKm0CLlJmCoQ4aXkkcI1t5Swhz5BftO157OpzPCVATlrlpncNCowhWzxykpfC4eLqVATFL3HwBl8Y2o-5hAFVwzs7VPZdceI8CGWLVGDS8wWSNcu-2JJ0jpPYUUAvk-fBKnj9v1LJLLO-ZZh1AXVGlsT2E0WBBvW5XkO3iGABaxWOfXtmbRDwTEDw4TL0ZrYNSFsbgJJ-XmkIfYFq9wxHFYjQ=w711-h947-no)

Then, since the part was already in the mill and centered I took a few passes with an end mill just to bring the width to the required size.  That's a 4 flute HSS end mill running at about 1500 rpm.  The brass cuts like butter.
(https://lh3.googleusercontent.com/dzKw2AWvxdUBQV4SP8wQ0JxUszCsFP-Zexj2OHY2xfejBNGGAlK3sE0lp1glurGw_JK4qSDRwXV2N11jMGoPSCkqCMcZ3jxs4MBrTnGJvoi15xgx_ZoT69H_tLAlRzLO6P2GiUjNwpRFSRK9ke9eLJrrg7fThtZzU0CcqgfZIoGfblG-YyzwAAdlR2Is5mu59ETPyl2TqatWUxsE5oGEs07V8riaio4X55tpuRfgccXBIdar3KTCY-JaN9ORoW8lrosBTck4RsUFayhnOf7gJavxNQlbjPpyAln13_U17o1acU1D7_NKrKGy5_Q62tIONWRvtOFEHfYr7ppfV7CSdSk0P9jsPa8MUq5fN-BF87iU3ly2PBg-1hrbMiLUogDYHPKYMh_cS71AjOrG8SRvvpopzPsQTHdBQWVmclWhNf6xOCImQfG0L2Z-X0L5BlmDO8rTRW6BQhsFhgyf4b6im1tOZQyX5o3VLvx56AhrKlNjcH6n-774K5CsxltEYoDYAPz--q5804yiQL04j-Xt3jty4IsY90BzUJ8UqUOVK8h4Up_j-uLrqtBQBQlJ7ZTpWZWR-gZtybOKLd-IVH2bgOUJoyeV95UrbhE0QOog5hQSWlIfWL-H5o5HlKDu_MmK9ntXhxSZkEnMQrNGSc1QniH_wZZHjZs0QL_1z9QeX_RnP3sc-p1QO1NKn1RuomspQdAsWOGCCO2QsorWNA=w711-h947-no)

Now the trouble started.  The following pix shows the first attempt at assembling the filing buttons on one of the parts.  The first problem I had was that due to the small size of the parts and the relatively large radius(s) required, the buttons interfered with each other.  So the first thing I did was to grind off the side of each of the smaller buttons until everything could be bolted up.  This pix shows the buttons all actually fitting on the one of the parts.  But to get to this point took quite some time.
(https://lh3.googleusercontent.com/dfM5nAaYWLCk0uPRtyAv-t4QNOmpCY41bbdHps0b2i7_16ssIQev4TZSy-NZ7iND9_eBtUy-aga7A9vANlKBNSxPyv6kLVptYlPUpojrYrybBVFkyXZaYK4rZ4loxCaWfYINN9C35uRpskRDEDdAj9ff5kRh6friJx37wFPF2wUQFYGhhMKdQVsU5RwBRATHv6-CZ6RMv6q3rPIsyzCNtH4VTk9t0Kg3gsrHuUf82vhfw7enZuE4bcfQdescMD4RWsIQPl3EGWwFuXJFvdax1jH397xofILx9RQBr7JLcDe8qpAbSvjdRYyDVCZhQCJ0NdtozvLhcfE97HkVlFkVB7KoBzv6NRtq6ccPsIbCax3i7y8jxoOzRGFeM79AMkIGMYQ8GGDlSjxNiPP2lhXPvDiinRYqFPK40WQ8GlbMK_BLOQSJsfS8lU2Ih16E6Di5P0QF2PoRSY0aZ7OnrsoBtznyUVdX84bwLtTAuvFtyYLJkCqUzlubhTDD85a8UhKWE-z5N7wYLAaYDySMJgr6c8Q5raNUouiTDoQiLf6QsGBlKiWL9stEXcytQUmsXRVJmm75qm-AmXvmpB3vfVNxqVQdPK766KgORSb_NvAxD6akAh3qboBvRoQUWGqG4GNjSu-e48bsmKSwf26aUpnmfDGbe_QO5SyKWMI0rSNew-5Zxjyu7L5pOzyts8OWEoE9nRrdJjaBU94-foodmw=w711-h947-no)

The smaller part was really a pain!  Since it's so small,  the head of the 2-56 bolt and nut were too large to clear the filing button in the center.  After some thought, I decided to try to do only one side at a time and stacked 2 of the filing buttons on each side to get the head of the bolt and the nut into free space.  That setup worked, kind of sort of..............and soon another problem was revealed!
(https://lh3.googleusercontent.com/ZQEKYeLAmyN1aUj8qXiP0kgcbbkrAAdhYTXLHWm5c8L_dJvPzu57svALs7bu7zwhieyerqfKimQlDlrxvBO7ZwRkwHpFPv2oBXsMM2k1302fHeIy6w2koQyITwLiMVgt2Nga87WpBDbI73908ZgJ6hqriW5w4LOuKABD7uKnvq-2k-8OLclEo1jzqjlojuIRx2pTG1lOY_JLzG0VW5-XMzpuOyGJlIQcuQ8EuKKBlghoJJdogFaUOR4SFKWT3THA5nFKIGtzffuyLXus8BPvZMC8VAXly4pPRNXJa5XwGwXmBlaXXYbHDTgGHBv0xW-NITKdyP4yWmzU_4q-mBCNDV2h5To-b4Gooj2b7EI9479XZ9-cZWMvDIfbPLFvf0MEWt-7xdF_mzLh4lkv241Hd72LRcvJ-7MeFyTR9EzL0emwk3R-sKudVGfQ0Z78myHl6krdhnfORIP6iwNGQs0ylvt733XDQ6KcY7SCVaH_-SBaAceaHpXgjNL895F46ZZ6kti_4EMfhm2REP6QjYw7bJW7h8qPyWfILP66SiVY8EruIjyGtVD49Qp_X4ew2pzYOUOjHRmxCJJ6bQQ6IHui45Xx3xuiHL6N30XZN4U-JN87BB-2Y99SUlYYO1mZ14rflMHgIIyl57yfQZV1CahN0GO63P1lJjgGpwgn70vmS3VQKMrUKe8YdaHHkVLQDjP2PyY2pgVisebskwYqmQ=w711-h947-no)

I started trying to file the brass.  That turned into a miserable experience for a couple of reasons.  First I could not hold the parts successfully no matter what i did.  I have some AL soft jaws in the bench vise but they're only held onto the steel jaws with magnets so if the part to be held is near the top, they fold in as soon as you try to tighten the vise.  So a near future project will be to make some replaceable vise jaws out of AL.  Second, I suck at filing.  For whatever reason, I just couldn't get the appearance right and started making a mess of the parts.  So, late yesterday I stopped working on them and had a think about what to do next. 

Today, I started working on the parts again but this time, rather than filing, I used my belt sander with a fine 150 grit belt installed on it and gently applied the each part to the sander until I just got to the filing buttons.  I felt pretty good at this point, but when looking at the parts it was obviously that i had used a bit too large buttons for the small end of each part.  I followed my print but it looks like you have to make the buttons just a bit smaller in radius than the radius that I designed in CAD.  Soooo, off to remake some more buttons!  After doing that for both parts and touching them up on the belt sander again, I ended up pretty happy with the results.

Here are both parts laid on top of the drawing.
(https://lh3.googleusercontent.com/kc5-AhOy0UEtuo5pz4EcGSGrZWXeVk-7wnLzN1-EGGkZvEju_mW2cVnIBRSeSeUhQVTOWTQuDeO9IBE-hRjVMny7eF3SzELNA7IwcFUukytGnJr5NO4LVJHUShkBTmKllJfQhv5aaDTO4pAEnlXCx6KAqq_pEyKpkSV3LoE3EhO5emIpvqHqLEBj0_HT6sBtPajKZTQ65s1x-X1wtBSjjOIPHUIbZQihdhWmLbn_TOx9qwVnPl94oKY5lvFbsevkljWYtO3ufmK97dS6zbZG6na-H76cLWUnFeTluUjrtt3wP8oXIiTWcCRvpPd4QHeflZi0Qo5pW-9SEhBqEvB7F8YWW_xQHnwrRX08ORz4ZHv6f-27EkGZfnZzmc7FVKRvsiPuxB3z6w3cwDfYHcrChGlYyMgWO2U50kd7AihfHjuUH2l3Bxdw-MOj3dH95VqlQqJ8ezgF8h8lWP7aVTGpw25kwgn8_whBYUSQbGn2Q2hHImWt0jJnQD5MgtCenaFv7Di7BR4I6u4ADHJodm8BmmlrYBd6PyE9zQPn2VZYjZwsaq18kPfx6XrYmJvuho3d_Psig9PM0QdtS-tAl0TGGLumUSo0l2WH4K89P2v10cWRxWWU1IE6Q7PUsh7QaG8sc7xIjGG-hVLw94WcEygyaiVMJz0hqj2yctH31flDCLftpbpWY8kBFSRGO4W0iRdrckC8BagBznJ-cZhEJw=w711-h947-no)

The finished air inlet in position on the valve body (without the fasteners).
(https://lh3.googleusercontent.com/l_EfM-SSHKEClsnNtteJkK3DSeC9j46NL-IFHMJIFKlhU2_V9UW29DPVTWrYsJn90d4cntjxKJs52WhLBwpuqx3Y4g0ssjqa-9ccnlHYDFXGRAl4ZdJZyMn8Sx0hS4kJ7hLwJaU-W0sUlJ3g4PBnTBqtkA8LfIFirdWsy16_4wlPYbE6gzKdpN03j4ITd1yOchY-dxi06OPkd7W28KKbl61nShR7hW1RUonU5aOr0F5EhaqsDFRT0WUf9Oxo11Gs6N5TQwCoetOyJsggxQNfJRz8Qzyjo88uC8IuNWwpaicUcGJPYb-IX55Y7Qzgz3S_t2A3y6Rriv2hX5PRZ02zly4_XbhK-aZwEsvm8uE1f1sUltM8UAwr95Ya_h27V5kEhqnVdhxO9hfJx_FdAypIxD4BLIXSp1jXQDGHdQSDbDViSom2X2ykGsP6pqud8rKsU-WgvrC7qEJkBKv6NOPa_tI3BHu1P3g-MwkF3e1yHZau4X2rByr793GVOCNsKJdgZSrECsuoaP01ARslQBSbECiNCRaYSKKtv4mTx94QB6zM2tDVYyWeD1gtoI_lqof0YzxumK4tN7TcyAC9YJgAQLrEe8Tt00JebYkhDFhrWGCnmn_DUDM3Dz0betRl_8PjfMsJCb3CgjkbMSmufWoBmCpMuKf714xgPIPLvQbUJqLE6_6YDB0ZTYZyBrnA3WG7Lr6ayz4gaMcEmUKlZg=w711-h947-no)

And the valve rod guide in position on the valve body, again without fasteners.
(https://lh3.googleusercontent.com/i9RFFJLVlqK4TPL_DNxRM7osJefh5BiQKgmW8raR45iHXdl93EKRl_KGmgLmR2osa0aiEnpP0fgdxw5Yfd0gY4Qz-7PROewajrie2NdEeTscGrVoRLbh2vwS7RTY5P7Wl8PtUEPDOZZG3mYHeTQz5MY0pDa3FjBcpv7odOJJc0ZsZP13N7ctU3Rf8BSQ1Ws601_X7U_jN0Fgt0y6lISMp4J5jdpSG_KZZNy_-qi2hIUe-02f97M9hQJDupIHYOPj5_FXm1cES8ilpYtN0TQNYAqbQtXSRTRlms5P4nbA3R9k4cErP2s3nPXCIJpdaS0u3I8QMIjopluiuH1aCZhNhXyzFF2h-eS6eWc06jMzmN6Lt0wDWhlTGdRUu6cP8P7YLtgJI59ge2i_F6cRdi5xqs96n38KXDEZHQt2UIQwgC4fn7I5dLt3yoWmrCSGaVsL60_qW6XNOSo4oNZJuhMiCwr-iyY5_Dza430Xx_UBQZ3eK3idQOLWh8piX1Zk-SLsqqmfWCNIFPAf49g8riwbXM_3xesrz0WmaWZOHnQy4nW2CFvhLpq-SxSzehbyOwkoCBWrZjEPKp97lFolDyXL_0NUzW77AD_az6KbgQeoR_o0HyzUYg29uAllRJjZaWRN_Mu-Eys0rcX6-B9UzgBsLIA4UQ8F_yvyfed01DD3gAHYgMkkdTugUH03GiwnBXzq2dXFtC6pANbctom3gw=w711-h947-no)

I was happy with the end results, but man that was some tough work for two very small parts!  Any hints and tips on properly using filing buttons would be greatly appreciated!  I clearly need to study more and need a LOT more experience on using those devilish little things!

Since I got those parts out of the way, I made a start on the crosshead.  I had some 3/8" x 1/2" stock and cut a chunk of it off and brought it to dimension and left it about 2.5" long, just so it could be gripped easier for the initial ops.  First pix shows the rectangular bar being held in the 4 jaw and the end being turned down to .25" OD.   Since this was an interrupted cut I fed in only about .010 or .015 per pass and turned the lathe pretty slow at about 230 rpm until I got to a circular section.  The insert is a CCMT and worked very well.  No issue with the interrupted cut.
(https://lh3.googleusercontent.com/Dag_OLXvTJMoTLIPUWe6DpTmk8YiehEq_8Ap8IMl3pKsy5AsVLYMOeujFQ4_fTZNIp2ykYUEUWNWhcVDGov8VIqFkRGO_IWvcuzf4k-1lZUU3A9U7PiP_MsOOlrEongFfdh_bwmtcDHb7DvZcIYGejUeelyrbkqN8y1XUFuD1aV9nW8R9vMy7cf_MQaIzEQYTuFQ7wNjAh8deugz-AyKCVrCTw_t4gS_KEOHJ8TQ69beuFd0wak-w32Bo5NzT32PxYccxOPEBv84aDeuofkAbFCE7q0jkYdvHgPZ-AEWLN_psodbBv4rv_ritIYD1uU0U3C4R818B8niq1Xxdp6TsQS3JLkb17QGaY5kKTGYYSkVCXnQHKxR5UrEpp-CAtKpx63g-HmnNQtjAlSCFKYaYRxEtCvbZLMKZJveG_fe8Xt19zq0nClAOX2eum6-1xqTIiUcZZ3i609CerXQONgaFiY73_5TOB3rKi0YLn9nBAF8UXPlYoBCK7NgSCCel6svFx-jg01wdsByhWexjND5mR--HEB8Zx50IufdXu2HC1HhEvs30Ye50QBNsi7pIUh7rQdC6VGKYLdBKzebvHYE4d9bGyQTuZSW7PX_uFKZ6bkx0pMj2LasIkIbRewLCYemkA3f4ayfuMfiy5RaS24kS9T65EdKvUAGlOkQ6pZZbWVOwmOIM9LnxWrN0ng0_3uq6zcEiiqcahcNgvF0-Q=w711-h947-no)

Then I put a radius on the rectangular section just to blend it a bit to the circular section.  I used a HSS form tool that I had previously ground to 3/16" radius.  I left the lathe turning slowly and slowly hand fed in on X and Z until it looked more or less OK to me.
(https://lh3.googleusercontent.com/LX48x6RVWwbtbvAaEnf_u5HN94B5cLFxxUkwqVN2If_BCqc6b1YcpuU2Rm9ef6n-SdMs3Ne9WWygj5ZJPk85OcNcVe5kGovQo9kkzBwpbWY_ouClUT5s6nCwdyovUmQoFP5FCQBlVwf5ANmbd7YT1VVHkNcuFxYJz4ntfx_MniQm5YUw4rXIt_4FRBSbFU1s8vaZ2Pnt_IuI4s9nWPIAQi__PcCrf3aU1TuTPMaabL5OHvNHFCLRJOIPJM9INueJcpzvVierphM8mYXasi-PgEf3rFJVjAaEc-qd2-k2d9iI4kcRYWT-Fusq3EuEcKZNQ0jOwLHaiQ8HgI6BtSPd2c1_xYDsfamXjRWu1BDgEdWK-TXF2hYQALR7fdHKQ54eSS1swEALnjk2VSthkmfZu2R-nvS2pETa18qHua6disOqag3zgWSfVJfRCioVVMXAATgHpRQEFUY3RxWCigQKPdKl4lqpgXknHe9iBZDpnq2MNb9dx2MMrlTyrGkHty7Uo-h5-W-S4-g1Bm8tAS5FRjXsp1VcwJ2o3-EZqTG_iu6aUOiOzABvQS0NKxs3bV7LUgnHbfLIXfApikdO1dD9YbfMdA_XiVaCAL8X9ejiUR-uhTi70RaCFIa18rLMY5CK1KcRT88sQ44pKOqmPHzLDkTiYPvkIL6n-JKgS_2hna915BgxZGDia138AgieNRkv9CqPQmsNHDfA2w1LMg=w1263-h947-no)

Then I parted off the round section to .040" from the body and drilled and tapped for 8-32.  Shown is the spring follower and a small tap wrench that I often use.  I used a plug tap and it went pretty well as I'd drilled to give 50% threads.  For drill sizes for tapping, I have a copy of the LMS tapping guide pinned to the wall in my shop.  It's one page for metric and one page for imperial and is quick and handy to use. 
(https://lh3.googleusercontent.com/npGlilVWm339NjpQrh6Tu3iY1RqwrEBwUFFiTd3CjZuNrq_pweVKcm0RZ8kv82Lknr_EhQcU5U31yHCIPnsVfxMnV6VVsIlbwMcGxC_TbuVPTfTFhbVp-7S1jkXfxALpeXkOc9S3uVseo1SDLhOWH0ZDWI1OrrxT9M7v8XRc1dLOmiddB8G0_AwgsrrPSi0j8OXhEIXQu64xxpnzqKAwwPQtIa_1Vzjd7e4sjlqL1j4kyEmM4OM7mgUBT16KLDv4tZuz5x36acQUFl2fyswe8eP0iOVDsuBRJsc84Ind-ltusp43ibAh70a6ijUJqMlH7ka1D2JxjdpIH1YC6xyDOmVOuQCySXMVtapUwOB0q0_2hcUEUgoIO4TtVIERllUc8RL4cs9FPJlFSjkpsHu9xYTsmNC7ijz3Cw2XOnuiLjm4L35kgAWc--mc1C_h3JCPrtnUhywv44UaMkr7YJyIwsDpXl5WuS64icpWCYCzoi2z-NbO8XhbsP7FhtRhjn7bS0VL1jgEERnCgwg5JFZUclnfCSGXe47DlOYu8aT30qs2xEPXYaDovoZ4T-_q4qlhsY9xxd3spi3CZSqOOemQjhJwt_Rs260-TEMQtM-DsfsooU3io_p6nAlRSk0kOQ0NJyWMaF0p6yk2tzbz7D3eOZ64inMljyrcfyttTRZuSqepfzOvOEcachBIbVmmwSf6aMfmA90dKdtqk8X36g=w711-h947-no)

Then I took the part out of the lathe and put it in the mill vise.  Quickly did the edge finding and located the hole use the DRO and drilled 15/64" for the pin.
(https://lh3.googleusercontent.com/kt7BvAjTlE-fDVDS5jOdv0Tl-SzZoNR9UYxdZOZX2z2rMR7Y3toXuzNEdJQnBzl3LzdbSHYQjoqrXWF8kT2yhKJ5Cs8vjy6iwtOiVzCD-Mba5XL1UyqMgGd6aSoUwlUdafr2W1-0DYE_2pviux2A8iExrV7-NVlotLOfNQAq_8GHtBgkNZYQmMOUn2EtOenfw_kmPiWC1Up8SzergSwW8yBPeahK2JpdP1tZtkVa8GYJdjTeh8kENfSYxbU--m_4ZppM69ASZguszYyxyet3vaz8WJFtN3YPVM9qRRyI02nMoBTpGkmO2V_sYVy9360RIjo6aCRHANHpt7-qVsspWX_-Wcc0-Y9CHZ8bEtSYapPaW4H_ilgN6nPO596PUgPil20RTT3P7qa6D_c99nMn7Ae69--p_DTJUI0ADrFwnuLgQANVv_8WIctZ3l2Q5-1PpLZm_XgrIUI1Fi-UqVGK5YcUzDpGCyZoGHy800cSL96Rz4UIj9e_B5ZevGjZz49Oa1JrR9GjeRGh1TVzxLLpwhBkQVqVrftt81DRVcUdK_XSY1VLIbVRZ1BQ5zrhhbhm2DaUo2iyB5_AuTpqTzQp7Nwj28nRYNoi6du8W6ijjsA8Sb5scD78PyWks9NivXCF8sgWJxfSrcP51V3DyuI0ovXaDyMANLdRlUT1z-39CqKmXU5E_b8zskXmheRInHpckpuk6C4VOFvpSpwG7A=w711-h947-no)

I didn't show the op, but I reamed the hole to .001" over 1/4" so .251".  The last pix for today shows the crosshead pin installed in the half finished crosshead.  The fit seems good.
(https://lh3.googleusercontent.com/5urdm4Nkw6ot_8mBQIquyB_lxsbSrsBYpZOAFT1Ek3LuJbD8xJH2gUmSbi74X2V5cQsO0IKGnXRmxHNdBGa5GtLqQYlvB88mm0ieoW0n-HCbuUUSVo7SVfA7T1QcCNo7e4G-sIqv5jaXLxDh6FCwW4UVz3ZzY-FE6xp0pwOyuGpyfX2FztNZeUZwgLN5NCCB0e9hqkRMSuyiMtK9NXRgkECzzZ16-jAFz7lw4TvojIX-j53-E0dziLAruavirrzDgv6PZorYeE8BWmQyllpsSZH4kR0OuS4VMWir4bnzWm-Hrgpu_8UQd9rIh1dfn-shNBJGzAhcFXXBe2vr9b6nxx-YifeceLWALpXONHL4Cdg8mSVmE-813XXAo6kla-YwnShbHQ1PSQ0_-GmkNqbJaQvlbfOjZEt92O8MZe4seUa7--13jMmkFILYnUhu_ppHzbz6y03qH_WJhupQUNabmX4cgcnxIc2T-nLYVqMUPObE_kWdK3ZKRO24ca8MUq99p6r8ifoLz3g6IeS9oXJBny_VKg8h8gFxQqabUyl73l9ABcbCfiq2ZAKq7pjV0dwyXjQQ80sBJ6GnW69iUhqSdsd3Z8bNd1-xbSGmxZaX2gdvlw3cY9qMDLKNnO22PrQlYyEbAdIDy4VzNmPLS7APIV93ve0pejxz6zlV1fovp4yBzx_SD_2fKBs_fq3c6Da2rQzAjwtQGQVKcGcu4A=w711-h947-no)

All for today.  I think I'll be able to spend a fair bit of time in the shop over the next few days but given my slow progress on these small parts, it may take me awhile to get to the finish line!

Enjoy!

Mike

Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on December 15, 2018, 10:58:02 AM
I was happy with the end results, but man that was some tough work for two very small parts!

It is often the way, isn't it? Plain sailing through the bits that you think will be difficult, then the unexpected brick wall!

You got there, though  :)

When I first started using my belt sander (in fact a belt sanding attachment on my multi-function wood lathe) it was a revelation to me. Immediately wondered how I ever managed without it!
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 15, 2018, 02:19:12 PM
Despite the tedious nature of the work, the parts turned out great Mike. Nicely done.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 17, 2018, 01:25:20 AM
I'd left off the other day with the crosshead not quite completed.  So the first order of the day was to finish up the crosshead.

I put the part back in the mill vise, did the normal edge finding and using a 1/4" 4 flute carbide end mill, cut the slot.  I had to step over a bit to get to the .275" slot with called for but that gave me a nice finish in the slot.   As can be seen, I left a solid end on the part as I've had bad experience trying to mill an open slot.  The vibration in that situation can be terrible.  So in this case I just went to the required dimension on the piston rod end and went a bit further on the opposite end.
(https://lh3.googleusercontent.com/D5T1HGjbeQLo9rX_xkaM3diVIMOXMm_4eroY37g1rIdf69KZEbZsR4YVGLty9XVgiNZZ1oFaq_M4ENZxhstckAZ9PLG7sRqE3BA8O_dP77OVOgWK_k79rRNjyzTwysd7Xy-i7Pgha5DApaO7U6OeyKdH6wbO33ZnrSChCgR6ef66o_VsycnHXAy44xMOjrx-soVdbpXCCeLmJFEOMOZMjUowflpu-yk0hkIXl1X7DeKhPwF2WgdyFVqm87mDOBWVqbzw7XF3FcaOL1FSkgeG5ol75_WmQDE0lXdV4bwS_MZrxeKf_gXUioYbHzAXeBMYlkFfujmEAK7SgokHKjbWHclOrc4swVJi1N5_Lfwt-FAgy5F-dFIwFeikPDR7KuCTzOyiXFbcwRgTXx3wv0RKAzAES03H1uKbwg5h9BgKEntDJXnQHQxErG6DnyJSEuDYCEsCQ4c16nA5oEN3nffDuFKqfWkTmJNcRQdrLKxA3Zs3uYD57Jmtit7JusQ0oCzIXGtYMHrUvrwzPBMyDvCe555e75z7YL9wUPcCsdurCj3tX9DSCmD4FTP3Pu1YATCYDOliokwFo0vnymjlXrijU0zuMUXQjuaCFJSaf9e-Sjo5Sr51SQyW93xcw4Hihq6TW_EGhUMz3OOsAN5Fz1cKFNQXmE_PciixrW4OEA8YbXtwOWD5AGW6ZyssR0FddObaRMmtS7_jwgS4u8nVzQ=w711-h947-no)

Then I removed the part from the vise, cut if off in my bandsaw and then brought the part to length using the same 1/4" end mill.  Notice I held the part in such a way to try to avoid vibration and chatter when making the cuts to length.
(https://lh3.googleusercontent.com/8JMuF9xlsHMcr-NjffkAshWakrdi5VsJco-wEzWHCcY-dgIUQMofu2etwQmoEKXhN3fKrg3r7NmCwPi8M-PGpUspZ3oaiJ1t9SoZ1ppN6--VxPAb-OhXOj7k32Ag0FwP70vQlEHO-zunk3J-fR_m0UFIYdVs7vvs7W0G8F1UhNXz3TwhJIM1TTQWDTTvEqGZ3K63pXKnV-GQe7qeyf91YA-rTO9hs5szRCfMUjRRSG-5i-2B87PuQfxkiOcw7E3aOFfTRmy6npznApD3Oq1mSQ7T89KZzxX-moQMvr8cN4gIjg1IR93FfV-X_tNlHbGMuRoXBE9P9KWpGro6Tmq2f5yfYdprn632HbJOg5XVvLazADdaNJX4FfjxYa__ix53wWxcmc1X63TZyeA-nfKa7mDxuv_wEiwfoGGPDIaz_HbwMfjwvbQtcqBfEerH6EFK6TtbHWQYolRB9aLHBFb-1VF2g2EqwskwT-ZnMtJqN4dM9A2VTnE1vua4Fc4PEiKs8l0fOLw-AVVepoduqXNxm1luqBNYcJd8onBGDG0n2We9WMW6AO_o3cusea63GipfN0pOoo7ZkP3ZNfO6rMO-F2qSuQC93j3mPds0TkxnI76Zf9AjPkVt7JNpnJS7pEuWOPvYnCDpKDrI2MYM5KA_DMOXeCGty8zqmUwHPgWiFBeKDGkcOLkmhNzuJEUGNSNUo8M_ScMw9RmpJwjvhg=w711-h947-no)

Then to make the corner radii on the part, rather than using filing buttons, i put some Dykem on the part and used a 1/4" radius gage to scribe the radii on each corner that called for one.
(https://lh3.googleusercontent.com/HA7K_gTY6ouZ3iv8a2rvw652TbcRUvbixJN5BB4jMij6gRLaXicYa1x4UFLKh9tyPcTuTh1hP4uFnclATaLgscyvnnGrwdsSArF1lkBWc7prp4QnDbsNxAfQBsyKFiwU1olRh8-KpuIkEYnU6kXyin3-OReDf3mqjUcspDjMYNSiJwa84EdDj9SoBxZfvFLsEWXmrs-ftZA-tjayNjFrKg7Agf3tiHvV8_CtanB4CHbv4pVS-SJ4tG9pGLuzzesDK1rDfNiaA1V2TWs54hF36S_qdN94NG1BYHE0Aldq4T5OpU1-un95YS4Gu0lhatXiijw7IWLjGSfG58SLu8IBARaHnhClgNXiYFVQJzWVpAtjV_B4t2c_ZTPosZK1moosgxp_TW2wy1otyb9N_iSe4SbZkR-rxjavcPIfFpIBHBrsOLSrmJnqYjwk3FVna2ED-iVkQPxuvp1azU1iK9rwrLB26iHCQwedhQQHV_UZAiQaXjq41DeC_KkBlGX3ZmI9lE2as-fE_E6pCogJ84aOm75_fjr6j7_T85nLZBG_-CbwAUzRZpXjsBy210nmVZCqoqcrDLfJK1RXHiDsC9R86vJICGRTYWN9hrf92yY3DObbgF99gQffDL1IybmFsunBEgM96DhKfn1ib4rSWFjLnvx0c3y_7crwjW9oAf2W-aUnuUvoqt_HLJm_g31fOIN9NKCsjiFqvMOQLfHzWA=w711-h947-no)

I used my belt sander to made the radii.  I just held the part firmly on the cable and slowly worked the part until the scribed lines just disappeared.  Then a bit of deburring and I called the part good.  I do need to do a bit more polishing but it actually looks better in person vs the photo.
(https://lh3.googleusercontent.com/IVrdgMbehyOSLnnmJjmKj4v9mJgNZB-jwzlbcmiebkDJbTjYKpXtzJ4RW4QEGjUxwL9DRIFysLDWfer7vgAo8qFWy_oG3KIoqSanMkVc79BTDWCa7G45QOCE6YA5TmIIVrN07XNqgFdo2pWvYZKcsR6xQ5HfRKMhJcB6RfhfqbEtZDLF-6P5Z2tPtlawp3MWSirW01DuwU_fYBJQhLXx4jg3O4rPQFXFzrtVFAmFitj8-j6z8LV1mHBuAv60Nwa91XVUMP3nTkNq-2WjfGcDTvZ55zlWnMYXblEYVLTU6wpuf82POOAWLqLtq-phsY7iwzlvSVvpfwko453ntDuccjC09HuW5C2cs3BS1FuJXKhgJoOY6g6pKwpbNaWSytnkZ5-4Xujdc2daygF9OgxRH3-yoHH6EGSrgYqbnOwa43eHjqyLoG1aLCv6s3JsOJcuVZPQb_oC4piZ2Zm6IifrLeKEuCcO3cWDXHflDm7ysoQaEhl48LO6T1-439mucjZw1eN8_JQJQhN5cphKpp0i47IaD29LatQar7-GK_KxSVAHiLYoNuqz0uDSrrgZ_D-bCx2C3u8zdo91NJz2TRWqAdYJmV9V-BERWi3StAWHDU3Xr58tMHG-WUZ_R0L5fZjXvGzgooGvgvYEfkTl1li57arR=w1263-h947-no)

And the last pix of this part, shown assembled on the piston rod with the crosshead pin also installed.  It all fit!
(https://lh3.googleusercontent.com/JwUveyhDvBQ4sIJQvtDX3tt0apDUdZM68_0xCx-K0j-JvFcvEP-DAgfjKe7016j2sglrz32mPVI33ivgW7pcf4qiDoKod1-c5RlXLlXJyzYgC9B90_GZcE_SyctmrDfAc6TJa9O5byqg8o6aKOV49CNUTc-Y_anAUN9BnmuyRmbvQnzyU5qhu0_O0FjQbH_rdQcWRmYzfzhVNuY2C_ggQgqBYUL8CydO8HM3B3hyikxmOCt9PaLfi-n9S8pIdTdjOl_E0TgTxjbsamSfgZcuV72qQFEhpteehiYM2utw1tz_HC100QdN-frQIStdJhQhbqrOfRYM2tFFxd9bkC-2ulhO9BoyRpBotOyblWS4Dw1LFPsr4q76gWBobgBPF169ipdmSC_FJch-BHI0qspJdNI4DmeuIkx8vwvH5cnMqqrY2L8xpK2gYjKe_5LI8YKzHEUUBxZQV38kDVhWL8p941YVh_avrX8GZfGSozG5fgDj67t0rYcE9LO7mmShjqxq_qD701jNpFnN8CpB7nAkf5LQPzUyC7h0hNtZN3bv55rluRaBr_upjwCbZlHBFnHX-eSYzmwLPdYC67oS1U7xPfdn9W53F69y4vYym1YD1UHswX4fKr6TM9FCCf4sj-izFgzDXPxnDnQ--K0ddkvRUVNiqg29Bv8Lws2qNFdXgW0qPotVtvYHI5dCxz_N67uHUnzdY_KW-0CHgQwwIg=w1263-h947-no)

Since I had the 4 jaw installed on the lathe, I decided to work on the eccentric assembly. 

First was the eccentric strap.  I had a piece of 1 1/4" brass and shown is just centering up the work and getting ready to turn down the OD to 1.20" as per the print.  That's my home made dual indicator holder.  I use it a lot as it makes setting up work in the 4 jaw very easy, at least after a bit of practice!
(https://lh3.googleusercontent.com/vmiKq66TWpfIN3tAzj3corH2AgOrEmrZ_K_zshegg8CJ1duAGb44TBKopRnauuyJMRsOUCujwGv8KtKoidV8hnWQaEmAWbvSjg5joZ05Tg9CAikOWW4kahq9H2nfa-Q0BbysxXgDZWijhbeyviVlCDNqgHdrXJLJhO2eY-lhyG1QkvcnIWzuBzPIs4sfPpKqNvm29dV08m3f23ifDv-hM356Qyk92SlKOp7KX70UN7yTS-DEyzhlHr9mmfkuh1Q5hROtPW1n8AxqbONpcJB1WQrMVC78VmeWd6c3ws9s2pI6kHn1WNAz3PP54CJdpCIakRZomeuhW8f19FtT0RmQknXrFL9fBilMHDowRTHvEPc7wnB2xF56KmAh22GOg_jEEzvEciazQP2Vxxe_G9ZhTuKfU4q7cWyD9c3RSar5cgdds2a6-OFBBD8vXJHizEHKHtzLrVFY7Kj3EFFvwKPkK3ua9X5M_A81kn7F97Fuyl5eD4vwmahcrsY3zyvpjihfjl_mphKV0si-KZRwgcet5c7HN_k1J4dRofzD2d6A2EBOeeK2tN2trZZzMjvZXbKdbJC1lggHMVjA7LqsrSKsnNlcXSRIl0IMnKeylEhUMdFxvD7SABjZdD4nOBRFX2kJ7AVo_kXONEpVvv9wzkkGs4eYQoECHPQQafUCB5p3JZz2iG0AKcykemcRd_vgYP3OhcQ7vwwrB9UPhEyFAA=w711-h947-no)

Then there's to be a fairly precise .80" hole thru the center.  Shown is drilling a hole to start.  That's a 3/4" drill that will get close to the required ID.
(https://lh3.googleusercontent.com/qn0CZpThXQJ14QiLLSOVF5fGPvfXubWrVFRJ-ZI3hSnsIlyVmhPsqNO3i9xd-R9NCgdCdWjszApY3dS0nHk0kD2cVrLklSqCVSQ0v0_h0DhgD_nzIUluES1UvlZRJ7sZh3jBnj7im2a-oEXdlFEMSVk6TweEpozKhM822l0KuuQG8yF4ErmTGxvfT3Y_Dvkzw1_D9z8H5SZQXyWsSf0RfxDXdSw_6zzFJIgPezlmGlIB78qLSl239GkU66n29-uim3hjDKezQj-BBESyOg4JP3SdtNoMNU2LZ1_ZsNnk-qfn6VQN7WxMedrgj1vQ3WnbXIDWBnBz9Ec645vo_VnrjNg1IX6i36g33XoEBDOhFJlFiCtvRpPIcyuHeTv6oMQbCJw1vm86Tk26vIiwuG3gJgap3UhTt474IEbywcnIwbtiM_yk90CqYhIErQTILHUZ8YKjTnGjsXSC3J84QNAIyR-JFFcnLY3tnSLVfq9e1ruQvN5AT4JaZ_5QQOVosJZ1BIjmrazffAGvB6alrPwocw0hq56b1KFB6ZSx_FDv6SuGyGSnwxtdfhvWlGpq3kCxLsUZJm2Dm1a_jOKpQLz6_fGccpUCbSkpPCaYyPwHVzyFQI-55mZKr2NswQ0jpLTu3bDN8qJLAs7MsT_oYeOE6Hh4PEPP2jPbYyz7Q46r_maMFfzfn6orMWjwyQukeSxqy1z9U9Z5EUhwXnei4g=w711-h947-no)

Then boring the ID to .800"  I went just a bit over as there needs to be a bit of clearance so I brought it to .802.  For boring in these blind holes, I usually run the bar in to whatever depth I need and set the Z zero on the DRO at that point.  Then when boring I find it much easier to not confused as to where to stop! 
(https://lh3.googleusercontent.com/WwaEYYolLC3oqlqkUPuoibEHZdOKuJAQbSOFereUOLJ6YAMG-DZtUO2-OuoNpRcsPfSBCWWjbEvvCSl2v-iqwko8jOQTSxgW7aIEJh45iH5k810BcZ0JaiKwRmxLTMBRGPGykty92iTz7e7p5wM1GYEzVr-yZZeyIeCNN6tJNwhO4AePALAbTFQXT5WxkkRW9bQJ5zjhrz6UQbK0XEbMRzg6-9QTWUL6ACzob8mGEhGFFwHggugw2TQk8Yh5RAqOdDN6Wky6ScKSXLcAmFLVr4g_URuxnFIKPkt-F76-syU-WhE6potDj1jgUsE5NNf2SUPUxq3B7G_EUNpicUqHKuRF5COy5IO3Wd4CXCW1aHSh-LmOGcs2vuylFU8hX9UazJRfhJmt7abOjBkHLjiFDAml6YPGroJ8io2757gEIP8f742feI7SU3tmUtW4SjN7RP3EoupQU4T5-V70AoHg8YhfeXzCqPSo21hZct4uE3qaxwPO3g0lqsPJ9JMrr5iRMVWhU5zNJYff1SxE6CBEl4Sc65NFVmg8Rd6evQhmZTM-KA5QS2XI_gJt5SjeRS9LsTLYzg7Tm1m-9o-K9zvOYmaGRuDIPvSNznBg-f44aSfXBSK54_0ubelH-w1OwKxX4mR5et40nOP0Onp4FUJRBCkawaXRvGZbtwMW5EBtgSMvNMaw9X4GaiXuGvmwYT0BSYiK1sD6fkh3Or93ig=w711-h947-no)

Measuring the ID with a telescoping gage.
(https://lh3.googleusercontent.com/MwjPzvB4e8_vC88PdRrCCNGEEaB77t8tzxzfV_9foirDYChXwXtIcwyMmyip6LxkTR1_4KiMiB9WKljqVn7TCeKqxkIay3-d_Aq_k-lwYeZ8EtQc0KDNsRJ9vUx3a7zFChUzBusaofv5mNv3YOtrJ0ftZC4eNhTvTQdMD0Z7XWOBtYbp_-n91kZBlFPrPnzpzh1j__uBgbKYulGn5YLKHIhLiD9WDXCMWIvJfR676z98AOqF0o1GT3kOP-dZFW9cKe0p8xDrDXHSXbtyJAsotAoNUkxg8gDO8xx03h2ctTqtILh5haF90DfYdoFCmWFDO6o4a8f6J_7KQYW9vfWFbThc5Xo19OWN3wODeupfRSQ-n0hOug3rnyVmfPYgwRNJQAbEy0N7ugVmX_Zt90Q3Plb6IYO7sWPQPCLIFjmMCuzAoDvc_DylHtbqJ6b9gRxx6V1pG05vJqSCRPDv9vl-dyKWxmQbymD3sfnmwd9c17wseSYqWf_V4htEcd8GQNmv_TywKDfxQI7WfHmjAmlvZGS7GfjEmH4iKdPaAJUw9qRjtPrwiz3oGmjxzB7d24m_zgULMJ57u8s0h5B7aXhSrk1CuZR2aPyDSxuXRs_E5Qbdm-B6Eib0yCIdPuYGVKxlil5MemFBuhFSZFQ0b7K2MIUS51FnFZ9oWHoewGsUNsw3G99jJ1KDixf4bvaVyejOyEAQpbMpHtb_Gixl9Q=w711-h947-no)

Parting off the ring to .25" width.  2mm carbide insert parting tool with the lathe running at 430 rpm.  Parting brass is a dream.
(https://lh3.googleusercontent.com/FY6r4rISPcadQdJaSK1d_4lgJmxfmjTAAeARJyl_sVCjO2_zxMHgxpUrsXCSpb_XIhDIeVN47_sUjVFhrwMH0fBaRrp_f0nDm6J9kI9tiw30XVn8jjHZNK3VB8nzqOPVKLh2EBfbgRsO2zqGeTckyGzsRY0tvAaky8mQw9zO_-iyr-tMrrnPvDczU59Vj5tKXRlkpiEaBEoEeznRLXZtpQsKoF1w6Ws_Zt_a1HeZyPzk473Cx7oHzYOUWUjOerwvo2ZFUU1RsIiWDtxmz2C8W0Ci6pxv5NJAHWhhX7xWM2x2LhhMmxQ0twBBdRZUpgXWebPN0Ky_wFpUZj1EsYXnnPxRNj8dmakA2O8lK7IOnrx8TNDO3FPj8G2YX1P4fW765idUc38rRrjl-nkJnTfEGdNWjbxgKOeRyEslNofApKf49cmFFzvTswvPNCGjtLlSNtHxYR1Qu3Hss2qsJy6H3AfmF0l2c9j9A79jF5fDeXGcZE4uf5xJ860sVIwSy62QXCwb4Stddpwvux-OKOBAYR5Re6zx4Ey_mu7dr8NdKu3YIBZN-fuyLMQFE0cWy0cIrJoC4XusIjc_YHzVp-k3_ptXilsB9Pyhnkw5_M-uf0je_c_LHQnrEfb3pkfoUWcxBqalcYDyW1LhP_a4sXJkQre5dfFXeTtpozUeEOABV6Eo-DTW1OPKdHiw632_zaYD7R4_coWg9NE-iUNV0w=w711-h947-no)

Finished eccentric strap on the print.  To be fair I do have to drill/tap a 5-40 hole in it but I'll do that later on the mill.
(https://lh3.googleusercontent.com/kFaMvR_T8iC42UtuF2Av8gbY_fIrGfvrLldrzb_C5ProWzX7YTVfVip_mfqbmVbAFRFzLhuN0jOEo69YFBTGUylza3-owOcadbOwOl0FI0WqI2XomXmA0rDKe9P-rRbifgFufZ2MzQZ0DskBaYawyQZvaHhvohiFLHXPAsPQP6urb5JhlbjrN_saFPpmw7somxWhsx2VyqYylEgHSjq_qqnFB_7o1ATaa2tkxvLz7epLxWW27ufW2N2cIGfyRpe8wSZV066d7AcBfqJD_eF4xDxXFEjPG08AMAYdixT0V_EQsErd8FNY8YLHs1l5b_6O4pNGS4W3ku4FcNpavXGSzDGwvbjlXPYQVWDGs_ZzH3p0B_l3bu2Fzgj9BzGf64Aaoc8APWys3k2OqTNPsgmA8MrDdE3zintTLKifLBwHH2ZLZFGPu0SaVTISv9Sn6H4PguXh_ok90qiWKf4nzTWeMXasa26vZkwSpr7gf46XmniaJQNnWMNOKQXwlVrobDVCncDYsvDvEOJTEoHWmLe22R2MNd_ELchGocFPaWfiYnikSRqMMHlIgMsdZOAFKda6J40MURGwePM41gMhoVLPmLhjiauhG28uOVfDcxM-WrrjoYQsN470615v8Z8JGg8wg42xutayux2-hnoSt76uiMH3jpZCxt4_c6mtyExXup2h7-f3U9EilGbOf3DwUO2T2ItsNlRXeSLdty2k3g=w711-h947-no)

Then I got started on the eccentric outer.  I had a bit of 1 3/8" 'Mystery" steel and used it for the part.  I turned the OD to 1.20" and then turned a section .255" long to .80" OD.  I didn't show those ops but I needed a 5/8" hole thru the part with the hole needing to be on size.  I first drilled thru with a 9/16" bit shown here. But I didn't show boring the hole to size, but it's just the same as the previous op. 
(https://lh3.googleusercontent.com/bCvv3uDlaL-6ew6UZw0lL5jIJvMzDPrbrFmvQYk2svgbegJc9f7gRqE5wz1ND4RFg6f0d_ObHG14VFrJAiqXeKfcsUckkspKrEWgcE5V-WU_SRsMdYV1T9VUSg7CmOLmrDS6mduinwGcTDgmmgTYonS_EroSZQOLgUhShGOWaJ3opk4sDIzuJdG_847b5GuFQRZ5Bp9Hg9_b11AkSTsYOACyawYS_HzbD6WLdoCMLTpbVSdcIiUh_PicrV0b4pDlBJ3Yj84dduYmQV4CwUUHyZeTZVWuvAlad6PuneYGF-bzEYxSVjcxxGsw2NYsvuYWqcaZqaEreoGQnm_huzMIwscm0B4G4K3Ipl9kADCaH2-W8iydypWeN8Mb2DFkfI6I4DKOHt9-wi2vQdMjl-YSFMdk2KLj40ZLqLOWPMpH1pdcTkzO8Ux9XI1h_lsCh_-NFN6TPLLDHAM4SZxVkHsAJtqGelsX40ZD5wXyscErbrut-zzk0cuMYBl0T0foQcAEE9T_WxhWU7c71U5P6L0peAs6eHXLIyp3gTkhTmGJZo99moC5-wXVkO4vKz2D5NHrdLaZCx2wRMHOkph9Yqtg1MZyKP7UlVf7xYCUKn2wi8F_SurNN2UyiQKJDPeAgHPm-c1o3jKu77rBej4zzQYtsZhrX00CZW08j-wap113AnXng5pkIv-ELZozYvUdJlSC4TSgGfZeFyU1oNm_5A=w711-h947-no)

Checked the fit of the eccentric strap on the eccentric outer.  Fit was good.
(https://lh3.googleusercontent.com/kQn3DsNq1TV0XY1SV2sN5m0jEo0gk-7eveP7V9TrsgTsJYVLXzy2iuc7tI4iUL2LGMZzEU0u-4VCO8f-fz1jsBcE_wgHtPkPiXF-_WXh3h4rfNGgmh1puk9-Ein_XMeY0XEmRkqOez05qcZVKqJ-RK5Va7z_m_kId6-f6lHKLfLxSUjq0eKHWTAD_4hKKUa9yITGun3GPwt0ET0rBhEITf1XFY1AeAulGPxnrNScWbytKiVNmNXXgjTkQZjMGR9A6BUQqwKuhMnOXfdDAL0wTh8JJhZCAo0qkTAhevHYu___3UrUcNIRfnaYHh2eK0jAhmls8YMZmEKpLa93cJnuhuPQQvUB1cpcuvowetuamTA_zxqTMrlV-ATo2so4VFzu8tESxP22FJWcqLYWo3c6kFX7vcIc3N-YHFXyBAkjZ_x6uHRtwOTgI46n4MuqVaIoqkcE-xw7oRa-APHMGt2el-3OJ5_Jg-GH-Dk9Mbzrh_r5shjrHHtHBQ1GcS7yeq4Nu574E-q6fr0UzZba_tHTZpyduHkR9r3xB5HPazhC1LZJ7r4b6E0Dr_JzRg42CjnR-1war8JnPur0mkgdsL66u0fe6F1Qnr5jdNp2lB5hUPDLyPWPBDo8ypdhlSHO1wpYDTXCIZQngZhHERZ_8xvz3mGhoXVIzO7LO8y4janv7BTJc2maoHL6m6pFGCx6dgViNkl4Q_1wrCkW_PaD-Q=w711-h947-no)

I didn't show parting off but that op worked fine with the same 2mm carbide insert tool.  I did reduce the rpm to about 260 since the OD was larger and I was parting off steel.  Shown is the finished part on the print.
(https://lh3.googleusercontent.com/5Anj4sk5zveAudvGnmd4MDJGyxHal_X4rrby85NkjO4ah3lYVXJdNFGuIR5HruaonXFLC8dE79-9Av4U33__ush0z0uE-BhB6Ybtkwszlbht0CYFn1ViW-HmVrRNSoPs5RGN311zhGGsgsX0o-pcwsfOa1_s2eQQoQPwyJiUwXJ-RDuudkaqwYz6dQgIBGXGgWC1E9nTLtCHAiIIxBy2AdrBkr5FoWiAy1wCpU-rHMgrB0XCyf37ClcsywBQMQK6RXI755f705u4CgKOSgVZxYJi79neHt7vgxlXr06LIXU-jIW4lsUS6LmGiyRvsoEQrTimcARSEL9CZaQ65XtYcP_gBrKEAoWHBdzE0NF_mHcATSD72Wvhy4lPXmF5QrsZbZi2zWdqPXdY_OKW_0PkiMy5Z8IvNDkry2d6XR-E21v7bTZzPg6X8hm0WWkjTRf5hvFhr0qUeheYf7IRQ1DNffy9DJQM5NUaUSPYgITnNa7rmT4qvZ3FvQlxyXZJEn9l1NPGINokMMbvX2s8ZbZJjyQD9vTxI8M0PPofCXdWrTle_-txKvBnD3zKCyJj0mzxJz8wz2WwDxz_KAK-5srVZvU6BOtLfv_KWDYoQSueqnsLBkpoEbn46RCfmmohkeMGD0MfJNBs7jo0Xn90cj0Swfh3JZHHqlvcA5IAYhbS-LMNROd1x9gyFcLUD-IJmEluCbmRpaqf6-bL87vu9Q=w711-h947-no)

And a pix of 2 of the eccentric parts that I've finished so far.
(https://lh3.googleusercontent.com/xdxN6jxx9hpQujMMdHVWOy2-iGEukDOzvuOjh20tzOFfuSDnRjnChb8AXOFx1wDtCe67kQj3dVO9qIXVUUfgj_d0842e-Vf9Egt9UqXQnWiFA4CGRPghqbf2WYsz0gHsznBhRu6qL5dpQVr08YrGz1EBkmgg1smfsHXwfqY0a4bCv4B8A32qywkA2QSD5-5HzRmFfudPwRQjZ65WzCTu2OVP2Nh-RTMuyyx0bgqwBEaKm2idOdTVSkXdNd3YiXE8_GaSZfzHZ4XC-YeVnA91VRJayscDa9CfXmSPTMrDTx3OgcU3WTCLaGKvDj6_X-AC_UN_qPbDms3_5ok4m6l52rrlklfCkeG2eCNhLyjgpSR2JEFaaasrC94JJAw14qcsyAxATYVsTjI6MwAoxpICmZus2hdKimR3RxQEpqEpLHjXbbE04Jr23gVJZSXUiVr1t3xGuwBHuGHzQV5uDEpsNX75kfSjpvPHDWqwFTAFHNvv3cgfMSLIc_6l-7w--CGtPr8TqPEhQEVfoUP_efkmYBEbfrSgHQpBfMVrkmK1YRwGrPspAPAaiedVVx4gan2a9tnSuTx3twA0bOJPOvQpO_VBmxbVC2_TLK_qM-n30U3vF_RNmVF8TcwQgy6fi-fbD7dWJA7U9U29qbCmf1ispYgOOEgTkoqcvsGanXrT2fIX7SX0DCG73-Zoix5byo1r8243yagL5fP2cEEFag=w711-h947-no)

And last pix is the 2 parts assembled to check fit again.
(https://lh3.googleusercontent.com/_vYh8BbFDERUo-YRs6eDPmD8cvY5PB_baDGv6-h-iBGgbQV__fJ7IxZrCOtJxBppfNT_B92b-R3R1FD_VbpdC61bS_wIQB7jdETngNVkNKuxSiqIqPJtP3LgO1dWi1yVVqK2Z12QIBBojkDMefbk5w6UmncQm6Xe1Sp_f6coX-6sgZEvC27yHl7oMMCymxJAKiLtrqAS7InvxXp8nbnFM2oPpdLeSB_cf1LNySbQA5FvLB4w5XUdTitZBnet0taFzLXVGlQgOkHw2_7VzhKCl21zCOSObpXIFfD4eJTkUMTo3sKzzl8_BUbJ1cmJn163gkEOCy_W5JOt068wYe1xii_ZVopHPpU1s6flBAc-Qmi1RmtGqPvFu7kGoFwbRvqi1tJZvkZH9oqMSDVBIXuZ7unv6dRuVE6Lv6R3GSb08sfOAbYbUe3EUodjcw7Mi6El3SlY9-CVlv7NS7c4m9Oc4UIq2SqG9I0s5rHsfpLSNjACAac0whmivRwXulY3zWK-MU62fqFAmQhdeR4dnBmwVzBMOMFCLMcPmNE80lzibR5gRUvtVA0D9bP781bCXszMODCF-4xs67KlZgpbr7wCSF4m1U5RRgkcLW8sipEB5ZmFaqJBkJ6NruBs6R6AHuPT3fB8HOs-fzvgE7zLE77-EY3UKT0t02T67REgSm9siiWpgM0SpljA5U6KL20NZiZwqYBfbN_aJW5bNQudMA=w711-h947-no)

That's it for today.  I think I'll have a fair bit of time to spend in the shop this week and the weather is supposed to fairly good so I'll be able to get out there a bit earlier in the day since the temp won't be so bad. 

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on December 17, 2018, 09:49:45 AM
Looking great!

 :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Mike OConnor on December 18, 2018, 07:37:44 PM
Hi Mike,

Following along. Great job on the parts and documenting your build!

I understand that the slot you were machining with the 1/4” 4-flute end mill was to finish at 0.275”, so in this case didn’t matter, but if you need an on-size slot use a 2-flute end mill. The 4-flute end mill will tend to deflect and cut oversize.

Nice job planning and executing that open slot. Those parts came out great.

When you have a small part like that link on one side of a large Kurt vise, the moving jaw won’t have the best grip on it. If you place a similar part or a same width piece of stock at the other side of the vise, the moving jaw will clamp the parts more securely. The Kurt vise screw/nut applies the force to the moving jaw with a spherical pivot in the center. For a 6” length jaw, if I have a part that is 1” in length or less that I want to clamp on one side of the vise, I will put an identical width and clamp a similar length on the opposite side of the vise to balance the clamping.

Your build log is awesome! Looking forward to seeing your next parts.

Kind regards, Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 18, 2018, 10:15:59 PM
More nice progress Mike and nice looking parts too!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 21, 2018, 12:26:10 AM
So far this week, I've not had as much time in  shop as I'd hoped.  Between my very elderly mother-in-law visits and trips to the doctor for her, I'm in the midst of a bit of a medical procedure, scheduled for tomorrow that for today, kept me very near the bathroom.  Not fun, but I did manage to get one more part done and I have a bit of time to post about it here, the part being the eccentric inner.

I previously turned a bit of stock to 1.20" OD with enough length to be able to make the inner (at least 1/2 of it) without rechucking the stock.  Shown in the pix is reducing a portion of the OD down to 5/8" so the inner and out pieces slip together.
(https://lh3.googleusercontent.com/44A6G9BmCPJTvvBG2keSQdtH7B1KubCT219OJzTiM9DitrpYqE_Sksn2LOBC3bSG7tbKiehY-yvgR6SzhEFfGeJ-XS0Q2B_djRcSgONZGREOegUcoeMzockLAu_o2kNUW69qLru-bYs8VNZAlkks7Vfp6NnSlcGZOSU4cu3y5Ffvo-vXtf7_hH580lQq0m4N-pJedhIer-YVhZykFto6VDXXh7XQE2X1Nbew2mpOT_uIzqkT--Zbu6mKpmByDoCkzrYZUhg2MJ0f0AkhXiB4WbP857aYX8BP7xHcWfyqV_MoQAJDQ6ZFnz9234LF86vxeVzzqvzagYAST9XhQ-Xzw8yHirroZnOfugRW380eNqPVJCSWswszwgub5oILj0oHcyLiijUly7MaMNiiI3s5HqVPq7pmkVpUoZEdQdRiGDZpPUC51UN0Mzc3yWV6AJbAjU3qw4xCfxpuKyqlu1UhS9LMi8dbp1b-fa9ZQTXyWi9UE3yfhQ4iKOZEx8tLpGTVgAiDQYzMIrYjE26En-k3Fx7JGW_pzjMt4G_9nqXqQjOSeBFH-MNuFo_n_449B4vlmXHsOCUKhwx4yiYtao795-SbSJGbVAw2AwLY56enje6YAOZJH8ezVTEzpsMtlG4PlezwbjjrD2dsTnfHAu61Kn4a6J8aWSInQgBsvm5HF74ULFf2itLCkMUerUJd_NEbP45zBi3z8TYA_bhQKQ=w711-h947-no)

Checking the fit of the outer and inner parts.  Nice fit, slightly tighter than a 'slip' fit.  These parts will be Loctited together when finished.
(https://lh3.googleusercontent.com/Y4u4TcehreIZQFXHYy4FDUeOSQQWaZAXW5sEli1Bt11bCfqC-Zb0G8mlK1x-tJyAEbkD3tvIHab0m_LgKkZ5dh_UQD_NWnfp6zQZfAytCdAp1PvWne6nvfgsCmZBagRC6Yo7cdAc-AbPhFQ4l45BI4uNGykVpO-HY-Ju7Jb9ZJQrDWUXBfDhJf0s6t7PUzNsYZZd03m1fQXEEj2cZshZFHSG8HXCRQdHKiLI2iGpS2wvAPHmjg2hqU43U4G7qeNh7Aq2qsckPrSS9drop2KOu98USiPM5T1vduZdY8jspzeJUI30U4DDUG8kko8aiVzYTQ1DOAaVPAu1BvyPFqxmJpPfJlh-P-k_hqX5zE9uw40RfthDhjdM4JdZKc1Ma_ABqOHcfU6Kz3DJxh0-s-UA_LQaBAw4K6sDbxyGnqHZuX47bg_WPk-ni_H9hz3_PRiIIxabNHQpuDVM-U1BzJmqgGHjAgsJmtB936i-JNnmfFtkuscbZAewgDqwIwV4vzi4SrTHlmuTmiqphweD2GTV_s-B41SZrm66IikLBSwJ1XxY0Ukl633q-0L6uGdYFKJIu33zBEEDw1f6GOy9nJx8Y6svcQsdbYgpll8j4HHbhFFMd6ejgjBpwdckm-Su_dvgIMj4Bf7lePvvBtkNGgkkd0eEgEeSplT7PSJgJNuou4aB6lxybAjqe-wQPF6XbaLHwz22Q2V1jTF99Nvj7Q=w711-h947-no)

Making sure that the eccentric sheath rotates freely when both parts are together.  Fit seems to be nice and free.
(https://lh3.googleusercontent.com/ekbo12_HCGP5xdpGNYbvvv-MtMngjn5mQj-_qESiRKg6Gu96XlWUsOhrIVD3Qoz06zOKqGjocIy_xGwIBuRgf2pjNvQzu3dIA3OpwSPWvkQWWRvigq07KqHSoM8SRE3BS1Fk5qydrvVvW3eVMaF8RZ-eVxav9CDeDMf6r1PJYkOzGmKYvj-cFAD5cMh66vFe-oAxL09XSxo__GT915FVvVmONj3C0Ldmg5QV-VHbV_vBG8ujPUBhJ9L-MvfIYTXNxNBGADzPCz0XRG_XB5u19DKvj_j9BdRUXuqi0FlNYJzz4e19WwUo-RWc9mbRdYZEVgmcYV4N1yWpZhKSlWINZC3534t5Ic1RyDE9AHxhQLIUI7XC-hOooYCfJzkN3FZGDkeJWfgtptcWm1Ak6HLQ7a_LfXSbME6zqaZwqyw2yGXvNngCM9v9n_iBvJfcC05iciMFQVj4cniYxeM8cOBpJGCtf01wDNMXdqW9ANpl50oQ_PZYWT8CYxJ9Q78oewD_0CENpNXJ8blWdIe-E5uiWPY11bVGNsoTzsOvmUwMuUqMEPlZAOxAJFUAhdNg2kAu0NXCL6VT0d6yiAFoWdFCu4vlbg9ICkYGZuuVLvUeA44rxq_qmc-sJyVrZrgLAnPE78_Skj48TEVSalNPp9hFMp7TEv3GzRMbAdLjGX5KpOn9CNcUNy65tlrPvBDBnx2z3cAjFsMm1_08s98_1A=w711-h947-no)

Then I parted off the 1/2 finished piece for the next operation, turning the offset eccentric.  RPM was 260 using a 2mm width carbide insert parting tool
(https://lh3.googleusercontent.com/cv96Q0RsFQAA6dBFAGYdQ83AvtldhEDp8L3LEYUz3wpPstxZPRWxIvjpFMifVZWS3SFvfsoxsQTdTN-P5BzWOs6CBuHW8fRSC7I7SVpHB7r_-JUt5eA_wUkhJO8KDeIY1jJy6S8f_mp6Jzfz-8V10LSh4wVENMNWS30fwMZv6BN-OhYmRE4ciZPGmm-TO47Mfcfn4kqGi-hiRNvdj3G1EQn1pKhaxytHPPFXnx_2GqxpIJZ-4BdENCv0sRXk5t6d-CX5n__XeQOVJUX6c1av426Bw2NtZftu3kEdSZbIy_vUsorjGh_uMjYZ11Mk-tG6aUlrCm3dsYxxSDiGd2ia0ud31rUYBehN4nxl5cb2EHT8rGjUh2-Eub2sua3lNKe5PenTzLTC09Yw33oNhLYZtPKFdE3ZnKbaeAsX1v4zH7XIz4v6rQzosUpcxwfc-GsEzJ9AHYy__1FgULTuvHHtGuCmMALzZJSs72rCQ8jLv4eE6pzJd-QwJhFyBneP4iGA_SzHjgakr9cPEQ1ZIB7m0KYEZsx85emYgWba9wwTp9tIRjBwiRXbBehaR6J6JD2IcRZWxPhelMdgYJ1OKj8Jur1qUGbhbHR2-bdP4VUWTRt5C5nXP1FkbwY7rggeHVijTAqMrYn_EUvGWMyezyJEWVNzytF1dJ71DD0bDYGzZvUl1kvMg1URMq84nZ4M2wheH0Gs7Oby9fBBXBP99g=w711-h947-no)

Then I cheated to mark out the eccentric center.  I put the part in the mill vise, centered it under the spindle using a DTI.  That op is shown here.
(https://lh3.googleusercontent.com/Pho0AZdUTRWCSbb6JiYX47FH-CHSPm5KIjvdGm1ZsBcHLhxWHgm5PAnYVzRgOr4dAtFF0vKRbAcF1lstUZMMNjZqb8_2VwWOD-JN4mfzegFAoV1y-Wzm_Su_khc--JcQ_HzF_kmw29OjXoM-eVSrx0y1wWtS5kZBXdmtDQnp8dXRzJtdVeSPJj7bTzHQD9V81XXxf7C4jZlFjcRzqxeKyfKMijrLYmTDcx_CEy1eM3_oWO73UlGc1bbhUOvn64Rg2Na0MAY0JGDehhdsq0xuKRmNd-Oxrt-ohTwB1Zs682_PMOtEscE7HIJI5KUZ0zTEhZYHuJLyTA17PWcqOk6JvAG9L5lug3zqr37zelXao9xSZ1MMcOp6GhbIvcuFxdnLLw4XVdrU2gv_OxzFQsYC7FqcioaMM3E3qlMHlgn4d1FKbKciHwjuAsIulRL4JDRFZHUxFTs2XHaDSOf6ZFDRjK_siKzQj7Wojm4eJcpcN98yQZCi8W2-xXEh_l9Uyk-p6SL4kfLNvzjw2b-PD8hp2zPRFlpKcb5HBmREYAIxCYDVhU-ysg6Jo7z9aeDrgQ2z5hu6jUw_YTzCXLFGBk9yv4jfxj-Qn80nISJt1qAV4CoboLVMegUeRl14c0LOYo1FAktYA6a2TtijDS2WhGFdHZ0YJMwVC_oVFKl6U3ugUhLssJVB6uI-IK6Zr09X88a6fCMp62HRVfzEkllyAQ=w711-h947-no)

Then i drilled a shallow center hole after offsetting the part .138" from the center.  I also put a very small mark on center just to check that everything was correct.
(https://lh3.googleusercontent.com/9bcI8QRopv3Bujn67U2SYrmsKuZ8tsTF6kid6FvSmFp_KQPH7bZlEMEX9mda_-zbIWVNN7i_CniZD8M3kOs9lSaRXB86UubcGo3r3BwhDExI_axO5GUeVqb-Or_hU1Gru5-6UqtzEVLnEFHyKbm7n4wEA9KmPHHp_cLH_vAn_qTMeDNi___ipXbr-8VdfxwKOt1RLOtlKkqq7drSz3frsna22brRCBpUlHzXuTk5iTOilD4pF-21J7ALyU4bwSiHYabxivOmKDrurTlPkmrYPv7NUUVb_bNVe4SKZHPd7Hg2VMi5-fCGRwBo6rosENZuKzVRXWMzs4-gDhCF2bmXhApsmfCrGp6ZXPylZD7FdxHFXvXnNwsbuL1-ZznBeLs9x2G4MYZuxRU6ldgjTuHiC6EwyYKpq2NVVsUzKiQTiSsRrXqhAgCU-1lQfz1KksoMroVmm0d3eBmouod_NMnk5GTX7fEdf8PoEbpuY5iYg3o1MgyFdsEb3n4Z7vqGZXQoHpHn4IwbD_zOdnaZRf1nYKwgDuVUEowXEFJhKDaPAvAICiIz0oMKUEPU_b7SQITy6LyrAh_YOVaBNiCbziSGf_1tFhNjoLnZAqtXyIGytiYNdblBm53VQ0DCvdSkDfcmIyiv6TJ3IryIWFYCzkZHgBNG2_o7Pcmjz-Mg-o80qQrxFN-ym5p81GWfhztSseWoEfX8pfrQV2_GyFZRvQ=w711-h947-no)

I still haven't made a 'pump center' for centering up on offset turning, so I used a mill wiggler with a sharp point and very, very gently made sure the point of the point is in the middle of the drilled center hole.  This was all a bit slow and certainly I'll make something better for this job, probably right after I finish up this engine.
(https://lh3.googleusercontent.com/lG8NY2TStURxqe3MZqzaR2sWCYv8XlTuIWtfXlgpJFJx8EU0J9ow3sBcXZJjBlEAksz_jxULIKqToijmABD6-JHKFTmDbNhv5M_84UOIoYs-ASMUzQ3Z-HipO-myU3yC3dqKDDrH6YNS3ViRN5BZTkC9mho2rzgO7A-5fJMIWwvXK2-1b5DN4feeRRiIiFqEbjY_x2FTg4TlmGUX53cIzLyV5OvO_EkvZmrFK0Bjpfci9bAKo6wAsZNBKv0MEYhrDIrludm7YhHRoU0cZzHMwEe6uxj6FZACTSAHHr4vN-41qJ6iLeblHMkUAlKAB-lud0wet_fF2G2rluElM0l4dL_d6Iqr54s3t90MNK1aEyrchE5PSQ4sB4Jk4f9eYOl__s47Q5G_rFqVqiedL0TPcSyxfSNex95REGDQdVcRyOw8ZXz3VE5ChbPM8YHPStwXYn-d4yaoKBk3--s6DEwFvobsY0sxvEe19_rv0Xl5XxsRH93wv2W6Wj1SAT08CCkrc0P9twcU7U7oSvLK4ucElEcYHQNc7eYXaJQVMy3f3JpwqhgWNDeP8wTNMM3qLFN4s7K3j2JC3vKs7SwGSnF2-2yCRpvoqS-hCcldgDdkTYSZPyPz9zZMQkBylRUZ96ETwqja0WFLnSB2vCvo_wVAJwT9tFdXLvPkQii8mzpJi8FHWcQZR2861hfZFX2Qqbs5FvhdiYiQtX1Hu81nbg=w711-h947-no)

Commencing turning the offset part.  I slowed the lathe down to 260 rpm since this was an interrupted cut, but it went fine.  This pix was take just as I got the spigot to round.
(https://lh3.googleusercontent.com/-JuG7AyIEp_zFcaruX6EodWylNjAobs9tLvr986N9yK3SUMVSZS9rAHNl90MMvDARHDVRzhKU04B8Er1aO5nVqvxhK8rxx-HaWLA9rd1I5-7IOZPVXEwCfTrpDWKQIH6t7RhN3dPysRr28UnUip-TKBW_HkrIq8I-L3qCFpiAXtoh-c9rDxttzRAKKXUpuOYdeUmWKcM3zku2qnAYkBQISmRggZl0Vgmv4SyPzlzRLulzN8rj8E8d2trXoEsUsv2SHVJinsbYCk0MbLMi87Nv_ZNPSXyygwciux2ANUg_BMSp3G9kN9X1mFa2eZfnTRCqNaBQUuNcsSicOf0Ga-hMuGrLMHpqHAjxpwqYAS4hsPd7G87N2L-76NdUZK55Jh3sMP9tVy6zomf_uD94XdPYH0QJQdhZn-ALy94SXjcBu0pVB3oLOKCj79AJ1H8AWxzUkzVLSlfomDIJlmDPtw8RpFtLn9rloSPfkq2ANzNFtEE-q34UVRFSLvn3vZ4-Zp0UAasepbx2vDRgUNUWS87R_R0upVExRb6uCpYbIS5FN4Ed1jxas8KYs-5yZsiDbNHKqhL1tUw8GFEbAdFcxq5rrl6VYDuiWo47gSKURcZgaOtEw6WN6gdTPklc3iL9MH4K6sle9GLsaN9BwBQnBPY6j2L1ZPvfHVXb1FP1uB3ByB0V4gfdox4LEbiJhLhyujuLlMPAObwiMxvvypY_w=w711-h947-no)

Then I deepened the spot drill and drilled thru 1/64" under 5/16"
(https://lh3.googleusercontent.com/VWhjULC_Tl9d03Va7opQs0SSAlggclrgSABcM1l_pGbx-KesvEAWHCqH7TaGV9ktFp7RDHrKQRPq0x8-1rpapH8Pg9OqUP8o7m8RzNkHpxlnXou2pq5IMvkwCmLKyOtMIW-k_WNjJGM-nWtuTGzooZgtE9hbHgNjTljxBjSJJx-Z2vnQnbyyp1qc-D8CRA3YdpO3KriPk-Al3SIEZcxiOiCkQt0_Soj_pJ72yAzWI-nkJ1POOUcHhu8P2-6oT2Vr6MajMvS16IqFzb_GKYJbQANTvlBML4s50lEMNsQTgKvvHPP7PMXyuwx4hhIVK6b_ktCm5nCdIg5E02NWiSv-667fiH8rpVb37eDQnTZl44Ew0gPR_Zmk1HftSzGHwujpev-0LhjCLinyGWRVldexhHHXXEmZ5mUB4lmSqN-ASHYH3RxOGyfmE0jZ2RD2a8VZJe1bphdUrJ5aH2NfN-cUaLeJdTX8OgvDu4RV9YhmyzAxix7lCbZzhhB1wNMknXPzQWqPyumY8-q52-EU1uJtk85LUWN14RoK18Y8_nHlSp_k6baXQD_I62bS8FoMoukdaHQvfvRuZvNPgcrSSnvmlps8DZfdOP1M8ro4_ObHOO8JzrM2_Na-MMKazvzb7umV_QyOQVp6frSQaxJUSNAkrASylpwjY2SrXfk-w-vXifiFn1CDqrHmSbyoeoOxtRxtjREKOoVKADRVyNVqTg=w711-h947-no)

Then reamed to 5/16".  RPM was 260 and I liberally coated the reaming with oil prior to the op. 
(https://lh3.googleusercontent.com/xXnkIIHDNeh3IGCjRXpOVrCIkZh_phwUlXHqTpY21U-w5r9EdWS7UsFbPuq8EHGyh7AYfXtFdn4EXkCAAkBt4DtzhR_F5FJzEwR9oS_PG6KbwV6tcRjG3m6qUE0oZci3oYKoo1QZHgcCSnVqpQ3z7x7nRetQ2427MKkET1b5_6ic3MTv47vr4I7QvjLb_EYDsgFpYwpFwQmWQAI-u84kuRMhjjqdPteN2IKqSK7CN2Ngg1vpENfcPWB-enEt2fInappgMhyK7lL2xQPJzkYX4yaGBc9gNIn1hGxRsuTp2nLlOEOrINtTn-4WvQswLXOyzyIQQTfiJga8CvhNERqYza39kEB0LeveoIJwr1dsCsS93xTVSGdpQdSVbqIeD7_V-oLC6kH-CpLsMDVRVzXGEwoJlUy4Bp5oDccseRSAVW24-uDTAs-pU14hi3PyQbtPaG7N7gFJnJJ741Nv7ZHz8TXfQK9ICOotuhBQr1i1MIS6eI-gt7vtv1_pMmXE6XPvet5lp-BrrBgepJwJMnEEqCjeEtgS7_foLsuYNuTT2ebQrc2l5Dqx4leUAE8tnCvzu9uZIeVNtbQ9cQOSO8fXRQMnE6hdXHMHzEXL90NvO7W7hc1N51brKHdD9ZLcJktIm5Oz3QRX3A0-DMpq8i_m7oCu1V88xGA5WWVdSMaWfOIFpVHPwiF0oiuEJBJ33qBvX3jLMg-JpBHAT5yAhA=w711-h947-no)

Checked the fit of the part on the crankshaft.  Very good fit.  It slipped on but with no discernable play.
(https://lh3.googleusercontent.com/YuXdhLgWrHDg2zXBbfHhOVoPMCjGh3opMh4MqQsIqX-sHSoZgIavL0tBnh0WSA_ahb3BGtBcLadIvbZibk-FhIIp5fjgTdrsG5gXJlel8Ji49ePx8_kEANmEbJVJFxGhPZxF6m0qSUrJW_qwElcxjzlPZ77ujMCmdXIjSyaTrVi-rlww7VH514c_OA0HqTb0CyBZAZHEsi2tBHsnwlLfFQbLwUm0MLfkTeFqD89PyTWn97IMrTzvJFUS_2uBGEBCMH3H6M6TOsVrzrz92U_7CkS03y3_asiSqmWMKQkicH6gSoPZmX-FtZeJ0MknAjaYgIR3dnj_mIlbd82LWWqERD39stoHL276yHP-UyhaICBTp5oexmuAPaYcvbswcIfrRPmYxTNt1n_0FqlorkmM0ztsXMN546zU-axFQ4Z8UuRguMcGwYFOISO5QVWpen-dNoQgJMNFpxtwykvrXiSAPmGSYKnoBCGaOYUUmFRwy7fTvGJYE7UhfEfBb6tX9ZmJR8mbnlOkJu3lvOQP-G7sopUDUeItjCYe1bKc4Yd-DMwZ8rNs8XzAP9tH0eNfRcdudReQCbbyxc9Ror_bC_1tjtv7fILz4oFOKt9-wVXMQ26Vg21PlIexUUCONXwYH_xBz3pKlxu1FQJM-hdRbIdTxBkX6kkbs7Hq802APVwFI07n04Y2i30ePactrwWOT1hVNOgt10SrJyHOT8YXvg=w711-h947-no)

The 3 almost completed parts on the print.
(https://lh3.googleusercontent.com/9XWHnR8YdFSCowp4D9bMUWp4GCxzd0PKbD1IDx3pRz-fXUZFn1WNbnb-elmrQQvXrPClQ4uNaYH66CsutllEdELEc_PFlaJ_NLrp3fqKWHFAgP_0zkK2l-hVTKnhwVL4PfrijT5a8aXS_7UXAezMiZXoUSkUtFiGaXc_t5Ta2zpX8AlF2EnOVTUYlgDgZV-Q0pR7VwyClKcMaGOYwXqHT2Acxk2oPYjdaXLcH0JZixd_-Cr3xZtHCWAk2GVZUZj8fmMAdswrAoiRcQWSb5KtgH0f-dNMMIMrzLoeTqa85aksA0gIoX82B1M5vqz_1Z3YyoAFNBaw6BW-pAFPzS2islEJfDyFHos0oO-62ydBdruNoSQflxlM7-5jYQp-gmVSQJm9K9Ean1GFIf7uIeTVzKcoWf8BGP06fx9fORho2jkWhy1kl4L8UAMVL_gTOXwR3xqKNpqleo7nCf9CaL8frOyekCdUITiYmUmerb0mfkJT772hdXB_m08bc_4ehicX41RuuzEQRZPobFZRqsKX0b3aHVOgz9WYqmqXjYT1tdjkA7tVTwkTEGqpH6uwoMDq4_xsgISWoYVMoEI6HEGgRsONSGj-zsf6ih4TWc8jDxgPDcZyWOyDRKl02XRjdAu-3bshyyrEH4Gk7n-p0NUKe5vktqjx4K7kuFOASivPZZuSlGTZRnRey4I4cJ_ctxq_AY2NxTb-ZUqK2DI7cA=w711-h947-no)

Another view of the 3 parts assembled.
(https://lh3.googleusercontent.com/XIEXIRJe3B9KnN5ifw_FZfjEfuRRblAOeQNLd54fI6n5rxZ4_2taSGcWh6kM-p1XT7LAJnqswS-ivIP8T3wzvyqlbeYBC7Z5Q9JH6sJ44AUP2Vnr6RRIjkJpdyMpMWq3pA9-lrPf5zWQCdPY70ZZTVT0HVhQYjsiXgUAFums-sTDyrsltI59VekvG4N6tgpFkjWp_87AZNb0xwxwEWWYcIAOIt_q1ljzlhtBN2RX4_gzzOqzHcZRPr04WCmPGDV4P7YJeA2kyfof3eQF1W1vVk-fXtaUogR8Mq-3vBYXrFR7Bs_x0jOwkNUlkasD0ynq4zmDB9bYV9XCScimE9Z6z1_eILvLVSPcUmVTSyE4WIGMVYmjgMXT20I1qQ67Z-GgMkC0sxDwAJWmG1mznCBeTIhfP-lPyzHM_5z7n0vsSIilKvta8GlMBK7hudU6VqACTJPfGe96xCbgU0LbrjA1Cc7TOQNYGwtFzIR68kgnE0WBgZvOtPbK6BVvcKSTpIOFGhtX_CKwKdOK_kErurCSLL1GvAjYv5Q5p3sOBsRCNoc5mAgieKmdG7LVK2fk9br6N-miI_1MYqtpvG5Q5Ulrgt-95MM27Oa5CrDbUPAgUMuYOoKceUOUgT2D9drBObBQShwaOkdWh4JnQJoI9q9U9wnGD6oss-I0DYhslJB1inWlsNqPRqB52mKG47Mz-sd3qM9yOEdQrlivP6xfUw=w1263-h947-no)

A view of the other side of the assembled parts.  I'll clean this side up a bit more later.  It's not as rough as the photo makes it look like.
(https://lh3.googleusercontent.com/OksMLQqx65LDsSfl0AkBc5-mN0UHf0hLOs8xMotPCj2W13_CNpmdJt7tyyP4X3XPZp1PhReVIt51RvpDgWPE0nHqdFF4sC9AQ6glMVIlDWbmewIl98uuhj1XIbfZmbZoZk8SVYAoLCJ6HQAOakpqsmwePGckQj5uiQFAfN1MvJRMI8--dGrlN9L6EYEpIf0ZBFXTginST2DRwiDzz9b9MVSPVDFiudH-QwMIxEDZbgpDC4XdjGOH-xf9k8dAnc-Z4bd8WU4AXRJjQ8zmfIqFvHPpoSzk0ABM7MOCb2ICdNya97gXQQsy45P0FOabmFmqg085c0a9ZVuiAEIiIIalvVqfleFOsWkpyHi4K2RGVAu5zQNIXGhiBytB4jKlO_v7F_CFhsTx4Dn6m6BzIz6Jg1sWBtm921tgZPP1hshxy2jYT7Xmsc9NpYZX_ySP5Q6YOcFIMWCfLM2HiDV5OF3_aGI09HGHo4z7J0wmAVajaPZOjzDwVU9sBYZPvQRlvdoQnvxP2imOVtjYFM7vZ6_yk6uN84rJsn6FWwo01VC0EWvTvdvp23wae8EMFQjvKRamlpxqFu1nDtYwnXzEB2oqzwofOO9Ug46EHP0qSjkrfEWjKYGG7ICazIj2pQXdfm1lIbiZnXpG4MZCBrZnIVFRvqNbJ0fGwIVSYs9swSIXfw3c9G4n8oIsFOelxICO37pKkPx7XtO4p8doyroWgA=w1263-h947-no)

A quick mock-up assembly just to make sure that everything looks ok at this point.
(https://lh3.googleusercontent.com/4M7ReSA7Fc7-qOgHQYuSLfBGZSKaPitAXFQbOWFAA9BjS_3ftjKPCeXaW3d17o8QJ7J-n0cf-QZUOhpL2qoWcIUZ-8NySSRCb7GPRYbG12SfTG1TDzvcD-2NPDmImZmT8DDKExQjv8f-KfaDr6PwsLL4KJpjnBr6ZKS1dOxPz7lq5qkWxpXUxugmNjASACAnf9VmWxDi-xd-JiCUz5euLbWtgxfMwnYQBMGhJ0G41xoOvwe_--sWaGXSNHYful5z1mvuiwzCL52NGypDZb6tpOPIkf5QwJ7BpGIIn8dMu4u9ccP7nbB-V5fGlkGFUfouuPfXAwSAHTQNwrmg2Eyy67c6LrMLpSeP6wIEMDvmW9fLa8y-s2dl3EI5EAsUpoB1uVeydnnbYGtM183deD88C99Vb3A-YoNEN_zeoB1s40hq72YGFYsoOXjiswS1D6Pb3UWUsl6QRK-gsK59MPIBYD0Y5Roh51-kmSR_FzAnjHAgRtYek38V1bQd1VmzS4xqk2fjB-LT3hqd-nqRxSOzw8FCbMTbiY33wRlRVO5jHtEL9VXubHsffpXzjsRvlgoQVGJG-Hv5L5M_S2QwZ1QhTcBCVx_aoDoSS1MkUBHF1KGQ0Wv0uX8q-526lMhPgKupQhXaXyKqqiqfJome5zRWFg_VgCMFWnGi6H4qADYAqeOUHPeqTKOW1Vuwj8FUEf0PMGDOlY7Hd1LoOOjp2Q=w1263-h947-no)

Then back to the mill.  After edge finding, I drilled and tapped 5-40 for the eccentric rod.  I kicked the mill out of gear and rotated the tap into the work by hand. 
(https://lh3.googleusercontent.com/7JXWrJo644qcqoBZhtXiFLa6PCdFz_M1QMGEQWi7v4PTXC5FfjveCURRxI_HfmMcpSbv3XNcg8gmalhWt8TU_RFXXdYaPadk60_1uNsn1AN9u1QeOOUoUZgY5bvJcYSQEDdFdfM7MVM3Od66TIGgx9xrpMUnrEKIRj3BDjsFhVdh9PDUD-7D9GqFSuQkl4zQKCgKLo7VArtGsP3OLM0WptpBI67QZV0nDb8a6cpRqsqd1MT7vZfM5JOvFWOxVKher9Q9j2crJQiQwNB0bTl15QQIFe4tFtpAzzQLw1Ey0-9NUSzB3PQqhC0tdf3OIyujQL5ur8v_V77xxjL3R3NUVnRarnJl738JQDkH8gDEM6o6FCXHvs-FOUTOGtM8Xs14JX3s8S0KrNdUymudx5vsgE5iinnbZPIPJKZ4ysktRM_dNh06b8eh4kedPxOb3tJKTTUsk3qFTLzBcppjOMc2fmHah6DORDDSucuSSvPDdfxgsV20W0t1SszrC-8sQCZqKZaaK_r1edVZENpbO2ZQHr1AOmDYYC24jItL92oY9n0cbhGZjz_mpOncXTzCq7Xbzv79_YKimmAM4SEify5n8Djysx-eGAh6SI2SA6S-qzNgnAKQFuouMQuSnttis69SM-Btq-pbQnQIYYseK2JotTOCT007vgsRw8MkjI_mlIizD640KPhR2dizalSz16B2cUzn_j1VL35QNWE1bA=w711-h947-no)

I did basically the same thing for the grub screw location.  Did the edge finding, center drilled, thru drilled and then rotated the tap into the work by hand with the mill out of gear. 
(https://lh3.googleusercontent.com/I2lDkYMpBKRvnQIHdHoCDAqdCAr1D1RCVMWyVm4ofkVI9Tn_YTAKf6zYQxCrm0V55K5VTrseKVD65kgAlvGe_Pwxthu_lmEnGG0SpQWk3iOMRYFd_mxtFZ6uOKyvhoJjCY59FpWUxDQDH-P6QtBDApIs0Dc0kCfTdI2arbqM-h-7dukRjjhYcpBpK4oLzA-PjOXJeXaLPh4_FZAR4_8xdwd_-DpwuBaHleAo4mg_wkbWpVDq6PlULE4zylk3MsYYEp-vAP-iZ_AWUOZo0_sVCaLSsCYYAyGRrNTOowiAfX3CvNewUzubAIuu9JDCXypbPmTdwrAfGYcAlimZ5N_ql8WE_l5WAstmuT3ItVTTGM6Ed5mY89mOZFx9eLkjsrIdJYXk3ROqlmE7AfgkqIbqfQfWB30IrV4lAQ9igZMuqCIALMqL3gJdUxltcRMrt7b1KVC4TVX-2lCwtmXj20yWHIhUV_0UCEe2LB6zaVuGvqdY6kNGR7wB22GQFOha2hfb66YbUuWYj1wCuuSNynQzPeiC3zBtsIdrUH7dtOimcqxqIbTC_QiFMccJojWsr6FUlA1_rDP_mNEG2IPGvnV7heEUt-hMlzq_OYFxyAFetOrUkdmPVSukBkgu81FJjyUYEIqwGuy6Jv3NfMyw-_mCNuWov0br0HJFu_qwlMFVT4QvbmnJBhGPO8Sr3KN3RtFJUsCYVAB7STbjKZDUjw=w711-h947-no)

And the last pix of the day.  I used some Loctite 603 to hold the inner and outer pieces together and just lightly squeezed the parts together in the bench vise to make sure they were seated together completely.  I also verified that the eccentric shealth still freely rotates. 
(https://lh3.googleusercontent.com/3KJTb0IDZguUQat1pb-40ZVdKMDpwHlzAHo7lkdDLzcojZpPpKCKDlhboXvpAeG-8sCB0onFVDpD2-JE0sT1kI_E8dxa83ankfY0hKbXFF5oGZsqltSPr1FUm2npgxpASJIRKEkJyNG7xFHmYNzMd7pp3bc30rlNiXhlDJrW1NtZEx2wi3UXLckeKkACapEbcnlWGXNJ9iHA46LU-pc2I7X3_gXyS6TzFUWKsquYmTeyaUtcozQtJEWs5SxOdcsTkm6xA-_l9SloRTYqpvdSVyXop9jF55swJERx4RlNf6JqBMiJabNxT8JJF_RlfX3EjYQpg7c0GC1Ci7XDHSEbf1iqTv_pjIOIMHCMD7nTzGvAo30jx_MtY5iGgnW5NTWgsBG8goh5pqNdlpe6J3bIDIsEUdmRt6klCEns7cTXAWYQBlXQb8goG4qAZL0mu4ww6uG4XpVDq66zUjlxHULRwmORKuc0oFt3g7Hhlw-E9vcGVccw0cVEDQNCj7I-Wth2bHQJU9n-C3BOzgmqXVUg096F04qmFOFhGSwlOVn-kWJAqGLtF0380sbIFQzd_XgE6Qzflg9vOBP3nvoxCHkmQPd75lOCE0IHMolnrsZH_ne4JXaUIDXhU1zySagRIzZd8A2VpG_ozn9oxgbJXztAKpFaM2X6tCk20g8QoQXOB3v9Fgn5y9P_kfiXTYpUfQBtVLJicVLzD-FVhNXbgQ=w711-h947-no)

That's it so far.  I'm not sure exactly when I'll feel like getting back in the shop, hopefully maybe on Saturday. 

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on December 21, 2018, 12:41:47 AM
Beautiful parts!


 :popcorn: :popcorn: :popcorn:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 21, 2018, 12:56:54 AM
For not much shop time, you still got a lot done Mike. I like that eccentric design.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on December 21, 2018, 04:30:27 PM
Respect to you for achieving this fine standard of work despite the other matters you are dealing with currently.

 :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 30, 2018, 06:38:42 PM
Well, the holidays certainly interfered with progress on the engine as did a few other things, but I did manage to do a bit of work, most of it yesterday so i thought I'd better catch up on my posting regarding the progress on this engine.

The major part that I had been putting off until last was the connecting rod.  I'd thought a lot about how I was going to do this part.  I'd contemplated silver soldering 3 parts together but couldn't figure out how I'd keep everything aligned well enough.  I'd thought about threading 3 parts and then silver soldering them, but that seemed like a lot of work without a sure ending.  So in the end, i decided to make it more or less like Stew Hart and others had done, that is turning it from a piece of solid stock.  But I still very carefully thought thru the order of operations to give myself the best chance of success.  So here's the tale!

i had some stock that was 3/4" x 5/16".  I didn't show the operation, but I took that piece of stock down to 3/4" x 1/4" as called out on the drawing.  In this pix, I drilled a small center hole in one of the ends of the stock and 2 small holes .089" (#43) fairly deep.  These holes will become the bolt holes for the bearings eventually.  I drilled these something like .40" deep and you'll see why in a bit.  I've found that I can drill small deep holes fairly easily by turning the spindle pretty fast and using the Unist coolant/air blast to keep the drill cleaned and lubed.  I withdraw the drill quite often and this seems to work.  I don't show a pix of it but I turned the stock over and drilled a center hole in the other end also, just as a contingency as I wasn't sure if my conceptual technique would work or not.
(https://lh3.googleusercontent.com/0_A0tOj25PKLKubm0GMB4Xp3DWjKN7jy6thkOhOnU88EFqLepG4LtEvesmWM7JLeRdYZjJOqVigaxZlALsDja-Wsnusi8fpsKsvrXDVoFJZ-bsB-xDQCjqU6PbSAdu7ytlgXaZvTdrj92kzbM3U40_KpCWCZFLw-X8GgNmqnJ606QTOAsagw_Qqqxt1aG2dEODrTkTO7NqNVRX2YlZXQdsPyK8f7r3bGScC3cZs_VTY8SIIebd-HKKrIrLTuMkHxf1jaQaQHP6BcW7HF11aI13l1ZabQHOyzj02Idrz-6v_ud-8Wl4Y1Z1ecGT9-L3mneUXRqiXVBf94kXPLeFZ_9FOEy-yWECNOkG8v-gH37ggEtMHHVFrhRk2SgW5CHT4Y68RZr0ZOYsmRLl9rP7ibQwlMvAtf17R23aLhw8l84OvyNkCgMPuc__rYgUe9_ljA3BOqC8FpRaFKlVLMmrMVltYq-94OVtBv-_Gpn9wxxPymz5US9FOkl-LkFVF0qnypRgmUg007HphDq3uFGq6HPE7G_4_5yoMVFxBNera6brO03CCrekdm70qhXFwK61X2JIYed9-G1OTBQDqzqKvtafrLbST-0DhOfIBmWVrkmkcowoZEaKnctICo33KGJrr6D6Jad6P4fvL_mEQW8eRE_hr-REp9vnKVldyQyenvgR52fNdR5S6CZSYRT-_apguTXprc4ka-jxL1Ipq0DA=w711-h947-no)

I also didn't show the operation of drilling the hole for the bearing/bushing as that's pretty straightforward.  I simply did the edge finding and then left 3/8" extra stock on the each end beyond what I needed.  I'm showing the part on the print with a layout line marked showing where the round portion of the con rod is to start.  Notice the extra stock top and bottom.
(https://lh3.googleusercontent.com/hNKYrVAblNxOTkFyj4oxwA8DyxKnq3FYtj7wjTVaRnq382hM_f4X7e8nBjzWLdyRh3CdftbW4NGQTjnh5pnTz60r99gEJm-BfM3hmklhsJp3MRwzRxR1zTTI5B8noIYzOdoiKcE09QbkC-DOv0toqB9CgIlCGnIHbqpScBnx6WTDKlFtIKpCyfzEHoA4eUZab3sbZ0dU09vT1c1eb_vl5Q-U_AdSnEI8-8hBWBzvIgKQzkMP6oV65_QFPfo4EF95wlVE0pC227JFLSPr7hjI49GHO1Q_M0snD4qJOXCtSgnCtA26hU3jFEmiNJ7RrCcYa6lsfPlVDeOLdxB-EcsLYO49SOeWWf25oaGDENB_eRpvF8g-Vc5h0BnnM2thXKrM8WuGBwCrKNN5MsazBs-IUWNmoKI_ySPM9TjwXpmKlBCnTY0JoGFxZrvG__OiGQAmGNmdC49c5wl9-BOYZ0Comr0exTS_Xl0pDJTjvRHB6VhTR8LanMpHqMBJfMWkE44bt4PALLXEkKnGRRMhC0hl8hJjoSUB6pb0oHx5l9u-8ZKWLoo4CM8oh5J-H-B-aa-iJAM76IGoJ161mzZm0M8QtlLfZStrwsuFNPDH3y_Iwkhe85OTH6dTl-6JfddECISBKEcR5C_tDTlmFSYAl-OlDHGoS14xMisvEo6U5wXyxAKqSmcLSmVuuZB38fnfpm-v0QS91EJVsyRz_YiXYw=w711-h947-no)

Shown is how I ended up mounting the  stock in the lathe.  I used the 4J chuck and carefully centered it in the jaws using a dial indicator.  This process is a bit tedious as you can't simply hand-rotate the chuck without first backing out the dial indicator.  After I got that end centered in the jaws, I installed a live center and rechecked the centering.  Everything remained true.  The technique I used to remove most of the stock was to plunge in with a 2mm carbide grove/turning insert until I got close to the required OD and then I took a light pass to take out the resulting grooves.  I really don't like interrupted cuts but this process worked ok. 
(https://lh3.googleusercontent.com/pc26ckCitqGRRZXDj96QAGC58XsW7zuKyfhRV5Ku-PGZJGMkVQCMTCPLhcUBLEowcie2aDFg97RCJMPe_F-yzWOSx86ppB3TRTwCTRAtJs8V2f4IbfJgKUwc5-7Meo6awRI0FJFUZ2N8Pp2txLX8ZZLol-o7G6sb5XkZ3CCnERzdKfCR2y6zq1JHzqb-KKDROe2lwI-xdhpJO_GAehMU_xNqRqcaVDr-fwIRq0VkWEB-r6LaeJyrhDUVbZX2duHQInvXaIT04WY89voYpkLeW3FUNIn6SfIQVuFm2fCEa-PBA9R690J4DP8cl0lHWSjZoNrwMi6xpZiKBir3ymdzlFMjmIcG0mclpIErjIVZ5GKHEq3zw3v3vDHQPKt_elajgp4PoYpZYB_PXm19Y9n_ExHJmwcnvvjHE46K-3VMBGKNfPHUZQuZcaJtRVcewP8IW04G7GLEqcpo2yxfwcqY8ljQoPBkEgKFjV45ri4LfyJqwEt1UvE8Po63UBgRKMlL8drCXKFy9Ieye-bODJYnuLirSSZL-s8z_Otx02zjsT4uuaphILNjS4a7m4CyuIqNf-zCvYSTze_9-m2kUvduDQiJUvFxkEbzZocqT-xqNfMCwO_6vPOCpkKdbxEBIN2Fkj-0BKbw4_c4NII5lGSQTYFoBdgehk2cXG9aPgvQK9hLMfab9YZwnqu3x-fzDiqJ_Jugt-cGoOxMfV7NNA=w711-h947-no)

Next i switched over to a 3mm carbide radius insert and brought the ends to dimension and started forming the radius that makes the transition from the round section to each end.
(https://lh3.googleusercontent.com/vVN6X7RtHSVA-vqmgxTg7G2fJ_ylyGF9-bj5TBUcUp_YKMIXLYfgXdKxttOAyLtPEX6kKu1TKdhl-dhBIuWCrFAFNxkQWGk5fS3Dj0pdzovCx3OHvqNmLtnsTBHX0UW8H7uXAktCWSJWZGqockULXZ5N73vgKKxEd3Yocss1uPz7p1-xkcca06svaETdIYkV2ha07bjVVN9lEopmGr1pumP4WmWTnex49O_bnFx4--pEADDc5EadHWA5eV-mIMcXz13C8dX1Glbe3hoGL4U1JUSS_7sNVViyLwtOR-6YftS0Jr6Tp5gqA57kxnUGTpGi9GfhIeUq_YikS9_FmWG_1wko8ESQ7FEY7jn7uRiPkPsUsV7O7CBB8CCTuIHIktCTyHAKq0PKnRZSGxrsWigO1TXjoaKgb7XRnZildHODMaH0UCHxKpMckcPf5vWv0xtV32nCXlBGFUOYGFXI0B3qpxcNmOyjUgAmOFDIBhLLdNgcUHib5_cvREH9AtKWYu0K4aB-g60jyogpn585h7rvWER56R0AZNlgSXJbhJ17v4TyKd4pYHHX7w7rqzv5E9qjiB6PML51aMDC87I2IC9uJGe3n91_oZfPl2zXuJHCQ-cEe3U-e8RwVqD3PNpo0uLhy7yTzcvgfomV0ZjSJAYxO-rRfGOT3lntbSuFvUpL8F3s8sNSa1Rf4qsMYJLn3Ta_UkX1uM9lD8arUc1lzQ=w1263-h947-no)

Next, I moved the compound to 3 degrees so as to cut a taper toward the headstock.  I also slewed the tool around so that it could get into the root of the joint and not rub when approaching the headstock end.   I also marked the center of the con rod to give a reference as to when I'd completed the taper.
(https://lh3.googleusercontent.com/SVyELggIV2pODqzpo3lmwCQNUYYAh47Agrfr99k1NeEfcKI8C7pUvq75KPFCwaq2jjrV9J4etezZbaekJLhMir8xvSOgeigqGbTs_8B6aWI-qeyr24Pg-6LRqAY9iCoIjxw41R3TDxzaYF5h_nlLZE3O7x12ytlzgddEnJ_u4YQz-VVr25w31k65a7KU1UA_M46-P0YKym0DziXVvDcMZs6t7UnNHGgG73gg9A2M0jlkGCYR5bV_oD99kcTK6WcsNO3k6sFI7VhnmoNUdoDvLDXXeqeLndWKza6bpG3rbB2gNd4HYtoWpgW9OVBEYrX3Gtz8Kdh_5Jvl14dt269_sKdr3PZsK19Z4KI6lfsQaj6xoIaiUxbxGVmX4A5PugTkjoNCO4T74vHfHGtaLp6LJ5H4DtujYwdW1HomT_Lm96zrtp28zPw5oPeLNURp74LRMwYd0LCSuTSqSPxdJjLrgjjmLcYhN1U2AViKRzXKcQJ9pm69H5yR9BJMyrWbBFyacHRczJOy8MWiQ15JvEM1NPaMOzczM7nlBbEbf_O6Voyte9fxtGbXmrZLBnPgVPbdzZ9CV4iEAJhbBssxG8p2OPEwkuyUr7iU-daCsT-Ld4u993QvtkwHFsIw4Dj_D0FJoL7lMA1zZc96CH7Qq6L-lbroDTtXh8JM4opjrXQTL17bipzR3Xdbl5555IThGb5ta-FDWanjJoKYzE95Jw=w1263-h947-no)

Then I set the compound 3 degrees the other way and cut toward the tailstock.  This was the part that had me worried and the reason I put center holes in each end in case I had to turn the part around in the lathe.  I wasn't sure that I'd have enough clearance to cut a taper in this direction but it ended up working fine.  The radius tool I used was long enough to work well for this op.
(https://lh3.googleusercontent.com/MglW2NxH_1ZD-OTXBkRUILrUAcXJETYzdKb3VN6vzbLT4H_fDXL7a341Rc55O2L-VNmpXuJfsgbyXbGTYMrzVWslUdjunD_XVgHdZWYjatZ5wwSWfYlBmvyKPen5x3xwcSKunJpl9ivvgLUdxvhV6ZNMPq0NzYfQLKtgmAqeabhQpz-IHMnTAs85CJWY6TzhwiGxwTkJNk4eR4cmf5DTtjBLw3Q_uYoY3RTcFvlP3tvnvSXcm-JmGuDNZCtr4htl4iA8zBNh42aUC47EXR5S7OSWlwKywLXrIIfT0zRE6nAfuv-frmVShmo_lCneBCXDsmw4RLVCT5svbbJ4SMqur3sbKlVis2bgFZwzmde3I3d4uE7R1IYndHUK08hiMBwkBM4P41VmVArK1_HMpRSWm11-3zgmcQfQHgVV73JUnS9rSPQGyTRKxARC5dO1vdbt0an2fRXqHbkOJ_onAWWEQ2lMhatNxyA1lkWjnqqnqtcbS3PpA_s9HvDP9mR8BjhUHLLPJnIwD9ivEZUTWCiiAE_XMtJ09HYwIRhV1SVV_HTfyEjjJMQzaQ9WORHPD5FTJypoSI0YQYSwggnbuMmFfGs4r3dwHdrzmse8EmOmc0j7BhCdKPA7Ja0P3H2siJGywevAHtelsxea5Xb3Adl6xsyevS8lTTjHaIwnHmdL8hAeVvqus8-3WtkagsG-tP9L0vSiOXed0YYdLCpCqA=w711-h947-no)

Some work with emery cloth and Scotch Brite got the part to a pretty good finish on the round portion.  The marks from the 4J will be taken care of in future ops.  Hopefully this pix shows why I left extra material on each end for the lathe work.
(https://lh3.googleusercontent.com/iKO9qir3ma6j6kYa7GP2cmDycJelaJ2WBouCtwoOJPbnD5ovC1TCDx-KTpRrEu5j3k7PS36qKf-ZZSOyND5bm4ylcAfMcVkqmEuD9GrdWW77k1TWuPRxgkk7Gv69pmA_lPZTRok8mwK6q7kyfjdCbkAkUmKk_0zOPpnHljfzd1WKEGFTg5ywa-79EKjxyWFDRgwYb3RuFjVFuA1jfgkgpQm8hRHi75X-irfsUAVGFvLTW8ZBD-LRt_M5z92sqUCGKDVtBGxsTXGyYCZjOI_ckAKFB_4hgOeP3AaPIJYWDy2R_JbDyh4nlVcQjhfPlrtXgRyUSRQgI6ojlJ5xu6BbqsjvhgdNhZ4HtlJQ7L5yvbPNExfbEvtXfUZf3zkS--hygWmGSOPD5cs3z6VXlh2CmJRnlAcI4C_G8sYTekvTEKa8noo4MwzyConAqxsBrxslRy8cSiY5JcSLMylR09ZiYwMCbM1VR8JbkF6LMmIGN3sntDjSo6EWd1Bhrkn5UKayQ8uXjRZurqqe6SPbBri_VyPDWXDOyjUMU8IYFntuM2O9XH-HGDpZGuOd-B2IHPFh5VTEBycz0UWIqy1_31C__krkfX-0feSLOCAlJGnaNSNxCFzhATGfVyebaMfJMtouubL7h4iGOdph7fUvoVrHWjf-ua49rzOW8T0EhTsRuafU_3Se3WUCsgMBxH5Fezvr4tVr7DvsTXp1dF9U1Q=w1263-h947-no)

A closeup pix of the crank end of the con rod showing the bolt holes magically appearing!  Doing the drilling earlier was easier as i was working in a solid piece which meant I wasn't worried about alignment or flexing.
(https://lh3.googleusercontent.com/6ypE__baz5cAcgL3Y8_ama1OgnDO80dlpnON5W8S-3seVoQSJP7jzzvVCRLzsW83x_YE6R5qVwxqTTv1R1p1KFtSV2AD6jzI2GenUb4uYVYytJGLRLeM_CVAs7NxMg5H3KHOj9wbXDFDtECOSAtlockyTU0aXZ8-EJRstOPSox_d_BiPuu291l8OGbFlyUOpgMe5DXIk68BX6P4J52DmmwMgBeGbFHzN6OktEexUTiulQW_Dxvlk6NTYVZqlcJ0b1PhabD9DNAaT2TrQCh5yButcrEc72-JP_QGl8JP_AMKD2UrYSwmUax0wtP-nvYknb62AKP1hr-gwjm9leY3DMLKk1Hv1pgQK08BPJIgR1rwauoekXAoya2ktTV93fyAAsRDHumX0d2U2T-HhmItRo0ZaW0p7VmaBjccx-JEyRN1wLa9hI2n-tf3WmZi4JyUGBy2bbWUzVwk3R3f2A_XDJ44noK7jTUstI5GXsPEW6CvfIEWhXBkM2uCJuEYfgxW95t_d0LLNDfdqhfRXyZT4UHHabsaTzsnwbrWd76sjf4kx3ZXfYxmUek-Qj_BmE0dtBjOZ4Q2yq6rG2yXTNtPUC3fgG6nljm-2uEBcOHmtZr4A0sbhAY43NEouz2hhsb5QmiFT8cfDeq0ac5X66bqVNJ2KIw5bhBadSoTVZ1Qpzz6JYcmicB0x5Y1LFDb_8hVxc3UHzH6amyVNQ_Q2GQ=w1263-h947-no)

Then back to the mill to take the crankshaft end of the con rod down to 1/8" thick as called out on the drawing.  Since the part still has the 3/4" width available, alignment in the mill is easy.
(https://lh3.googleusercontent.com/bKRmUIos7PNgUS5gM4Xtgh__tpEGIz9Jl8qTec-1ihlhsaCB5AtrOx-ElE4fcAzc7PnovavuuQimP-13WeC8cvGMj_p2-eCf2VTQ4y5lPAnpdocmDaWsq8J2y_8aHhLVSMeM9ut0zX5JrifU1R30JHUaXZsAm6zvfKhGFHkRsy22nNlt5KTULnhNKV9VpvoQPqMGrM8u54kcJWWPPWech5pmkf-sk1NQJ6-a1uyPtnlpjA-soV5Ep12RgyOtLt8fQn8Q6S3yD_84-jjG0TY8I02w6w0cC_EhVrHI9Wa28t87oo-o0pYtAzTU9TheIBUfzTGKLdGVdrUeQUtDKPBxgMGRQqGm2ceC8zYC23Dbh1FNE6KsFmXKEG9c2Rt88Y55CDVqWXmlVnnHoe23eeo15HdzJch2crCQ4x7vuUgXJeLoqvkz0EM86vxggFzDgvOIGIHoMAFbcOrxvZ3RoBcvDafLGaeKthWOUfwA-wvxKgpMMuWaAE5Og0BCIJN7KKsXwQO1wGZ9xOAyX67nyd9snE_1NvyycYkmDxUOPvwHx_BnfwcSvwhESFii5Dg4kg_TTwa3_0Z5cEKAdoTyfaR27ZYC4EUFVfDpMJ5N0R5dwqtP9OVagkT95CVfMdC0mzQ_ir75QydL-DSMq1zYijTGI_yoqJH0Zw9G4hz8PtcmHZeUuu_d6VPsp-4F81RGFbpUjMZUo7nntXAGjhgheQ=w711-h947-no)

A pix on the print showing the crankshaft end done.
(https://lh3.googleusercontent.com/Gkq92TEL4fl6U8XFgXTxn8NcX9RWxS90iKMrq6SDBSIiSRN6YAFISQOdJmTe5SDCj8LmzhXMC3OfUOkvN0rVSvA1DVit5Apljc__juw0ZVL9JxVl485XT7OwKpf2ZmMeK-B5-CLPdh5n90NSHAVB9-eRKtrMNIRCMtCtsuC780Ro0WkZua7GbjAVjdfATDG-wJi-YCWCBS8GaJbe44NlggZYzkR0dpIKmgVNRvsW1E6Rsv0On0gdLFGQJnYsE7O4Yd7KeeYgXY9wDLpERj9lf_hB-C4Ie02V70Y1TvB0mbtDmeV04Nthz5HWw_T-P-ef9RERwJx-h43t49NTrwd4_kcodpI5-vW5WsnVpafuqF_ivyTLJ6LFFtlimAzo1PuRO_c_ZHzI3BC-Kxv39dxViZd3hALm970lUy689MM9QCmvP-cTeoN_KtJAoj9oH0Tf_d3ijGAQb2xESlviCuodAKI9sYhQaJuIk37zaYKhuWYMMWmXvnZOXAPX9l-deElXh8_j9l9nPhI8eM_opSIDF3z_K-tw-oFQkh0cLEX3okBlfipSP12oS2iYWLbyqTs3UDunm9M3IPYMwx0SQXSgGDLwWxqneyjOxRWy4Lq05Wl8w1NDfnMUsfREtXpC5MYLDGZy1NR1N6n1nDjQyu916Re2X2QbiIef-7gV6vRJEyhUXqR0e9anx-usPYHaQjptrEET5rbA_BstyAZ0fA=w711-h947-no)

Then I needed to make the con rod bearing retaining plate.  I had some of the 3/4" x 1/4" stock that I'd earlier prepared and after edge finding, drilled the 2 required .089" hole in the end just deeper than 1/8".  This is clearance size for the 2-56 bolts to be used.
(https://lh3.googleusercontent.com/sAx9RlX2bRFBC_3IJWCPTDy07NPA45s9duNO5ow8fqpUkEncw7MkfKQm87O0sTDP3XMFOWpL7w8ZcQbmAcdHHto8EMycRHsRsv73YzTr67mITPb9G5W6un-ewxOEhl-ieH1zL5VuMjjHefUSm3UIMJk-WUttjhzeSP9xkgowqfu-gKHAXCPbrHjKnDJwVvcHcrFklXiyRzsUOBULL6QkhLiL0bzZs3Jjs6JFbJVnv7pTG2dSSgnYe1BSNSki6OgFp98OqAYCpC_vGwquIHdty3p2HJjSLaGnzGElLqfCVP-ZX89swg4B26ZNGhoI7Bc9dJ8xZwp7qqfuZykXUv3Ge5g-wn2UieaMpmNREgUbE7-w_BBt_ApS3XAyLOsSu8x1Dy384jRqP8p7t-Of7Tf5P2nGiX-ADla8TYrLo3CZTPXRh6oTikxJZF9bNnHp4t2UVdpn2zD1Ix_WrPJxRK7VgD0VTJmGR1YluJ8uVfYW4337Rc88DjQzekWyb7l88FkX2OeMHBi6fXw_tfjqNWQ1ReFbZkrQXFwukR7kD3-ao0q9GbcYyeaykLelBtl3gMfcayI8rSSgRup86u9s4nXg_yDLvhyzA8s5E9LUA6BXusPlwDyNuLa3zyACZstUlyXwrWHtvLtK_0A3PP3DF_bxwkJxxTBMclkyK6T1xPvFvkaWEobTJpQ__P5JfUhEbsbl8m8d0yuxfsIKtI5L_g=w711-h947-no)

Then I used a .035" thick slitting saw to cut off the retaining plate at 1/8" thick.  I used the Unist running air and lube to keep the chips clear and the cut lubricated.  I'm always amazed how well slitting saws work.  This blade is 2.5" OD and I turned it at about 100 rpm.  The part was on dimension and required almost no deburring.
(https://lh3.googleusercontent.com/7b8oo_xLkPoMiaH7wIDpnPCn3frxAuWXQBUmKztXj4ukcrtTfk8Gvh34oLMR8sy9I3ZHq1EC0MWuFb_WmKNgIAAfQG1Kpp1_SlUmPpZ1rqqNiTkAy9rbP532C8QZglnyJgqQBv6g7y4CfvL3UP2frqfgWLDO7vjAtLXEFG6auD64J34QmNziuu55Vn3MhbgBa0hjYWLvuJ7vzTu5wekC8G7WGPlqu9e7-tu5ZIRHSU9VHfoXo1Oi0k4_tXJugNF8suzAqVqeoFbrCIpPeNH4g2ozm86Xcg3b9iesdNtSFtKB4A6Xr4-gN5WBxti13WCOrj0LDwvoqbJrCIe8qPIKRRtkmzplpShWddDerHchkbTUS22cAgt_MNizmkt5e6qRxJB5HdZnzGoWoeGPqc08Gj3psVdz_5l5u3NjzXH5deH5hWWgaJqN3G0ofnnCGvzurfTKAPs0JDj3wJ693x91ehIp_M0fMjcKJwCWzDdIDqTT5FI2Yf1UHmH52K3qzhzJTzKlxYpjzhCehrh-9kiGyXU_qd6E018DTg367PGRNfHgbqE__sD7KvSH2G9QDKK3q2JoXEmaPq_GRMEveNplnuRDsCAXavWPj4l5L5zYuIla0b1qS27j5lUnJjOKgu42ES6MQi6yKKu5FFIMTGXzfYpzMWb3JBMO1tHO8gSz_yyEOdCpf1fGZsmDycJ4tuDWBWxk5rlmVSdXQDd3GA=w711-h947-no)

The bearing retainer cap and con rod shown on the print.  They even fit together properly!  Another minor miracle!
(https://lh3.googleusercontent.com/grAezMUQE6p61Z0VQQ8EgFOhGjx22uJ8tHTCyACHtv1N1Tlk3HVN9V4t-Xw6HME0nhi6RLzCfYq-tIE968AroXGvBOecO7fUs2D4bZ3Q9Gj1mrXDjVzGS_QsBKfnxYQmoSxrtmvclGooGuDSaTo3wMAHmPTiv5XZ-xjB3deEshji_QUUs_ajojE840iy9LRhj1Zo8HltqIVGNaLSwGKV685p677JcAIQkvN08JdK-JobwjrgYWySCTV7FWObilDTYaN3ReEb7p6Xp9o8AmvjuLoGZ4q1x4z1z18gio-uV6J2m-SUMMJWXmaFAArQIJNO9n_fbsnNg8IociJlKNK_oSzHJ4BcoPsi72e6BO1NFaSJxn7-EGzLhgffushpGFXXOCShSytOo6Py7sGZsb5AK45Agh3sH1NURJKcQXqGu_whe2OknKq6fwu3sFJVoZozkC74dWY9cDd6gE88Hal41E6F_9hPG1XwqS5T28VejItTqxszoGQ911Lp8i4U-irAltryrG9HwGKfKLALHrPPMd9wHtYcg4CMh6fF9bqAhN4DtnUNzpOH40RHpKrMVcRQbbJFsUhkK-dxIKwee8lsCVcwBpfvr3CmtyYcXiFLY5ygjAeKgRmssbs3iSPx5lOSJASdbcv2z3uXjEd7O0_AH9tsBAAOq_wMo7rfvaC8cR6gsb_hTNVr5RSDvYvMF_hjH7Jq1yJ0hgLMzouAfA=w1263-h947-no)

Then on to the con rod bearings.  I had a piece of Al bronze flat bar and milled down a small bit of it to 3/4" x 1/4".  I didn't show that process as it's pretty straightforward.   Then I drilled thru the solid piece in 2 locs with a #43 drill for the clearance holes for the 2-56 bolts.
(https://lh3.googleusercontent.com/1Xfb0m8zTno8OlxRB18lPAfebCeyK23j11370OhIb5IgZ3mCN8lbJeQc0-do4GeikOMd5yraFrouAK_xctRWaq-3e9eAp0Y_GLXOhb5y0SY_QWzuznjWFxph2EDm3qPME-PRmhTh6Ebch7SsG6vS0XnYGp542HWl3Snht6kstgK2qXj16rIKdXmxruvcVRR69Q3Q9rlsdcFRLBm4wyE62wZN71m1SwXSija7nIpJN3Mkh4sftKkmGAYpiRU5CJuj2AC4iGaaqNH2bWkP4wWwng5ZmApsZI29f_2OU4hFxCwCMELGlwzMC_i-LGFdNb6dZMoGJ52Cl84_vZDNfITfuYJ1v72Yw4DgxNcbzAhLnxjnQcPJ-AXQBwHzDunOGN8o1phW2p9rvBQ7bmFl5NMUFKiqX5z71lz56J8U7ZrVWIdUgNhth2UuzLLTd2A5w9og_bG8DPa6Njw50AzrRfWoS8QnB0lOEKu08rnp4bdvyB7Q02w53cx9TWDETOcGZns6qi6-uUtO5kBNXAKKd3b5hSuUXuMg56z23j4--0UlYyrggheeLKpw9k5Ox6EPmYNqE8SWf-9bSMH-4_c53IAJjIC-5zily5DqvEZJLSF9ukZ5_L-NCoO55_2UAo4RdBdIoItKTp9Mq5cIL60grL5lSd4rat8P04S3Fwh2M89DGt9iDa_XALF08DekX7pCVoVCOfGnTxHFAYOb8LQrfw=w711-h947-no)

Then I used the slitting saw to cut the stock into 2 more or less even pieces.  The Al Bronze cut very easily.  Same setup as earlier. 
(https://lh3.googleusercontent.com/IjxEpbeYtYzHMdW9nHk_5mxqARmMLY7ix5TZBy8i90UimhX5wUHJWkliOSewwjhFr1NKihdmRH-YjTYNjl9rQtKrq5uau6K0LH1K6X0tzP9Ws4UGNIGAaKbxszk5i81qkISpMhe8I_H2IFbCc51gFlCi6S0vbHgSA4wQIyyYRsmlATXJy08BXxXQDk3Wse5sNh_1G0A2be_5yF1Y_X6SeYEcKE5fmJfivCPnrXMMDm1_4d1QGcciT4MZbSZ2CAnkJYKnmubZLLlTfjbXyGVYBYvKbKkvzelJtRotjBvGU-UUXj6iu5tlLyR1xrCJz8PYgdr-5uV6DLSdKPKTMClBBksPonrPySNTWJU-8lBxWXBXRQHgwyXf5XZiywbhFs0Cl2W7RmyCbCyCPU8_0aTtaOq-b7cRL-DARztiwA6DSnpTUdIXiBkxvJZslMvckKsWP2Kb1SlD6abnrp7LZ_ioCkvwXjQlgrGDKYTmqCigP8rdl3rpMw0K5M1uCwNY3B-Ye0HHJpamGXa9VjA6DvZg_Lx_5Qdqj6tpqlBgGr59pVwYX0t_6HvZ0d6tX7hF-l-QzGvw-vCOJmEcA7HYI-2NkpJ0wVJaP9NTFAt1v0shMtVxK3RmXhzDItnsGx3ooJQFZOLldhGLvY0MX8jmPcIn76DAAfs2ZoNBV9CYf2lZw_37ZKy12KTgEqpbkuppHCIeB9pf2vpX3VjYj629hg=w711-h947-no)

Next I put the 2 halves on a parallel in the mill mise and took them both down to exactly .25" thickness as the drawing calls for.  The holes will match since they were drilled thru the solid prior to cutting them apart.
(https://lh3.googleusercontent.com/TajhT5W-yMNIvamzm1si0tAUZ5JVSMA1qOiOzRlQWMpfEJemUR4qzlTFhrUOfXEsffM8zAjSDHnnrFxicrNzxtvfodafb2a2CYxOIR-ngtEodpVCQb0GpeYCBtBaUVryJMDw9Hh2d-oWe86QncqER5N8RPGVHlYRk12Qi0uLzbboGGmmYWfxoeA0flqUwlHuxyjy0-k4pIsoFOWPdMxWeW3g962KU4qYqW0SprYeA3JwKFqmbhBGbhGg3WL9Wz8JnG8Cv-3S3OWccu__vnbY4SHO1PWekwiODP3haXXyaaaPrl_szXRqAgHJbsjueHog6Sd-Fvyl_SdQfQgJn-TNBV64xeCxDC7Kj8Zf2TVjSGcOVDmOcmT17frxhg49l0NCVPZTv07MFnbjjvlKcPq1Bcek5XfJN7CGqQoVkirLCL9h1qcgfU6dIEG0sZ2rRbzTjXknmkmcwiyd07Z18ydRlWD_D1Lva2NlDxVdtaEpy5XzoI6twr29_y9LZn-3aLbdJImxyZe8N6QrorA31Szgyt2aULXZLUf6CTRpvIrQDpA5wOaM5XrtAU7oSneqh6rXCZaUvigfvWxhdtWcl1FbtXzwPEWAPkaVaSSIVIrLvRaEdzk5iIyDzQW6hcfJfG1yH2w_KKTXqcckImE1X5Z0zG3ht4jW8uU5vhb9HtOFSqySKrB6BG7keNbjT4g6g7JJxF2qLj4V8XuFP5SXuw=w711-h947-no)

The completed bearing bronze's on the print.
(https://lh3.googleusercontent.com/O42TpZs5ijcEJdXheMQ6SkIMxB1no8vCIO4L4QwGZQ2AYlOPjflGDzuAyRTPpq6FLwXIkGpv2l49H2RIPZcUxQum0TtnMFTQMVIHWqV9uaUscHuij2_Y2btE7oWHnNlVd9eLZw37JFSUizpbPp2kjDm_iEu-dBMWJZ8uhW7axQ5y4Vb1zeHtPRNd1r8tQR8FFeKFBejT7aoNlKsVf4zKRX60CZoou3WwHs6iS-UrxPWukmSGFVnMCXBT95LJnV-aazXGGOAQS58AxqzdLTmEjzCSpaRHiRwwCVQE7uhBjYAtDu6tS2xR5TsNW-xuk8RxXjpjKsVnfn6-6FXGwqlYi6hDCl6qaqXPa-Ja8pL1wTg94fxRuwGc3VeOr81SfZxXyL_cSwdhQ4A3s-l4YAJiqgCcnFhVc0r8BpKouCPszE8QYsKi-4eVQwe5_FOghWcQKUJGEiqHgNe5qlnkqX3yrookBn14m8JibjNcTQflwcyCQ7aJNOA8lSgz2PaU5GhRMvhUBnwiuxCrkoi1aIPSs7fKfVqphMlTEWZ7BsfscMRKv0iO4zF3Q7z4YIck7AJIac8L3Y1RfwlS5t7o3qnXNXqS1JnfJuGm62LuNLLJfL7TohebZMeKUbEb2UOrHIrz7BjDvGNQtLihpvHmfNlrWuAv5gK_jOG__3XHX-dGd_eSvYGbzlt-wRN8UWo-cpDGhG6yqvNHPJi8VGBhCQ=w711-h947-no)

Next was to drill the bearing bronzes for the crankshaft in exactly the correct spot.  Since I still have sufficient flat stock, mounting it as shown in the mill vise was easy. I then located the center of the existing hole with a DTI and then moved down using the DRO to the exact distance required.  This pix shows the centering operation.
(https://lh3.googleusercontent.com/EUR-EYrKsOj_yu8cJ8Mez-uwbdE-E9suQ2Wag7ZTk_831_GKxovBB2rvacl6wiwKJBjmTRGIqt_I34hL-bArowtwptGpPyZ3phEt8CPtzRmJhCk9_5Ac7yuwyDbAo2tVOsQ2SaZRikXhv0g76DmlAgVoXBHhe504TWtfWV1bcr1mXjKxgYlJpWzqb7JGTB5RWb0etnFl_Zf_DupWCvvpDPb2an7KE4SlRGJEtFeKyZ6yJWdFuR4urzwR5fbgeJyqT_WqcGRO6ebFC84IyvwBozCpnpfXWOs0hGvBVNtKC6rbHV_3b09LEnJsTmtzESCK7pzhjMeay5uQl18ohOG50N1Xxq9SPiDRJlA4WOsEAQo4PXDpKm1So_arRZ9sptIyIBei55B2O_iTwtmSiH1h_OxJ6pFc49tpFIGFDuei3xgVw4MH5Gw9_NLY1GyBT8FLYyuF5YaDfNOpG5G0o8ZOASFa6VGMyocAyT47R2h-bHvE-EAGDzcHumQUYFn3A3A3CEqCSoU9jji2scWXFQwWebkwP28pYd-JTK4xAd46b1ZQZAo2Ib2nTAiZ5rfv8uNTlml-wBdwPd0XIc04J-AwjMuVx_LDbqd1O_zNQ3k_eXxcIBS2x-4svDSsNeTYd0WOuIr6vm1jzQfUvUaKIcGDoJKNteLu-bn1zkxaExIhiEMhQ8r4DvU-qgoj161BEG8ZCDu-KvyXXPUOGQB-Uw=w711-h947-no)

I didn't show the spot drilling, thru drilling a bit undersize and then reaming to .001" over 1/4" but i do show a small piece of the crank material fitting thru the hole.  This felt about right to me at .001" over.  It rotates freely without any slop.
(https://lh3.googleusercontent.com/3FJ6iRVmtF9Fxy0Z_0llBQ70s2YBh_ut27QJrTWlCRbtAO_cMYQ9OBjvFnDOH2H-AVi7sXI9J93-pFGwG1Oe-DJecP-kzH8Aqaj9DvP2Aw2V4wvoXLO0ouRtTxCmDCHOumv7vwev6bseqk6ZWyVyve0SduA2UOvo7PjWjx1ox44BKZLmxqPK0Pi8H75agupUquOGL_uGRE2LgGxydF8PXPN70sZaGXrr5I-j3ygD0imJRCiZPXAa17BpuM9Z4TOCH3XCvz_zb11M2WsjVPLNtTRuU4T_hBvHMpHZpaeOKZakOVqlpxtHuuPHrbTp0XyKHtfsOEC_r64AAFvZT0GYuhOO_4-T4UwUjmckgHsFOYEO7VIkoHQgKbPJa2f2ON-OLRQwfX2WY8_xm3zvcJzKz8rT7fTGH-puOwcwsvvo-mswTNhZUkLkG-3hQn35yGVAiyMv_hD8zCarfYegeWv7i_XI2VIwr1Pu1JPDO7hmbqW_Ntq5VhNlkf7C1Kjvov5A_OlZc5tEvOS8VpuDMcctsnwvX6rzujuCP6FUH-uxVHMHpAtSV0MkjMCfr4hGSi60lqg76s3fJhO11oozS6kWwfwF-IVAXe4J4l581KionRE_zDB8xuuNoT_kZuPJW3TmLaNVdxbLhTagoGm6HM-xPovrkKZXWjmEF1AtiOeoZEDK4cDAKhSFKIO8s4HmnQuWjfhFRATp3nKyFfCwug=w711-h947-no)

Now, since I'm pretty well done with needing to hold for alignment, I started bringing the round end of the con rod to size.  Here I'm milling down the end to get fairly close to the required OD of the round end.
(https://lh3.googleusercontent.com/Jdj6oCoMKK8PnfICTmS1Gnd0JwcfCUL6YgZr-5UrV3vmTlITsGfcvGKbtK8E-w-U_kZA350ugxguIWsQkwA9PogxZjcmeTRCE0wd83vESlKDY43FwvTJbmk8WsAuB4KgiAlMYBd6GgNPtQ4ubmjwufxTCOp_xhEmD7o4V3W9kjdgX8Y2yZSp5o6CH6rcOPqZ-iYNH2sCykvyA41PnW08A6PEm01iKAzyap3z0jRapo6mtI9DVmA3zhbu07mGTGM_AeDhPwwZMU89jm9dfncZ47xhLIs_0M7CmDo_d5oIpNBm4cNa6Cxqi7HUDvHvsCn46Yb-fR_EYtiZL-534psGWw0FU0Yh4rhgin-E28NIY_wclzBG35g_rXYiOg8u95sdSTxQ5d6f8x-4wQBiM6QLPloeMQ68YQ_LiAvLHtN-x7doxUFiIfudMclFs9mN4qzvwbNaWk--Xd_Si27-Yv_U53kiiMK429_IQLkh09muxFgQdL8VYHu2Wprzp92mazCWuUySdIfc_E-4LbAXWqD4KlHXYOh2e7QVLrlk4BWsjFKc6KttWJB3hrU3V1PAUmgYR0zMI9GCXmPVkUBRTqLZTSd_sgVvIxBGnxKFqySPOfqWfUve0IKCauRZs81RFeifB4L_ewhvQg5exyYMQDncmf6tvAoT64Sg-NFxZYd6BYKPp3AJHSescZ0MatOvSfGsn0ioCPkuMBTkoP7pSw=w711-h947-no)

Next I made a simple 'filing button' that's a 1/2" OD with a stub of 5/16" that fits within the con rod end ID.  I also blued and marked the to be round end.  And you'll note that the part is laying on the belt sander.  I used the belt sander to get the part very close to round and to the final OD. 
(https://lh3.googleusercontent.com/dyA6aja86VEmALUbkWkos3ODb-MDLpUYQ3JilTFs6MlHqPrmpmnYOkzjImp6lvbxai7iuIdJTdG0FNqJOFgdooRAw9ObAhvU5Z69DL1v0wnT_9og6W-Gag73rHUKl7RY5Hcq_lyee2_hdAmOfBhq9gISBqSVslgsDYmCZXKAeGIW0auzlqp-ohcEICssN0O3gaoGQYCeiEBgJl78GZYZlqCjhBBI0nfl8FS5yffAycFe0GqL8p8KfRXW_Ohyg4ZNA4iiVnMJcpYJT8HpEMzVX-0eIYAgcgb3PZJz9mHOXihDX5ukk-gwXuoNYuG-dcdoIkEOivDxX5Ka3k_xrmhv2B-UIEUh_YrlWW_DcGS2us98ov_FQt36obw4-i4UccnYpBltNmiKesjopRThHknhkfDnL191Jx2ms7ht4F88P2QUXWupROKH0FC3JhhHx6MwNlndlwf0ZWZmdGJMNZh--b-2zUm3j2plcubc0KU19RFucG-pLBnCJwMeUfxKPQMaisf2rC6qRt5OjrM6gk9SdIc7gu9A8bO7CWP3gCcz-u1XKQEjBkdxO7S7nhVVmrrrvU-rdfqzsLA75jWVIdYyH-NwUvnBdf22qBHKknR8vleLaqrTjwtsyUWAk3tj_ALRBdH42J3gR7JsckClUqqMHDG68Rlbt3lrZEGbRNNXC5m6_cebucbsrxDoNIji586HGHNc3L6KOhekQnD1Vw=w711-h947-no)

Here's a pix of the con rod in an intermediate state.  More finishing work is required!
(https://lh3.googleusercontent.com/GJ8w5cIFrDXN1W427REx7AbIpXTYJk4MUuX8vYSKGVFoq1hyfxi7H6V06P9n6LHFLp-ef_9hIQP9AQU_24OCkcEGcwVNOQmGE3vMCroluJSNhbN3xTfxVzGCq2tnAWRKscV2Jo4iND4Q1EKjrVKKj8UZXtD2OV2AGuO-cRS4k5eBfOtFKRotncjo_uftOypdowRTTepgc4StchWdcfFC7eFiebgWgoVmGrtdKauPuwAs0P3utxAGmmX5Dlbh-fMfPuXcRpSVCcdkhWWDFeqwfxwIsrVSyr5uHBvHkq1M1dHwcZJ7rcqAJENQpTjE0jbgI_f9J_PT08GGNDl7W1lWjZYuyXK8uL8S8ayd81F7_zl3TpqS4Ki7_LGV-c6ZPmKOXP91FUb5rg6TN5yMAr2rdm9h2pnsI4XvBP_5Y0hP5lA8IpuzzCitGJyJpQ2MNSUrxWzkaTc5drKPKBuphg5xJRlDTZYTjEVS9grR6UU2--qgmXp29WqvTo7418gVvl4veW7q7JPvX18vi2GPQk4uiJDJkBJmZnUQDBNAOc9AvxroLTklCsbK05h34mmxLENqXNJqOZJTFRNvgbk_FnXQnrnnyfczZFwV95s5vDbOoUprFKkrnooOE3UZxPbJkF9XFD15bN47y39NP0D7QyJZP1KOGygHlpmj8eprGXBu1vuKpSBxJa0M0G8aus_4dkF2jiYRY5YGkC0pPqVfsQ=w711-h947-no)

One of the issues that I'd been having is workholding for small parts.  I had some aluminum caps for my bench vise that were held on my magnets.  These work ok, but only if the work can be held to the center of the jaws.  When attempting to hold small parts near the top or ends, the caps would flip and slide around.  So I took some time and copied the Wilton vise jaws but in AL and added 2 shallow grooves to hold round work as required.  Grooves are only on one jaw, the other is completely plain.  The grooves are dimensioned to be able to hold work as small as 3/32" round stock. 
(https://lh3.googleusercontent.com/jgOuxNUsdUADlzbtNgLpAUfE5GFZXTmDyr9Ax8-tWw4Ti9oLoOmla-mLaYTj-ut0UWvlABh0nwjrOqIJ7-JO1a0gWUW9WCgMRAEYC8hl7apDNAOnGMzrwmV1v3k3V58MFxtRCPprmBgqge9x7Qe77a2xaW2aC8ja78ako-jFs_G5j4oV1cxcJmkuz43GyzmLQdAJWkr0wuqYjNqsxqiAnkI0-F9hgVq9wDA83sAQ7KZLj10SCDehzNsR7oZP0nfUFcj85d2nYvoVAujEOA4zB9duAQWwgF_k784cEUyWw9GRLfVWx5CmH0AZxCWiPF95OsvRW7RyJjKZyxfmSMY-NF79Inh6oNHPpg976sNCk4A-9WSPf_z4XEem5vffpvQyZwMy1rdeT4ne8fJiru_IFmbTtAZd3H9c_DmAEcl5bNjxgO2Nx-gMJdjs2Xa-6uuaeMZowJowRZSQvp3wQzpSFWMlika-d81ggOefONJerxtQpOAYLxTBXMpdh4_8UrTaYYKND--sO3ibsl1SB8lv1wHxgeVQ7zkx_ji75vvTA7RuUSku-pW7evg4OSYCQTEC4fZZSjIBReA-dSJd1_bMU1QmKS2MOheD_rkg0RH1Xs-VorHjGR5Twy738b3_U5oNygc_3VOnxhPD3NH0_Zb-F9n8H3LCP0ydLbeC5ufuni7uAj1WZIvHxNT_9ly-ERSFx41DX-E1_1dZnGmIzQ=w711-h947-no)

Now I can finally hold small parts as I need to!  A very worthwhile upgrade!
(https://lh3.googleusercontent.com/vZiLIGR4TV5FiNln66ugVuWsRXcUDoMvL4kvyEKh1Oq9WRIsGiF6kPT6Qg6huNpRIewwOPxOvq48YvNJUZoYXamWXNSOTicXRr8FSbbBYYi5ncouQ-nt2VsUbUzUxKbIOwYtaD6Vif5jBH8FQRD0ubTZphL-ElQ0zuwpW0FFwRkGblKvw2m16yp0vC5wecSXtF8jr7kpvzZzoZWd_Vp0hlAAQ8r9hZSKX-BQkE-flBX-mKCIZ3cY8B743s-3a8phwRxNdrW7GgbiiLbAdtWmryiUIdstrpnJKMTDeR1EVjy6DsSCOfuyXU7gZrN-MyPabuYJmiRJqHIJkMaiTo9kOwtYa_UDwXFcHhdKe5F3wnZJX8Ny5J2nLZesnF_3_iaIJlOnaG9DDZRHc0aIWcomYx4QXHamCbH4pb_yo2qlVCHJ88N0fLDlEZA3fTxHE5uf_SpTRAsZQ0ngTGWGVYdktC7Y3kGN3p4m_jwUHQVGlZyO3_H_55_JRU5sphsxwzadYIb6UyZgrRgqNZIH3DlP7JzzIv83WzXmDjqIbOpWlTuHBZxYy2dZTgogS1fkPd3qP5tAFFk5DorVV965tn2eJzbeDM1XUv9oLBY49hEqUATUd-ON8tI7RuKvPZZDQexZF3lFNyKtpMJQ9BdgLR6o-DWZEmeeqQe7EzNaSDiMILG5EzhVD_Leq4XvYNonkSnSXbqa0XxLEl566q-M3Q=w711-h947-no)

To get to the final radius around the circular end, I used needle files and then to smooth out the finish I used this setup.  That's a piece of 2" round grey Scotch Brite that uses the 3M Roloc fastening system.  I chucked that up in my drill motor and gently applied it to improve the finish in that root area. 
(https://lh3.googleusercontent.com/HUBr5XgdOkK6b7HiZjaDn3vXrEkjw31nBbd0FqTxzp51TnJ-HgPSGSuX8T-89BVlYaY6PQOlvHWBJqGAKHCNPdlrrJwpQwo9LDEhWzDFFdW-kIIv0A-7-mg7CmJcdCTI2U2FsMRONWCCg8yP1S3hOjaAyMCCobfZJcmMJgCSGXi7js5QaEkaD4Y4Bc91SIZtEF78Lnyv9be2wC2Ud0tyBPu25l84sDddK33lu_LYSDuaQu7gv6GuJ5MplBO_1_LvE_P05QvsDONbEuz3V7Th2MISkGxhsRdujSYtyABw02qi_q1mqKn6qwF3nmQUJm_VjWXk2Umm-TM6eRgjLJ3fNCCdQJCf75LfS-051AWcg99V_V61W8XYqlmxFrCdwM3gOPZLGw_MmNNTiB79HerA2QJNnnPZJ7tNKsQdbT-jiwKLRhbrxchuTjWv4LT8VA8AmNCjFvgeWNB0wJBx1jogeHrb8WJ_fosd9tAmxEAZqDyzhFo3QoYfk-uhuhS9Gzq2kF1b3fpfikckr81e0hdr4nXdlQTQkkN4OKiqWFZULvStFNHLvpKy4D9ud7ai-HLx2xSYEpWcxCxFbb9p50eUe-ItN87cbjiy0XklZZGR0MtyEHQ-H8FWt-WPmGOMz2EIjO4VmqeI6CC7oQn_44wcPfe0PY4vjED9RCJDKJt_BXRW-xG4Nuu5sJNxDTgK5iXxhUC_Cd5V8XDtrOTQOw=w711-h947-no)

A pix of the con rod with the work so far.
(https://lh3.googleusercontent.com/n-ZzIqm30SWYwIs6u90AWaK4tngcFRnEcdxLBqjNx9xXB2TU7c7pml4SqZwqFx7H2H_Jhr6Ko9l4Yj41LYFmfszfOrMsrJu0z-wqvJyVHCPlSR6Aih7vM-yKeDTQ-lEIiazDcbxQW3rbg12hnOF-IjdrIFLdYFvia2lrGFFEqlOgu7bKg2LS-Nf94PP8IM_2fPZyPUZC6zfbiln5ElGcIBRKnsGzQ3XIjrsFUBPrl3GOLoqLpaWBoJHvZZy-7b7EfH1Z7q_a8pC_y4ZWQFody8JwFdsXjUba_A77TJLDu1GgbQLrCc7RzV4darXKNlLkfNdj5MUWlItO8fLFWgPIGqfgOok3cGLUmXUe0ZKh_uFAaiHEw2T2bnbeGZKOQF6TIT0QBm8K01Rs258lwCeVrLikk_8HQZVeNrkvJ-LsMvkgoCBNcNju-NoPXOjyB5OW63gJx3wJ7nXEL_M74ExpRp5KBqUw7WO_PmZ9XsVMkEIOMUunXccWzj0lXgNMrwy-NQfD6A3AOZiqSFUdBJhnxEZZnZHfF_Y6VSUVSygAcbcRBjyd9eDyGjSMhJwnCFP-tKCCi0ThfnGBCFwH4-zL3PeP6RYM-aIdDsgOuGD3YIhkoh3D383EyVreSOYPJ884i9Z9iuKlKxFzMhvYW7cBJnb84uKZ0VBbPyQ0PbhBs_Tq4WK9F04RJbtkhVJZhph9RTcIoJrp8yQPaM7bfg=w711-h947-no)

I made the bushing for the con rod out of a piece of SAE 660 bearing bronze.  Shown is after the OD was turned and the con rod is a slip fit onto it. 
(https://lh3.googleusercontent.com/-SrsEzZQCMlpSO413oejDmzHAaWsARfaa-d5SY1vtIXnzGLFHvOHWn9lRMxyjXbw6vVP1y4qx5tZVyy6qBcs_lq26B4XDPLC_J_Ou1ewUkoJksplI2gS5jzS1MTRLfO-9qdK25r-v1ic4BHjjedbDDdifYdMG2Mr20D8Yz1P0VyvrzLVjKj843mkB98mw0yxOXFeFUxiwJkEkdI1o80-_n8R69z9Zbu_j6PaT3_C_4P6xkqQC875f4KpGTr5dF2acRu1pIkWdcY0gZuwkX9GRvwmCXTKJTLhZXDPynrmTijCQtEbEQAsdOGeGKxZHyBjwDD7Ug1NolAxsiivuSrHe-gNVdJ_v0xYiu-QG9JrQyls5CLmn-i4n8igVnM6ghrLGfCvcPD1ipYXy3y08nMvtxNTA1MEJqwStlkYGit32um_tTfxn0AxMmViFRoR885Eg5mRn-pRNZxa0R80tRMicU8vIC82ZJ_f8yxWDi7gNAyKA5LricxN9ATFNpinAhrHc92gmwOq2h2ICIxNf2TGsfArnf36D3OLsOxAYzoJGq48mzemaUsJLakxuxqnZHEHFX96p3eFbd0oKSZWi6pJEZrXoS-f6-osaDaF6dRnza8IC8qbaoMu3vtN8-TPO2QmWT4YOWjs9U0mtkxCNykGK7qBZKQUNZTDf5LjR1ztLxO34O3Q39TciuQDQ78W24sgkZBDNYP-LKTfN0oESQ=w711-h947-no)

Drilling thru the to-be bushing using a 15/64" drill.  (1/64" under 1/4")
(https://lh3.googleusercontent.com/j_zs5AjJa-C6-_2mGR_RrJeh1izj1_ZrZxSQXh3E33RxV6N39L5N-obZk7Ib_JklZZI_JeBZVB7xik7_mQJG7Audvsmj1E12vkd8FmbgDKR098yRi8L-QZKC2-5FEKW5O2K3VrBoIhdhetpGn40aNjtaUIw3M0wskV9iScHc-OklzJqLuPBMCKgagELRK7oPBJG-XVnCtwO-3k5i-fgYY3oNnlffjUef6Iz6kkC_AQp0Sm5KETS6Z82NcndOFyF4knUFufPpIFrkZSHoa8faIch1YB8LNgjqoMW-qTkFV0F99edZMNYOy0KstjrZdJnMYfgpIZeBnbUtwI6HDrRrHeNxZ0gFamolwV7hnAEPxZHB87jPzRKZOniJcKJ09FsGIO2Lp2ePuv1YqJWFwakwgjat3BloB3lyRlq4qyeg9y169BbqU9RVElOFqGJm3Zw5lhzFAUfmhOqc_vuSHYwmwYG4Ljqgqjnina8YriN0Gvl1PksNouD7ozJEMsofz-HnP9FOAie7i2BVUibNmyapAMz-1xb9fe1NY7q_9a0xuPl90aZue4umNvnxgAgYIqti2TDTg7sz3O7bvH40ovq6AiGcAanhjn5_mVTSyjylsDcdftMnZTMklaR-_g4mrHxKyCPxMuXMnZzp7YMfyN7qji2v9hr_cZ5PMOfs_zPNz83u_ssqZblp8CIy81SZZ74Dw8CG1zdmdYNBD7XvqA=w711-h947-no)

Reaming .001" under .25"
(https://lh3.googleusercontent.com/Okvp7DleBrO4DTE7ok0p7iWnLlVFK5tnfMGhgPiSkgWSk2NBkcyWtmCw8-VRXjTTj7hHoTIKEnQP2WGUltcBOKo3pLh80iuWXLgv98XrM-Dr69CkAn_PkRAzlfCON7xTrsS1HktnkJ3fT2pSg7QXlqpJdZ32vj52owijvkY7BgtBOeMzRhtYtcUQb8IPXTga6iVzXsVjeoC56D2aMYN4XfyQCJQ9GkFvBxSpjNOYEbhlqAxU5TJAgkzXL4LdgzBQqgHrrXIP87W-H48Zu-08HuKdntiX3B_4-J2WxSjAKFCzqdicwSIuEBgViH2HjlqrlSDTtsENnED48DniD7ttDiA53P8dHobFduJZMTMAY3RLw6jfR_p0XroGPUqBP_haKRu4Cay83j9V3sFYOoipMpdj5KFTQnsqao834zDDE4JhNgCZFFALlx6m1-czESxI1bt-HT6mmAWGNTiMaUrjOAeuGRNp-neo7JZwLdNT4pGignc2oH8b-mhoYjqU2v8vExUNOLXZ-6NtCELaUjFODwGSRmlNRDYNu7goAbPri961qsf0QTlrgeW2sfhzJS-GgiZ5qtNu2zXqbSXlInyUA_4PDu-pl9yH-Co-dQdQqbFh94HkYq0_C-L8FzZ0c84c_TUJTkDomoZjMZP-TUC4KUrvoTmGwASPoYemCmLnlC13XnuVX0bzBUvBrEfnnM5k5P1Oyb7kV0otkahi0w=w711-h947-no)

Parting off just a bit over .25" using a 2mm carbide insert tool.
(https://lh3.googleusercontent.com/MZc7vQ8oR9Yi3IhR_lH7Ikctx-Mav8od74eKdczw9D_Qwg_GcS-jPqYXEhwEMyX6DPbmyFam7IHnbh-mywFl2pY-CbG_UafK0MWMr7j0QykTS53n_7kOXuNNdYPJG0IkHFJyqegpKUWvaDu_f3-csq1FH1RUrZ8Tcyg9VMVcdRuldi0vQS1U4_uwj9xOw1r1JbjOnSTVxpS0ZrV9P5SM5YUKoevoJl354VbFtW4ewakoWprcPjibyNM6ivs19ZZ7jkrC-foskwc0B9QIIvTm9iB6_O8FEoEreSin8hyj1s4nMPqGZzhUtP8Hia_RWZkaedyBbkbwLIPE-GToSkkvO7PwoEnXjdogu2mtkCfgYjGCavm-5nySQ5d7fHuWU48iSKxiLQu7-QvwHb7CXaqJxl8l2JI_q8XnlL8LM25n_TKpgiWN1WHXaBKCdGQ5tuV8JKhlFJLLwYYmEtKIT1NqBJqr9v9L7e5mS60mOIr-3k1bqIvoDv1gwdG202JIuET3xkMiSkxYRrVk6iHfTmUYo8JSJhvv7owV8I6tn1u-Pd6ghI4Irs8g8030314LUlDaPP1SxBQCB2DeJAEnFFzxXroM18PExqaHY2T5LT-85iiuoIlnIxDyuHitdQ0Ua2XJqkjLsg2zy9Mk6f7Bskc3BndckswPxkQfEENeekdd-DSabJwVddl9iUlIzUIrbHEuOp1Rl-LeD1MyKu2GHg=w711-h947-no)

Completed bearing/bushing shown on the print.
(https://lh3.googleusercontent.com/P3ybPpKc7xUGj6LSUSHr4e1PWZClLE19BiXw_zFcUdxMm8gFKTB_-ow10iSF784SVZHJ1bI2rk8cqo-WWPRuOGU5cwBMuRmEocffonBM68CfEBcThr4cD2PI4Hk69dF8VXrNUbx2vnbLlaAQBV-Ba1vdyr966uWNlDvDYMYz79Y238Gzj6PcoepUAgjJR67KDi67Hw1pkF4xBizNiUfHy0M5BWWDAwTV-v5vGLPK3mRTOuedXmQU-GcSvudGXf1_jfsPFYz7sW5rxbbw13JbKXt_6dKoTmKAe9IDd17HhPUxg55kiTUBU2yhJhTBTBEMOQfLJmIGNhfT-Bungug-mSAQBGIryWZxD3uTO177hKpTH944Ti2igfELtLnbXB6UpwzLH6BGKIOCHjJIpD3kjVVQanBl_Cy8RS4lBoIHawMltT-q59me5BAQ0cLlVNxrPNjheGsPiQKd7X0uYpSywW7FKtMya08wWqW8XVU8aqvho2vfAhpqjgxUkvfnR2uVC0PzMiVnUKsnYMXL_uNKbweA4MIoRr8pUobIajGkurTMHyC9PKfsWXxMn5kq_blIFxSUBohHx3S5iu_oaom6bTzaCXPKqNnyax9Np8NL4jiQ0iYBKwq8u36ZyBWZLMVriiR2cUiKneeH6KY329cr9DDBXhllXZ-2HdZbX-YLEl9DI_FYdTIWSmJrU_IVH2ojUlHYgRZaQNRE2NHbPw=w711-h947-no)

And the final pix for today.  This is the bearing/bushing pressed into the con rod using some Loctite 603 to retain it.
(https://lh3.googleusercontent.com/oKQexYIVwYkj-4UhBFqED6o8wtz33A2xk35Pglj3uy5G3QuLMQuU9Wj7IWTfceZgZoDw_Se4h3HnvKO-9c4k087fryHY8Alp5bMfQNoEap51br0D8iGHstvzJ1mNeHL10R_ssBqSGQrGvYDFxy3rCgwYxBwicHhL3rTIU8aWi9_FeBsnH-Re9I1fOAFVEjK6igASO3_IeyFEe4WPXhQn1m6okBysJ3S9M_j1htNZPHklG7UQg9x0O7yPhWWGrBSmJDN7mQlprYUWDDPgm67LumqmRlmGv9v5iWXgV7hwPELqbeGhBlhR4f-wCSgCIzum3-yEGkrGQJch43OtmBkt4_aeI4va6sAuTTeHViZczFEYQ-X5nUGVwm38F-YX1ycJO0JKIF90wXdVkoLm5QA1EkOznknpxv7-1gu4SR3XFSuFSi3Yd4MbKCyy2EIn91ZnKL0KG14xFgkBFqwb_kx9ky2b31np6Po62mhn8kMKgqRof0RsmumlW51F4sb7n9UATL2Mp--zY9aNDvYez5Q5UUQ3GZZAcjTecZddvDtKBZ8RV79IV1iqBFaO_OdbW0jXKbt3e8nPpft7w886E-istNy6BOo9BBRrhVB2W0xQ-94rYouiM95NXIT2xZJzU6RPaOxc6peBHNEnVfMjQkMGselP5UNaexKS4aNZBl-Yzf-ePE6erXxMhSyTM9iRF-o-l1iozs6snliFXjBW9w=w1263-h947-no)

I still need to do a bit more work on the con rod with some abrasive paper on a flat surface to clean up the flat sides of the con rod.  I'll hopefully get this done today.

Then the only remaining bits I have are the piston valve rod, and the eccentric rod plus 2 little fittings to join the 2.  That should all go pretty quickly!  Famous last words I'm sure.  Then I'll start to assemble the engine to start setting up the various parts and to check for final fit.  Hopefully that means I'll try to run it on air pretty quickly now!

All for now.

Enjoy!

Mike.



Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Admiral_dk on December 30, 2018, 08:10:54 PM
Nice progress Mike - the part looks fine  :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on December 30, 2018, 08:25:47 PM
Wonderful sequence on the con rod!   :ThumbsUp:




 :popcorn: :popcorn: :popcorn:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on December 30, 2018, 09:02:57 PM
Another nice and somewhat tricky part to check off the list. Nicely done!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on December 31, 2018, 12:59:29 AM
Just another quick update from today's work in the shop. 

I spent a fair bit of time smoothing and polishing various parts but I didn't take any pix of those ops since it was all pretty straightforward.

I did make the piston valve rod.  I'm showing the completed part since this was just cutting a piece of 1/8" drill rod to length and threading one end 2-56. 
(https://lh3.googleusercontent.com/A_wERsK98DqpJc_OOlkhaIH2u2bWAnBqwCIg1K_cdnQusOrEsasOGfFvifbcRv5ZaN0kEtSZHrld7htldJ6ZG6CumdAdq_aoOx8_sg0jPDuhxk7kpU_9TkVjqhQtOsnpQvdjWCOmPSe0F-X4OVubNJXDfwplCmhz4fP1Ln-5PQJ5KWxzS-2y5wS5BL47Y13XNRTzIlLbT9bfO37bvZezQM_VPdmQokiLe5VTidjKIR7McnOLNQHUk4Nul3EBPHpfp3tsCzNbIaew9NDTzmWexLUdkF3zMPkn93_Re5dUZyXFLFRaV14Ibjv0y4ltTD5Jsi5kRvDl0-YE553a02nEENZO51p_hu06H54cX9Njw6DCzRjXXpYa-3XGG2cAgOBLJasnEwyJNUir-rZ4on0J5KMdpVSBhfdVGtKpgAEO4E2VP-VRj57qIsdWtrG4rbdb_SORXKpNaHXbvepB5F1h2ls-71p-2rIhib6lNVhGAMWhyCiJSnv77dm5waCo_7K987cP5PdXEgfTVZ6m6lRq0jzOqmGO10g_BGiUVOv-XMwo72QhbxnIXTYKbbyGtyUvQCRBv_SDIifmlbvAr136BNR_2aHWXmdHBsyn88otpJ_E-enuEYcMLCHYNA25vDWUZhT3bPHweSibP3K8J30iFl9dYn5-B9jkdwSHDDI-SVKLVK6pYt0vWYcIgM_YLW9pjp14YRN0-9-bMM5xfA=w711-h947-no)

Valve rod shown installed to the piston valve.  There's only about 3 threads holding this together so I think I'll probably Loctite these pieces together after I make sure everything fits.
(https://lh3.googleusercontent.com/zZ1yJx0su8UiGEt1tU5KM4o_JMvxep46CsMhOi9h--ODYS5QEd9slRjtiKAgo8ReqF2q04s0zrO7MGYAJ4agyA4NEJgq85lmAr1rXwhYZgQqd1EEiP3AfDTlDRrft1fVmct5WDeYRisQrEIvUGWlaCjL70Z3IFvWTcbwAqs2Io2l0GmyXfiR9C3nEjW-zT566eDaLRO2BPdiQAQou-CVoToi4pqs1iQXq5KsOo0cuBBa71uaEhVBABnZKbkPIgvKNcL7ZZAzHdWdHl5MZoWZZmU_2fe-V7sMLcIWAf35krqoX9LTxplr-4GG8tX4nlBjePbixYThJtG5nEimUsJGQmxOKhdcRVTY7rfwkS9hyCtA73n2IKZInydtjulC1-zhZW-rjFM4b1ESRgPp7SAzLWAYA9MTxbm5o6koSOaUXFCZuFqYgX82rC9LaOhZzsMfF-UVnM0AnCA_pCdXWTbd_X_9CDMyrxSpNGb-4N_Aeezi45i1fOrvsKMGFkYyFxXmBSc5di6iaNZn47Bh8nA_k8VU38sFydBv6yJah_teDMCwf2e-sSFhuZd4vPI_xTGK5Z8ncxaPM1DZxLnrj4q3gIes1kCffsHPSqEEHW8dQd2s2L1qDavGAEbSK31mo1lHMTQAo-LUD8AXgCZespmBFvnJfnmKFCnCDEzCBhKJUcvRmyeILZRSKJkuB5ij-zdAE9ST5zlSJ5C83ZCpGA=w1263-h947-no)

And the last part I made today, the eccentric rod.  Again this was just a piece of 1/8" drill rod that was threaded 5-40 on each end for about 3/8".  Since I used 5-40 thread size here, I didn't even have to turn the rod down at all, just ran the threading die to the required length.   Bending to the offset into the rod was also pretty simple.  I made a reference mark in the center and then clamped the rod in my bench vise and made the first bend by hand.  Then I turned the rod around in the vise and bent the rod in other direction being careful to keep the 2 bends aligned.  The bend length is longer than the drawing shows but the offset is almost exactly the same so it should work fine, at least I think so!
(https://lh3.googleusercontent.com/8Gf97pVcOzbkJH0nX43KfgoKemYwvJ_PQnUQeiC7hEtHsgvoJbtXuFyAWaHRHYqb1w6ocdYeM-UubjOIb5OqxsXIhFljdA9pfZsNmx1EPbZoYC3x84uAXA5rBeQ9p-K1NTeGp7AAanTznJUmYIpahIYtOL5hq7oaWEWgACPj94pFfmqs9onJNuUXB-uO3jCmyOW9uFNT8ONSc5RT7B8pI3Uo97r5dvxAEvKmkLLUM8EqWC-del7J6NBAmYCPCP6mDfzTc3ZmLQjjzxSLpwpO4PXtrqTdd3-NRRSDO7Cjo4ZvJM6M8E7L4GIyVivHLOWzB2ItFGFRqXpzu9T843IEuweRbtlnA8t_vJTvlo-DmwVkJIyUFMOj6-jXsTqlDKdRU4-MuvfX2WmaguJiYMZrXf5hkQk-7c0c-GMvceQzXCrkJ-HSFXZ22-lEa11I6pyXuSvJbumt6fYdlGhNc5o8FzmT6KblpxJTFhC1nRaC80WFmX86XaVJfTgbYhs93nkMydzkryu75DCU9EKpwRSR5tgpGK7d498cZXjbXavJAIe1Rxl8pXkUZj7vNul_EDt_L7_KBDzgcdKcF71rWuPigNmR9hgCIxVG6ld8vfwJGHLJ7tgCowXZ33a2VePKTVVcJot9s5_cP0yrYTuG-mqAnumC=w1263-h947-no)

Tomorrow I just need to make the 2 fittings that join these rods together and then I'll start assembly and fitting!   I'm finally getting very near to the end of this build!

One thing I learned today while polishing and smoothing various parts is that in some cases I was too aggressive when deburring the smaller parts.  That caused a bit more gap on some edges were I think it would have looked better if the edges appeared to fit more closely.  This is an appearance only thing, but I'm learning how important all the details are when you're going for an attractive finished engine. 

All for today.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 03, 2019, 02:13:50 AM
Well, I've finally arrived at a momentous day!  I've finished all the metal parts for the engine and have just started on the wooden base.   That gets me very close to assembly and initial trials!.

The remaining parts were the valve rod coupling and the eccentric rod coupling.  The parts are very similar so I just took a few pix of whatever ops were unique rather than a blow by blow of each part.

I sawed off a couple of small pieces of 1/4" drill rod and cleaned up the ends and turned the stock to length in the lathe.  Shown here is tapping the eccentric rod coupling 5-40 using my normal process of a spring loaded tap follower and a small tap wrench.  After drilling to depth, I ran in a plug tap followed by a bottoming tap.
(https://lh3.googleusercontent.com/d8-rVkuSaJ1Aoitd80XOd9-fqBHJkGvoIqUZyW3sHT48Z_VN4FWZUraCjpl_a_fShLq-oRupJzwbSJNqxm5C9vJDUTbxSEXy778DfflzDbUqMB95E9h-8uAlYLjlPyjnkFRpxrzY8qVEhP8AdtRAaaoDwaTPEMjhlS0ZhajgofaK7WUG9ELQ6yod8GI-E3wKrV_Tyo9Z_9uVcE3N13etRWvU5ZJlZNwgUZ4GiuMcyrMC0L1qzpIq4bdABsjGPl48xCiMOM3YYN1we7q1WLaP3YI7gygxK9cv_EUAkC1dCJTdFNc41hpIhUQosFMO0SbjLORRLDGw2GwPrP9NRJqHLQhbpDlql73FldD1EXduPB1PArgGtrfG4I1X_JOFZQdSoKVSLq27MT-y6s1zJvyhJIbNZ8LIs7Y-YWMeM-Rv4Mz0wJer8Nyeaqhjt4-JrawWa02s8O92B3rPkejY1Tpuk3u_sZBcSinBQ6EsyliqHnkiB1loPpdD3E7wDWow3C9E55TJBdszsALazXaT1goiwsVwRohQxuy57Z1fMPR_pOJLdhue1gfdXGSVdG2fTzYBhJSKumHaO6CFX31zFBo61redafy_u7ar71R2AZkrbQw0aHMClznc3fl6NARa9F94VtgRJsJa72sE5jdTYI87_14yLmdBBU2DOqfoBWPjjpnFCwnkdM9P-DHPxPx5f6XcK_uCAe2MPxsplXHANg=w711-h947-no)

Both parts required a .136" (#29) cross-hole drilled thru as shown.   I put each piece in a collet block and did the usual edge finding, then spot drilled and finally drilled thru.  Shown in the pix is drilling thru with a #29.
(https://lh3.googleusercontent.com/g1YqLUSLLcACiz8CXScv4ON9hQKZFH1twCTgqSN04xtNafMsq5BdgI7VAVwgEQNPAKCcedJ0lIAYzM8nGGc6mXVVhkjPtJgOgIzC9jrZlwpbG232pVzGt7p2j78xlaxDqtinKmfGBNqHf3jwRAEczwg6ikwzXaO6ok9THwd9q3N_IVSfEKf3IrChGm8tPwWhARHiIoU6dP-k2cYrCm022pjlu0EbHrSdUay8ot_oTSClDXZrFpHOSMl2c4HCzL8MfY5rjrzGZtPUUs62gPtVYf4gR2J3TsEcDnFJLnPd5vA97al98oQfD346h6e0Tb_RCICjNgW5lD46lwAa0HmLCQsvHttqPON-mlLaqUg2_Ujk8ex2CDf6XD6g8WuBPnJGRZkvogPUa5s7U4c5JcGDVI7t2juROUE33Viqlsh9qTvIDpKc5P3WoSOwwyDLFWayLJkQkgG8kYTgfNeqIJ78dpbZQ8-3L8XmFmzZ8NDcpQwVjwwFluNqwl0TylNqmahH5GfBFvmLz2kPHB9WhahA2Z10kM_tAVLzTidYtbaKkU19qWREzSWpujhlMW1c5b5VdyGHPvtbsK6gfJBGmurfs8iX5AO2EeJ0OEFvT6fqeScfnwCx8KQzeTywtg7bueTa3IsosHzB8GDEXBFv9AvHwfMXFyL5a1ffFXLDhmssHuD2GApRZVLz3NdKc-jR4ZxHe0XgoVhPJbr7TavbLg=w711-h947-no)

The valve rod coupling required a section turned down to an OD of .125" with a shorter section threaded to 4-40 which required the to-be threaded section turned down to .109".  The photo shows using a very narrow .040" HSS parting plate to put a thread relief at the end of the to-be threaded section.  I like to do this so the nut will thread all the way on.
(https://lh3.googleusercontent.com/FLefNUlqLZ_yH40wjEJT0S5VRLuKcsYpbeah3mBS22pCSqmD-rWpRvqKx0ZAVH3IvxqU9P53fdJM9y_Tqpm28BY-HV5dDfB2HXX6LtchWcs51vh9aP5eUOKmHG1ZBzpVHdku-HYuDAh6KUkxQmJ2krMYOY59EHYVPikAXV_zz1CRb4ig5YLA0kF8v-C0CPq827LyOp9j3SeSv5Yc-mBfiL4hvDD4IAOw2PhMGoptJ9GdjzZkzpIJ4GWGfWO_ADte67u0g60s_RiYWQ6dM4tocAfCDuruOOYPVTRRKkavqXI2AX6XNvpMKTxcfybMxUSEoIaK4_JdAlMa93EhwIfpSe9m7kRw3b-9H_hzt3q80rRaySdKEPY_ZwIjoK57pu-ekv8xgsso4oGMuaVzI5XjHMPPuJ8d1by91LnG8dAIIvqylhMiounjVt_WNsqg4AfvVD6fQlmKapxkMSROSBahKbRapuLdMReg8LAUmvOUvTjAWlKMh8vyYC7TvTlPXzPTL2DQbaKROFU47NOygUXFIj5y101uJBdJ0WShqroQK6U1HIEKvTumfZSVNAr2rVKRaGidOg_nkjiQ4nudLcOiSpwh3QwhrHbDgXW2Xa6QkPTIfu2w3rc58kK4yeC1-E0OATF_K-NakW6ozWyl0uj8bWwA5slXZ0U6KjFZ4Cse_y2EjoQ1sQE8TUJy4OXdDdilVP9Q-Mdm3SWWccFntA=w1263-h947-no)

After threading and trying the 2 pieces together, I needed just a bit more length to allow proper fit.  So i took about .007" from the shoulder using a 2mm carbide insert parting tool.
(https://lh3.googleusercontent.com/NMq_IZ1OGS2mDZqdcJl_6vIr0beR-oBRL4-4ALhomg36YfaEU9BW3g5HbHbc3-o2b2xcRK9KwY5zwBaL2_BXNoh3RHCCEYmRErTKmh4U6yIUnx82Bh--rTgFI0n4PmJj0cpr_xmQDGFTTG_jkb0I2pzYCU0xSAx-Z2_rsYKurzcSftMO5RTkhBv1botPNmu5KM_wrDMVdEbh9QovY2IIvAG_aZxz-RI6HwWVLX-te-_MtSpmMkwQ2n4IzGc7TqA3vblGJLshXAsvvgUuPyoTywiKoEiq91uSLo9PfvTU-Zixhegfkox49ToIrvOlpPH7QDHLRS_-O22Gcx6Eipg6IPrBQIoObzbcNKCNZ0EDEDRFObvk8Mq3kw3zVVOfni1tzYcOSAN9e-jJZt7aFWI_sAeQN6WhUrklY9bTiaX8yrQGWOApRvFr59oZxLtDb73SVUie-VZcJcLk4vU7Vy4gyJP4f_do1PhW4irUhRLFtlANgjZ4UhgxCDNjik0e9X5_CejiPT5aJiOg2eEooOQXsFJfRXbwnEJDWMjDTWymOwDUeSD4_BJCyZjPw3LU4ee5Fn4hwjzIrKFNZ-tgnZZWj-47S-OReWZHPXRTxpNX8pV6p6MTl2riCsVZgf8V9OIY9F9Y49aT4Nno0dFd0yEt2XjJRNGnW8ncNFSwAFUB9kggI8UQQJnSkX6KnpO6ItEcLdgAShd02gA44aSXIw=w1263-h947-no)

And here are the last 2 parts completed!
(https://lh3.googleusercontent.com/Rw8FwtqwDf3ypJfw_9EnhJWDENE1mSQzUQureLruLLrjdQ0URjkBjNkadMLGfkV3gsAanSvvyL4BUXJjs8BrN9FE9HGWQ_fvDAMkWmywG1IEVbKriOXTCXpcEhzZ9shytGo9zuvmIxh5Z-RBfselemHlpSu2KlXkQTNfba6-U6KD-ig0CLmj6X2kgz1fFPqfsUtp_T923pKcqQT0CyXixkDciIB5W0V4lpMzNnTjn1j6vBY9YJTKbRWKN68f7okfqhuGt52-ONncXcFxODj-8gBFX23Qr7OCnpgniDhSLWF8bkcIqw_eFToa9I3U0bRlsDahHXMITDw8n8kq8_VMn5yYgketb5jqNXvKycokJ1DtgK8WO76KF21SWZ1g3djsRzeNleVtwlVm7AX8yxPtVXih9HAy5d6FLmms07qcnqHbwNmcvfKRZmCkvvfGxRwGCWCQjV6Q6T4uNNaHVCVRzoVw2Xbm6F3sdWR_7qk28CHXj53lT42I_kc8BkSJ4x-NWSZi1BdCmC2EJJYYYGkK9cLjixv6KJwn_DnL-bQV2QUjLpx0hUPQJyRA66Zk5hStnE1J2H_WfCDePn5yZsG0wO1ua95uxFN8zenSj5HjxMgbIkk2Qg-V3zDOmzlXHZ7-e89QFOGqiBqD39VQQM8l-rzzbW8SHpF1jQYRyOfAGze2PIdtkZGa69EVMj-pGuZ0PEVia1Mq_xURmOe70g=w711-h947-no)

And shown assembled.
(https://lh3.googleusercontent.com/jJgJWwST3ndfW8Glo3c9_JRGyj5rqxX-uPRuiJzuGbdxi1kG0JFDC-AVBKmXH9y_8Q_hup9UJBAgS7CaJ33MpVlJnDqmZARTREpSi8O_Zw_ZJJ-dkQPmMaHeAaRkTzCjIn95VjidOLrt3d3aWjpcbC2INTDHZvkd1TNSrrfFqutGZkAzsIGNxTqiqWldT_ui9Pt49aFqrVlMttwlScj7dSSfJwAPHnJ948it0Hxy7yfUOIoMmsDXtTFNApv6u_NRb55Pdf3MdYD7vxwqNMpX32hKJ18FJnApkJvf8JivlBxW3LMiUDf6wHz02vnMVcY86aVdyhia5eqvsVnD9OYYClPJ-p_k8sC_x_CLADSU533xtHw0mra63dLLt58s8tjZSowOmHN5cyD6hA8uO0AerVZuvdfIyYNi1zV7uXkrikC9CWqanRHZTqRFtOxcuR8YFriDfgOI08KUgN97OObG-Aa3BQoKQgrbv4cJDxZAJcJBYZ7nj8-1lGrlXDJihi0BpzpPY_TAkeqZX2c33fiBKj3D7ydzOAKalYqP4w54Ye-phAk3bG6ln-YNaxSEoBhL0-uf7k7mJ0DcE6e2TI8fZd8kMmUFFRO_f4T27ZLX6g1SktgLGERlWuq5veymNYn2mTxWjYltG4j7ot3OnkQlwH2d8E_GT08nBlZfJBvy6vMM57pI1L5sY0HkHkxgUD46JcPIFshWfyVlmpfK2Q=w711-h947-no)

I've started on the wooden bases for the current engine and my previous 2 builds.  This wood is pretty special to me.  My brother and i grew up in western Oklahoma on a farm that had a river and a creek running thru part of it.  My dad cleared some bottom land back in the early 1960's and there were a few walnut trees.  He saved  the larger pieces and had the lumber rough sawn into whatever thickness and lengths that could be made out of the material.  He'd saved that wood and after he got elderly my brother got it all and put it up in his shop.  My brother is a very skilled woodworker among other talents, and cut these pieces out of that old stock and planed and sanded it smooth.  Shown is one raw piece with the other 3 pieces having one coat of boiled linseed oil applied.  The imperfections were chosen deliberately, as to me they're the best looking and most interesting.  Over the next several days I'll put several more coats of linseed oil on the pieces.  I think the engines will look good on top of this wood. 
(https://lh3.googleusercontent.com/KQe3s0RFKkiV8dbW0zvsPNSFKCRrhLNXPBG-SstwZcNfbdGuB3zYwli-86ibRF7luzctNGuRvPO0xMbpCQzQHiICLA0YZMXglO3ZqznJpGs5VhYUhgJ7jpPn68ONMaM8Hu4nnatB_uu0QHXgBMJfg0a45wVUytJqGIi2b0klvpR56yC5Xse6DQ-thhg_eYJfBZkZAiIBVXEsFasKVKnAYZjv8pfNoX5YZo73eFIJyDoffeysRzu00KYJ0TPnt8SMX4FedkoJrXCL3GXqDPj1ST0r_RAAFoQOjFcl_ml7tONeHmGG-soDIs0XbdKT8f08uiNB7aN5DDc3FgjUCWwbmEao5AKvEn6q3FnJQEoYpL3JsvPWfY-3XooGx9CIDmW9aMyjBrPV1MrrEdZKBbdf3nvz880AJ76yljHtQPxEI0LTRSqqsgLk6H2TdFnaWhvZM0eTwO0kuNGTZrs3Ru6t3OLUUGTTYRnV9PK6GAJpnpj_-K5yBlw7dhsDK27a4yjCC2dlrZUiXs4q3SP0Xovf7JGe3mbQL6YuDPZOQ42Ba6yHviYFatZAaUlhWK1DmoahgF3C9rmoiYYDmOp351Lq4JUEUAQeZL_CABcEmanLK2nUsUT5MA8kB53QkzvaP1UdyVnE7mCTrsrnBDDzOL9QCDjqKY8I-Jp1VNXxwL6Q59hSDdttSM5WJVQouElbuQ3NdfvlslYQT6kXVCkznA=w1263-h947-no)

I'll start assembling the engine and will probably just take a piece of scrap 2x4 and screw the baseplate onto it for now so I can assemble and test easily.  After the walnut wood is finished, I'll then move the engine over once the linseed oil is dry enough.

All for today.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Admiral_dk on January 03, 2019, 01:55:47 PM
Beautiful work and wood too - I'm sure it ends up being a fantastic end result  :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on January 03, 2019, 04:03:03 PM
The wood is beautiful Mike. Can't wait to see it turned into a fine base for the engine!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 05, 2019, 02:26:54 AM
Well, a long awaited day for me finally arrived.  I've started the assembly and fitting of all the various engine parts that I made over the past couple of months! 

Taking pix of the assembly and fitting process is hard as it's not really clear in a pix as to what I ended up doing but I'll attach 4 pix and then try to explain where I'm at and what issues I've corrected so far.

First pix of the engine.  It's temporarily screwed down to a piece of scrap 2x4 lumber so that i could install the flywheel and easily rotate the engine.
(https://lh3.googleusercontent.com/C0NrjjBIusLmnymTATqK88mNiJorijIp-jGOBfLOjf3t35QbY94gSmFMAeRMvxIZYILPwrlcnnM_Z83CTXiJpisqgvKpauRGQvHDkQgN2t8izoTiLjdPOBpmFLvSS92MYr8dxLul8h_t8ayd2t1zHeOwKJv0tMK-lXfd-eysUNO1ztPc0Xlzx0vyiTpV2-UtxJSeVjoCHAjotWYQZ1LT-M0vl5pOyCCxGs64uR2mMMIJpRMAHH7RJg-KT78wxT2WgLG7y9UTS6VEbCDFB1vhYJJTF9G93QIiMbM-ccM5mByks5ImoavfIQk2dcShYRlU_6qb1EKOrewDKX_P14D1ybUuwSWfEzHRqot0rbtghzmFbUVaWegnauHDDlPCo79Oa4gIUXuLipeY18XQqmnoakKBOU3FkmIbaQwL91-YZr3t6AmmrO6mMcIb3EVCntCUYYbv4srdES0Vf-3g6ST03rhGVNzHZet2EDnSl8zqPBh0Y9A9COyto6AH2A-fhyDMWlcK0AK_AUeJ4tHNkKtjLTmQibHvtXEyH5HkrW3RHz44mybo7gadXVs3ff8nc7UfmobHW0ONCIVc9wBlMPzwS_cQGsoQ-cSXNy7L-yL-p5BgTyZsZR-xLsO4XTUO9B8fIR7wM9csyPVzQkwL2P7ofOLQFmXd4gC13ChYPLi4obP_htEjyVqFYjj5NXKfS4nOAOdSMXP0jDSnSV8Vlg=w711-h947-no)

Another view of the engine.
(https://lh3.googleusercontent.com/Rwp2gSTyhphc2Zq-sqgF6jvk4A8-A7VoHlX79h0ZmSU1W9gIUle3SFJDFL9_QfffuH4nvqgJdPTfUyEdpd3Swr2IG4NLi5YmiRUawzaaanofM0OlS51AOOO-d-TM9J0NPKYkS7E2tKTGfn57w2nAZVKKN7dZkgeZzGpzjbPiZw1Gw07V7DjzqjypOJDO9iFmBytOCj54u6DZdwJJWKR8lwIngUo8f2t4ck0de5BiBIAMAw8xT63MXw0vSIXc9T2IN5ZnSXZFsN9nBJlSXOwYZtAT49bZ5W3gW7selcPg4WnTfz7Oq3YG_WdGtneYJrJZFnwh1AB-ibkQZoEloFmuq1MiWtNbLF5SBKpqCjCLmSsQ2SSbpIIUTG409-TzTYuCYaidxdRTviTAb9rf1_4LwcEH6JB27CoBxW-x2AGqIeGv5obyTQMw8HFGd7t5yYFqbLpJKIOLumNXYvVuLTW1SgbB3NHRilcUozpxQyPTEA2O1ReyywyopElR3grsDcWL2ESSVgnVCvdJmhHNWXvmLIrTq6yOEJFtfJiEsdiko_ZJeYTGG8dAsRYlRXIuLK0O-QkG09ACovLdiXY4Tkg4p-jt-5-7vs0nPJOa3tXiW2XwCFphxr7heYcTStAH6OQbGNJpUGjqSUz9qvBM74Mm__DXD-RWFYuG4ulYIjcG78vkSlcCuYVDT5CIxJUlklDAngbuRE9d9SxqJzFZEg=w711-h947-no)

3rd view of the engine.  Don't worry, I put a brass washer under each of those temp mounting screws to avoid marring the base plate.
(https://lh3.googleusercontent.com/NQYRqnkz37EbSZ1gWR458ZjVXFiynHbge44i6MuTdurlKMFXkjJtiYFiWEeBU4o1hZOJqwJeRZ2fbXtYiVybDKsibNuu0_OkcTkmoM9D11dVFUibkWs8xrxoOa7ne4F96Yse35SX9_K9vKaGPeDGRpXDo8pQ_hHHfVqR___m1e4yC8zvnWJ9e-yn7_6X3TfQi9G4oOLmqu_M7Yf0HiUVVdsY-qR9E8_-IdPHeze7M-ssjgZTNNqhUC9pY1NZ4dl0ghuopl3P-Q5bMGTYFqK1N9BgNpUWcPH6r-mriCyr-M72NfWfBj-TnQdGXY_L416YPuNSWu21B-HTVmOtQde5Uv9OwLVSaUJXFlDTyQgkWaEY9tWpkOw6hrAwhbakZ7M-m3C2HnFdI3Cg_NXrYy2hfWsNdgGJm3tDLR5ngne_l5ynPeOlQz8SMZxb3ien2yOj2nOD42CCvsvMomWS0fOm1wGp4l8aT5jUuxgQVTBPFzm0S2zocCHutrShIZN6neg4fTkaQItMvlcs5AonGkQD5N18390mQiwuPnIwsPot52XsPl-xad1gZq18EcTAnGrKPqfdRnXjt1uS9lE4H_coQ9t1mdMCwayz65y3CoP0Fr-CLu77c6KbbqMXrZ_gn6p3PHPFiK83YG7yDmIgHKEnYM59JxwV1vhHX5pw2fGqyjfDnhAQ7Cox2YKqMvFwtcRHKH0sjDy-J1eZTCl3Uw=w711-h947-no)

And lastly my wooden bases with more coats of linseed oil on them.  Just a couple of more coats of oil to go on these.  I think they'll look good against the bright metal and brass.
(https://lh3.googleusercontent.com/n7leh1Mt4AX7x256kgM-edsm6vKJpjGKi1XsX9IF1fuR1DGCglJAcc5L5awC3XV2-9X89wf4qmvUhLYvE7eQ-HmruwUzTXT5MDuWbf11cH3MMvDr9uGjBN58w2o1LY7lrP2H1oZFj7G-s6WZLu7_A6s-X43D9tswZIEGpaYzLncyTTPp0LXEKv0Rv7-15Tue1HGqQyP3UCuMdZFDn2shEAx-nb3l5hBxccNgdhpo_ZksIyHdQWFDXlwf20woKsKihglX12aXOoLyySsm0QzAoYNxoo41NFM2dQ92fHaTYugMRK9qYag96ct0JguFPyvy03YCkpbHRyTmwqGhg3NHxo9UGtLgKIKx4BxDtq2KGCfMB8UqilPIyP87H_XNpBGnz3IQqPsKH9c4d2lWj0b8VsUSMMDSwRMO1EgiVgzf6QXAnEWk_ePmyQA4MDj_1UgADWHBsF-guw5t0mRju72IKcyYShvMLe8orXg91Ed7OOMINy2BNG06qmx8ww97hGaKaiSK3L1oZdPFV89cjACZhMO_-TGVrGeYSV8wVlaYCqEFZ26wwEu6R0NZixEiq6i2bqzCzyEAVoHndGQ3rE09J30OrOV8Dey4UxhiTkRbl31Tdzu21daG01z1-bf0R4ZBbGaydcGft_6ApMyCVkcgVkijjbtKHUKWrRAHNsWnGSSkzjurNeuxrOSadnzAe6D_NfUROnbvc8Dp011RkA=w1263-h947-no)

So what i was after today was to see see if I could first of all get the engine to rotate and to see if the piston rod was the correct length so that the piston traveled equally to the top and bottom within the cylinder.  There's an adjustment on the crosshead to change the travel if necessary.

Here are the changes that I had to make to get to this point.

- Had to shorten the mounting screws for the cylinder.  The cylinder was not secured to the base as the screws bottomed out in the cylinder before the cylinder was secured.  That was a quick job with a collet in the lathe to shorten the 4-40 screws.

- Piston stroke was luckily quite close.  I maybe need to bring it toward the bottom of the cylinder by no more than 1/32" but I might leave it where its at.  At most i could move the adjustment by 1/2 a turn.  But there's no interference top or bottom now and the steam passages top and bottom are fully exposed at TDC and BDC, so it's very close. 

- The biggest problem was that the crosshead and connecting rod interfered as the OD of the con rod touched the corner radius at the bottom of the crosshead.  I ended up taking it apart and lightly filing the radius to give a bit more clearance in that area and then it was fine.  I was constantly recalling Stew Hart's tagline "A little clearance never gets in the way'!

- The crosshead slides and guides fit well and they traveled freely without neither excessive tightness or slop.

- The con rod fit the crankshaft well and wasn't sloppy or too tight. 

At this point the engine can be turned over by hand quite easily and after i oiled everything, if I quickly turn the flywheel by hand, it will coast 3 or 4 revolutions before coming to a stop.  So, i THINK this engine should run on air once I finish the assembly, provided I haven't made a fatal mistake with the valve body / piston valve / eccentric assembly. 

My next goal is to finish the assembly, get the timing done and try to run it on air.  If that's not successful, then I'll attempt to fix whatever is wrong.  If it is successful, then I'll take it all apart, clean up and improve the finish on some of the parts, paint the flywheel,  and assemble it onto the finished walnut base. 

All for today.

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on January 05, 2019, 02:56:00 AM
That looks terrific, the base color should look great against the metal. Great job if all it needs is that little bit of tweaking.   :popcorn: :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on January 05, 2019, 02:52:21 PM
Just beautiful Mike. Really looking forward to seeing it run for the first time and mounted on that gorgeous base!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Ye-Ole Steam Dude on January 05, 2019, 03:55:57 PM
Hello Mike,

A really beautiful engine.

Have a great day,
Thomas
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: J.L. on January 05, 2019, 04:36:51 PM
Hi Mike,

Beautifully done and the construction report is well supported with excellent photographs.

John
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 06, 2019, 12:36:20 AM
It was a good day in the shop today as you'll see!

First, i managed to completely assemble the engine with everything fitting together, eventually.  I'll show 3 pix of the fully assembled engine first and then make some comments.

Pix 1
(https://lh3.googleusercontent.com/p3TSUm8LU0-28xRavl4eUtYoY09TZIlkx7nAe-zwubXERxqQ_dV7UZCfczGzifxXmfzIDDnTqVdvsNj4VsUK_Fmb4mIlsgzdieySIW3xvaFdVkO3DynfsKhfr19zBU0FAi9aFggLD7qS-NqXOcDI4EH1ck3tTrqzP22cC5eeO4nM9MWJBqMDnKG8Mf8NbrzlN7ONhLKjQDyhVPc0LUfC2ZLHX0QjioI9z8O3S3INca_V0pIy77jeWPkYiDa9GO1tf2PExg2f25xjgiCK47jEAu4HiR-eeGJPML7SalKMZHj-fmUsLhv478REYq4u1U5AONNaMTePcQJqvAjLMlfyDrCfx0c2eUdKJutr7R7G6Vlw8_f_Vyb1NUHqMgEX9bT9lFptO385i5dyfLVCStINZH8fCBzZvvw6Mmt4RQDCNonG12_iLGwnB--Cm9QTzumHmz3MatGqRe4psusFeQFp_WFfgGTd6sMHlDkxcp5tAeTJwrEcI7N3kyG0dCQWD7nr7WmSxJnwWWCqog6TQu1geOooxq70G2H-NuURneruRwgW07UlX7n5wahpOu0pGtDN3_7L52pjAVUqd7rufqmzlaMjHqQCppW-cXAYFdig4I0aq6kDBSQwPWC41Kykr8x1o_OjvqyzBDVTdVLCCA05Ifb2=w711-h947-no)

Pix 2
(https://lh3.googleusercontent.com/iu41p7QJ7Cv5gfNcTAbdeqL8IaQvHHUmZEQkIIEVARxQwSVERRRYqb8aYIGgXoOIIHs2XiHmnan1asjWetiWAITPZNrdfKMA8HTttV7V8soRm053GXO3Ja_BP9WxHVKEWWaC4mNBYM9YSD5Nb3DE7qtDFawCOTG_6LDIUwk26JVVRzAAXjJupslSAuLpHlRdWPtvEguuVgFXDqXI8T37C6Y-fIhPSQELakLfqpsYqkTr1f248mnSOmQnfKjicQ7fQRTfkIJAMX6AF7eShLBOiW2RVWMgJ48wh2XhEEzOtzdQ6JMLeFUnF_zpp1w2mbiGeLMQpDvZkOasKnUkfs-cJ4z1Brmh91FFCfc4HR0157WpDBjIp4FIe3y4SpgOfVGQqRKepcxiHCEB8qXm_FTDMEOwZYpRPqppCZMpL-G7Kbn5L5E5xTNp42b5Mq8bouuzabWKJSVUqIaGuAsqSI_K-4eMJM7OMRIuGnWp-ni6QY7SJ1ZRqeXlCEeCtsSNxmSWXLwVmNsefxFjB2kKbV2bqfcAWCW8_bM9-bfw9yAkRxSGgeUYQ3GAFVIs3RIdaPB2d-y2g1yq2nuJKT1_7Y3iTfyCfNxgHileijp6EecKFrLuaJIj296GD_gl2H6qOZ-AWJwaHEin1pP3suEleSCqEVK3=w711-h947-no)

Pix 3
(https://lh3.googleusercontent.com/Fnw94Mm5qk9VIGa3zkmleBOdbRqVBsqM1889X5dTHiDtKXJNg6lgV6OvsLZBF582DTsZ0QQW47tpV2WjZRoqIRY58VQBbV71yKN4ED8bkvyXBbUtrZwLBkMu_wQ8f3C-PVNhYUR45_kxQSET65K4E9hYQgJwc61sATKGogEo15k9GY9mtA8aMDA-Tgk4mj6-U3pVHLV19oFp8b_Txy6ZiPBToEvCMlxdXNWYL3G9e7QR2mnyBxy3RHU4Y-NE8pijCUGaPSF-9xzgsntI50LOkzYv4liH3VzdMEWlYlaZmwGMIRiEESWDLRlHq2EVLpsI-lPDy9mJcrxmEJczhPfDcAdvtQdAduG7-vPmXHgUmxzm_ElT7GTLul6D3T5D_Zyt0E4V5RWRzEWfyI6HfngRx1Qo5eIefzArwWnvV_bxzHSUFEmu79YyCePQz10ej_Md2Wi68CdZj0qZZPHFV0Vq-F9fL9yNN_evGYblpj9xABb7N8e4gCGYk6nfzUlM19IZp0aKGcmLkJOWhe2kRvEOWEo1RU1-iyQtkalhxH-UQU2cf1h1p2exZUqEGhN-53z67RZNUmU6rT89jwBJPeqsywqzsOGZXbGP1BhRpjk8jROuRSNztmxFhTA6X8OPQ1x1AQPg5MincODuyETN-ckMATS9=w711-h947-no)

The biggest issues today turned out to be the piston valve packing being too long and the eccentric rod also being too long with it additionally being bent just a bit too much.  I trimmed off the valve packing with my belt sander being careful not to take off to much and just hacksawed off about .20" from one end fo the eccentric rod and then cleaned up the threads on the belt sander.  After those 2 mods, everything went together.

I then spent a fair bit of time getting the piston valve centered and the stroke of the valve even.  This involved repeatedly loosening the piston valve coupling and sliding it up and down until it just cleared on both ends of the stroke while looking thru inlet port with the air inlet fitting removed.  I could see the edges of the piston valve thru the port so I just made sure that they were equally visible thru the port at both ends of the stroke.  That's a poor explanation but it's pretty clear as to what's needed when looking at the operation.   

Then I adjusted the eccentric rod length via the threads on each end of the rod.  Essentially what has to be done is to make sure the piston valve moves equally on both sides of the inlet port while also not crashing into the external parts.  It turns out to be pretty tight with only about 1/32" clearance on each end of the stroke between the guide block and the piston valve packing.  But it worked and in the end was just right.  Then, based on Stew Hart's original drawing, i set the eccentric to 90 degrees lead with respect ot the crankshaft.  This is quite easy to do with the eccentric design.  I don't think that I have it perfect but it's close. 

With all that, here's the result.

https://www.youtube.com/watch?v=d2xRVH6uVUY

It runs!   What a relief!  I'm always scared that I've made some horrible fundamental mistake somewhere along the way.  It runs quite fast at around 10 psi and will easily run smoothly and slowly at around 3 or 4 psi.  I need t to rig up a better manifold and lower pressure, higher resolution gage to see where the pressure is really at, but that's a task for another day!  The video quality is also not what it should be as I just quickly shot it with my phone vs a proper camera plus I very quickly rigged it up just for test rather than for display. 

Now I need to take it all apart, polish things up and make some gaskets for the cylinder covers and the piston valve chest.  There's clearly air leaking at those joints so gaskets are required.

I will post final pix and videos when I've got it all prettied up.

All for today.

Enjoy!

Mike. 
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on January 06, 2019, 12:40:55 AM
Congrats Mike. Nice and smooth too. Going to look even better once mounted to the wood base!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Admiral_dk on January 06, 2019, 09:58:23 PM
You should be very happy so far  :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: scc on January 06, 2019, 10:05:02 PM
Excellent :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on January 06, 2019, 11:27:22 PM
Well done Mike I new you’d get a runner. There have been a lot made successfully so I know it’s a robust design.

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 07, 2019, 12:15:27 AM
All, thanks for your very kind comments on this engine!  I've still got a bit more to do to get into a finished state but I'm extremely happy that it runs!

Stew I have a quick question.  I was busily making gaskets for the engine today but I realized that I hadn't planned on any packing for the piston rod or the valve rod.  Do you typically use packing in those 2 location or just do without?  If you do use packing, what kind?  The traditional graphited yarn or twisted up teflon tape?  I'm just curious if I should install some.

Again thanks for all the responses and compliments!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on January 07, 2019, 05:14:27 AM
Hi Mike

You can use graphite packaging if it’s too thick just unravel a few strands or twisted ptfe will do I didn’t use paper gaskets just sealant

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: kvom on January 07, 2019, 12:35:57 PM
Great runner.  :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Craig DeShong on January 07, 2019, 09:51:19 PM
Runs great.  Nice job. 

Problem is, once you put it on that spectacular base no one is gonna look at the engine !
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Tennessee Whiskey on January 08, 2019, 01:06:47 PM
Excellent Mike. Smooth as silk  :ThumbsUp: :ThumbsUp:

Cletus
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 13, 2019, 06:29:54 PM
Well, at long last, the engine is finished!  In this post I'll post just a few pix of some of the final work that I did on the engine and then on the next post, I'll put the final pix and a video of it running in the final configuration. 

The final bits of work involved taking the engine completely apart and reassembling it, this time with gaskets and packing, painting the flywheel and some additional polish and cleanup on various parts. 

I didn't take any pix of the painting of the flywheel, as it was pretty boring, but I'll give the details.   I washed the flywheel with mineral spirits, dried it off and sprayed 2 light coats of Rustoleum filler primer.  Then I let it dry for 10 or 15 minutes and sprayed it with 2 coats of Rustoleum Hunter Green Satin.  I'd bought several cans of various shades of green paint and my wife chose the Hunter Green color as the best for the engine.  Who am I to argue with her!   I masked of the rim, but to make a fine demarc line between the paint and the polished area I reinstalled a piece of 5/16" drill rod and chucked it up in the lathe and then lightly sanded it and then used a bit of grey Scotch Brite on it.  I think it came out OK and more importantly, my wife likes it!

I also didn't take any pix of polishing but that mostly involved sandpaper stuck down to a granite plate with 3M 45 adhesive and lots of rubbing.  I tried to touch up the crosshead slide bars to make them as polished as possible and various other bits just to improve the appearance.  At the end of the day, I ended up with about .004" clearance between the crosshead slide bars and the rails.  It operates very smoothly with no binding that I can detect.

Finally some pix of how I made the gaskets.  Since I had drawn the engine up in CAD, I made fresh prints of any parts at 1;1 scale and printed them.  I had some .010" teflon sheet that I used as I wanted the gaskets to be quite thin.   The first pix shows the spray adhesive that I used along with the teflon gasket material.  I sourced it from McMaster-Carr.  The 3M 45 spray adhesive is fairly low strength so you can peel things apart if you spray it on lightly and only one one part. 
(https://lh3.googleusercontent.com/--Sd8cjY0tFV0ZWr7J00tYKXd-TleZetapUzEjO7IqVxgQUPzU-OTSxbUKTYcGOhgrlAc_Zul9ioVKNk5uhIoDYvuEL_JnlbQzVAU4cuPCGBXiVJnsw0vOAwIOeV802X2shnGY1MS0vyDTMxuKjNvHBAKp201K1457gYi_aSIBafXr-ZPGkpym3PGOdxOIykTO3bBgte-ja4cA9YuVRBt_0pThriVrfL3rOQWxta2u_MUw-kQNPr5Z_3zJLZ1nNHf2TG2pJjZC83z5eihhpaiab3hzxWnXLAHlmNB2ghjjcaH3fh0lG_Ui3RuPgaTmKP5LNVnaUk8gm9yTJIRuhm8yc7wX0hQrO1Ia-1ZCQh0tF7Oab1-vWjOsieDLa8v-tuVl3vtndacnHiMlePvBJkVHlupQbDpeS5PIQAJ8x-HmHlEKi8sNH2UOMUlG2YsCWppEV_DmKkPW341-NG826ctFPAkXwqY1u8Fi__lvqszX9U1tpbK11u57rJrkrMHtqMPgd39TaYg00K71xuT7TNnxw2ySkcbxN1m2OPYdXZox5QFDaK2U4y52O7X-CELlp8qCiFx_PYAC7TFE4zxJGH3OV4gBiNoS_B4lMiXegDLW4BwAcjdheM4_74oWPmqy0CeQDJqs63Z8k7IsFThHn0ddY4rnmt862caubNAJoxriYS32UQWmv5VxR7cRbf-Q2bzBqhFwS1NMpsYLHb0g=w711-h947-no)

Once the print was sprayed and dried for a minute or 2, I cut out a small piece of the teflon and stuck it on top of the print.
(https://lh3.googleusercontent.com/NZkYwGzs70mnINR4jf7xMn5vWvxLT-tJOQftf2Q_jDpfmbj74ndi8L_y9_cUP2smUJbOh2NCCzOA92vh2rLZ88r0Hhh5QSGOfWLEwyTIt1IqqKA72CH_Cfw08VsMLqGBDD3hlcUzIrk-KboXhZCj_l4ByXi3G1XSlbpjuGZ8KD7bizdp20rLfmPN6Syo6rRbuPQmv4jDansVEWHg7BY5v-6PikIXEGjctFOP5S-7cd5I70RpC7tn-LSocpEs67j4NgD_rCg_fyDuP0_PKvBKr2kfEcgjvi8IGfRZmqRHXCosxQJj8b5XLo3JK0HwxVmaFQpX_9jEDBCU1E89CTjoVCSbaCstbnT0WpwU7mIP1TYzXiuf0Dk0MOxfqXPLS01_YBoy2siiIlmh2WV0_ivs7lBynh6i_kEYDW2Ppqhpxz0fCW_3GEQlrKVClTUWnu6Uul2OsIiZGg8IUxNA7Uu9zmyM7vu5u0FokTfH0Ou5bIuB_iZ0TF9DL9mOvZU0N_ytrHsE6IOIcLkonaPZ4wXvtYwvToJSLZkdXDpCnJa6rR1AXCIOMNSh0w7XiZgzeFKxj3iz45xnGUCbuBgdic_t7bVsw8H-OFoPuK52IFHTUExOGJfCzP0JIi-ozJ0HJlQTBcoDexd4v01J96xyxzxwo2XnXZG6y559QOar0uDMPjYClrsPDgJVwmJUyV4ISIx1TSUQNqdHjMFD-6g57w=w1263-h947-no)

Here's a pix of the 4 gaskets I needed 1/2 way thru the process.  I just used a scissors, leather punch, and a craft knife to cut and punch out along the lines on the print.  Its actually very easy to do and quite accurate.
(https://lh3.googleusercontent.com/CGHbV-GBWS4B0-rB46ElcHVIb42Op2cT_UVW2AUMyUO4NcI_QABklcnjEEapu_qq97gNxjWO2r9yhBgahnn05SYm-CEe1lr_Vz4XzPzgCOAfBpsM5ERsX__Q3P_jU3VRDUzWuXyDKd4MMk2Bgu4ikRJ-eI04AUBVbisMSHhVVRbypoLJ7EurbZMj3Phr8MU-NiYlVJz7ovuP_qwuRY9xUJxgUIzWMdPJ7dPj-N2z6f3KILcIzXjJMuSuQnyCZDtCfTxnlroAGpP6o04KjhwLuLEIGZwtJhlK2UPjqWoYgY9T1vwkZa3rxV5U9jhZk4zP1gMa4bUu5n-hNkMn_ewC3GtMKii6GJsyI0zZWeGhVC7Gliy7xdWKW3eKoOcUBDWPRXpCAImsV9nspN2A1psGIBKXlWZRLvM7rImeHepIJ_ugrQNfLRL2W_sEQz0tPeA4Ay7RHfsriOCo9GmOYzL10WE4GOooDBax52dDglvKP6L_YO-l4SJNmZHNDW5xnxn07jp5JZnC2lZgBpseMUG8dE58UO4a7ah9XW34NJDNnCx-c_62CFgF-9IBXNbxzmHd467mqgnI2u-wk8in1BKDKA9B-jwrP-307oqhLpOs3WpCErcCyz85KykijJgk6WsjdzouJxGI_Fzkz9Gf3pP3jYs7u3gJox0f0lMJtge1H3nH1z7eZr1cfofaY34AVO9QZxwi7uyCDeL8NiITtQ=w711-h947-no)

And the 4 gaskets finished.
(https://lh3.googleusercontent.com/ireyVZ09r-j14qZQ73nhCDSc-F5PnPmHd-42ryosk8HWgANGu_K2VuYLIFqj_0rhQYJk4i06KzGv22-4JhMnVb2q5v6RwK7RHQbIeRVy0iPjNz0H8OKkHvj45vU1447AHMcOoI7dih_eCupwqOWq_FliPHl12iiUgskMztwxz7JG2dEx_BpSwt-ysbMYx-NQWAgiRMftsSeB1RcijNf56-OX6sUD3L1Pu2c4pxRDSKdJCmTE76AEqooq4zOT9WFZ9iI9Y_-n0lfbTx1ivxkpD0dOd6QZcVyVz0LaaIEbdYWNo16gWL0dz7IDYquP97A2yuoQI4bSGFRqtaPmZpEjN28Hu8FPQgRQe5PJTNxUmI6fwmW-aXCGu_vme04VOENbMAVTi3AHA_tw7hsYF2FkIW_8o__XbWDmGn39Gh0qousVgcPgtaF5Qlks9yNh0deo_07jj0o_jwAvAqvOAYbRIJlJnq192iPjifrwJS10FWXZArKsjduMd9ftCRM1ORe2m1T1yrxeoR25Mu-reNiCVQWJyXZ9BZK2_hQez3wYEx5khNJKOoc3v4E1-p5uYUF18aSd1L00jvjo3OSW3xf8ewdsLLKihNotzwFNk-VPFAM-khBC-6Db3JIeqp8aCFXmS-PmrEWG1Jl3P-6XdMwWQ7nBnm-4DZzBr8bveTWPB-Q6ZGp5iU5KXEEyQfV3cu2l8Zbaouo2IV2mtMuZ0w=w1263-h947-no)

A single pix of working on one of the walnut bases.  I was going to use threaded inserts, but my brother told me that there's no need to, just thread the wood directly as it's very hard.  I transfer punched the required locations, drilled thru for 100% threads and shown here is tapping one of the holes 10-32 with a hand-held tap guide.  My brother was right.  The threads in the wood are plenty strong for the purpose. 
(https://lh3.googleusercontent.com/AEpQ4Nq8KO0tN9LA2bhzhzYyBJQiE_Pz957n_L3RIGp0aL098yYKjWaeleeM87x2o30bWc8fa66gFdietmQmEBCyU1TOgm1C4HR2hbdN2Ehjf-TAdTO7xFe0LaOdIqE9LnSeTxNCKSc4CJMhBpFpms6QpSFZWS9_FrpqPD8XGhbtJY4H-c7T2fANiSd7J0vLxc0glfehJ4VGonPbS1FU5qKk24dTN6D7xSJqiVTA0qgH_xL9QTK3fIQx-stEMVEyFQSoa91XV1PLOe6lV9p2j-B6YrzfZmXH5NqFe2mGu4r9O0PDcGvwsMopctPoENWHX1B_OtjrOIvOWn1ogzu7Rn6OuDEApk4lm_70KotRWKJpFvKu_SG0KOEglyXxSjQI7aOA14fl5AvpRlWfdr-FdoSH5FvSOEn3HAijfUiGPMYAhIahwPOmzxGfQ2cfehyX4IUiUO-LNGPTVk9o9YJtvk1lZaSydF3buQrORC_537aTLLNr4USaXEfwQeQ2t0YqeRX45IwWWlXs4VkDS693gb3FYxY1L--pCuQroGJuCIFIyHL5ePD64ngfyLkjyHQdswIy37JGiKa2VniF0Yrm0rTKG3QpWhjgvjOsJX6bazOlhJqKLdtGe4870EoJm2fgX-OwEEmdx5xUCIettwBrrWHUeNsUe_bjPf4h30n_WE8sktbxyRnlU4ABz13LhFqoTVj7rj0x8c7zkINjMA=w711-h947-no)

And this rather oily looking pix shows graphite packing being installed in the piston valve rod guide.  I was amazed that the local hardware store actually HAD some graphite packing in stock!  For both this and the piston rod guide, I unraveled a bit of the packing material, wound it around each stem and pushed it in place with a small screwdriver while liberally oiling it.  After I assembled everything I moved the rods by hand for a bit and kept applying oil and slowly tightened the packing.  It worked out well with almost no air bypassing when the engine runs.
(https://lh3.googleusercontent.com/MdwrL1DYpYUNFE13GbxEP_K6aLpNJeY5AGrDdtxeQuNmS7uS3aP4HXRPcCCSNEtFmxHFRsZB1wnGQ2dVuIQ3wsBdTfNww8rxcQjX0II9VLqwCjChRKyCcrB1BGphvnjLWU166k0PwY_Lblq37ZAzKPUaV5q1wnC5oZ12CR7eunp7QvX9ZabSt2zMae3K9VK37UCuUIY1B8I8LoEHrqz76jRCv4zcFPik-MtBfMCWRXdmnAAj364o__8DbDqUal9TNECJfd9ZcV1YFY4B5For-RyYoTMsNOlULoyVaXFqojyOQOWIz-5Wu7B-5DR5NMUNIolTg-pUPO_RMSHRMeoRyFN1iSqsqQkeAwgBm4FIqHeoKJQkqfGg3F3HQKsYzimbQZ9_JCXsNNmMOzafNPdfbAMGUjjIZqW6ZAjwNuL_8QYr51ZG9ffBq0MoA-m_c0Er8BpJ12H53qzDs7k5Wd6XeLy7ssMCPK4MZaIeejf36OKotBc44hRs9lJWJRwv1fpSC-W8dQPKFHCn3EW9HT8mRWKR-He4Jxprxw4MwOncUW7WqqqIy6yjlHhvZrJPTwvGon9SwuD5kokpYQ4Uc9DOxlTSIUJ2vr17KxYj4c-IJ297uLcxg7BAiVotzeXHWhdXp2beQ0tGi3Lx71-bi7zqic4yTCoCztO6ly82fCCtofDMjWdcCLBVTUYo6hLspGrlnuEnI8dVAtFauE59hA=w711-h947-no)

So this concludes the final details on making/assembling the engine.  Next up, the pix of the finished engine and a video of it running!

Enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 13, 2019, 06:49:23 PM
And the long awaited (at least by me!) final photos of the engine!! 

First up are 2 pix of the three engines that I've build so far, all assembled on the walnut wood bases that my brother made for me.

Family pix 1
(https://lh3.googleusercontent.com/0pFrMj93VNRvk6rMJsWUMDEpfuVcqm0veeQicNxE1fPrTh1k9ye3xNj_qNTG26qrH5F9xZ1KM7P7mD6KtZ-1xZnJsmjtQuDHlfM2qabP3-UW8iBTfHpH8-kPabR_21nR-8sVwiYXJezbw3XOV4O6mI19b8s_-OP7ZfNT74s_3v0Cj17LW68mqeUmhwEG22-gtlAXgnrSUGcUexDz56S_QhVjT5XlNF_FCGAu2D4_inZDMTQ84cnU7iFDFWAOvhcejovzqJOR_PpV2kzwjYp_RKlkmwIsikAoDO2jXPCvZ1ogvNUNicxo8CTLKIcSx-uS_76U6JNut322oGnzpgpTOqms8kJYQx451WGXljesYytNVHsgfWYzzyi9llzvn_WYQn99iDZ4SsX5txoiuDGZHU977MKxsmtusIc9Y4Qrgg8w4Exd_aYVOUZOev5SWY7SXYIlHdMXlBBbIIbKhN1XhbrDphQLOIPgZDNtVcfJyQSIQQBqx4wc5fMIEgt-M8RUR6qIQqYLFbqdDbl-iWPztpBTmfdJyxtRUFGv9Vaxfb-egCC8fNEq0s47kRfmkhI5SS--u0Vs7OS8UkvvuAWHfVzAz2aQonIesSCiOHKtxJQFb_Vxidd5UTGEcKAOaecdzxD4Y667funTfpn46Pce9xXp4SvcojW_eSoaJmAgUtMkVYx8CTGsiKt3EuGsqbaqNlFcXwf6mm0Zw1fuHQ=w711-h947-no)

Family pix 2
(https://lh3.googleusercontent.com/uZwGOmteCnAoR1-iIxDaFRdMeNSkP8v405XOSdjilgq-dDNnkpEm1m1BBmjir5F82BAud58wZOlFIllSpnN86pXky4sYumvfAvL8xzzZQDBQvm9dgFWwRlVyUCI0mn59Lh2Md_CjIlKCBbei98Hh1pZG7onTlhVgFvtIB3UIEBletFhUtLpljkFi-dGeKkcDIJTrUc5mpP-hkAxHwKNy0rqxoxQWyn_n_1EAJWyIZHfJDHEMn4QDqFqFhuPxOHOS84ZmzJCDTRpzgFj8DF-US97pNUmk4DZgwAFWZMAWeg_HztRcpBMJEl5QFUeau5Th-5N1lFtJ4VDOdvZo-O9NNoVs7A8y-uAwj4h5fuZ4U68jKsGAq6OkYbXkohCUEcPlytqx-maE03aTZw16MOknAyeJnC1uyeTPzZi99P54uFyDSI9DxlD3lmcuOFYz8at4j8BwsVtBgLWut5uMQA_My-SsuEs0k7nH0Bck2weVO3eKat1kYhHkXjMTcIcc_Rusre61Lb1xdPNHuZlWBqaacnMhMwz_tASJueHMHH9dIjA5COrE0lYkpbanBTBrixlKoBx8AdSzia1FYO8SoDwmhDYJGc_ewwjhWpVHocR4SxtZXXtmVK4iiHX8Yuy2rHLQqONPREgZRx6K-v03i1viBlDHXULtY6ZUj5eLa9L-ieJFtOrKyIkehRvoqWuYT4NY5w7QotpgcsdqRjzL1Q=w1263-h947-no)

And now 7 pix of the finished engine:

Pix 1
(https://lh3.googleusercontent.com/x5GE3g9Du6gaPNF-jDGmLzgEMIasmIfS8QtKMCyCeoNn2foyKThoR2alo88XnOk4CYazeHXN5Q6iRhiuDFhwFWL8gnOWqZ3YiqzP8ZIxVBTYvUclscIpUzXw_qmf8UJNSVdcmkZm0Ilv8AZa75lX3WjhagiTkPKEHewP3F4rGbvjc5fp9NQ5yN5wRCOIBJ-4-zhst0GxAn9olzQlX_uvnl6hSzfXckAHKqq-CQYWAtt_CggxbxDZsEUQd8q5bbcae_ZziSzGbT4vfOmnaMyLNfc9WLIIINJJ_0umoaG3v8-aeUihsOHmbBvcEhmYBzeNpwVaNhff-lyDPo44LsTz41CBGSH4isIoBPycTGJOvDbw3ZEIax0LWra8O6JjCXcBN0XtVoSXgzS-CjtqrsOGQ7v7Ho6UQQpbZ8VBgVCw1ekrZ0dz9Zb9LokOCXYfE-PFk4mJ7jrMlTA4jN0js39CqdBYKxGv-I-IR5qbHDS_aueLGbp_7Dkfi2uON6h80-0F9EZqit6ejtmjH2reKNhijIUq645hg2p6lD3X_gQ6XlDOZ2gbh5vIza8HchHU292aGhIP59WzQ3TXLRYSLYS2YfAmtse1DBvbgJ8fBKm5gJP6fH9FL5D-7gUffuCkVQycoU63B2XctKp1OpU93bzwe_KPDpMwnxO7EgRL7Rdb4njJH54iZ9HjeCj3ZM_5KDDEoGOye1pkbmSylhS-ag=w1263-h947-no)

Pix 2
(https://lh3.googleusercontent.com/1M2PvSu8k2hNcUd25HKftMC0-qzWmdHpNKJIZlFpmF9NoTXqoTDxlxW2UKQ15_k3P-2OAvHxKU6Mc4amgcAc75xwHw8f-kxdQC9F-KSf-jw-r4DN67z7jhKFhmCZNEkwH_FVL6JyxaYT28gGxFYdGnLt3DFjRmmiYfCSh5XmwaAm9cYoKFXnAGLJhnf8L3eLPehuXFLFhP4pgBpc0PtMmHtdRESGY1wY-QcUlMifh4ET_KgiDLDkxPLlpKc2e18EUt4ZzFCt5pJ926j8qPU6Ka9OEXO1xgd_uPorviO1HnZeSn0iu2CwvG4Q_SX3XzzMAOkKLU9Ac6Q4g9h0u0BmS9p23d7QoJHxhwRXNYqyn8cZvt9r4jK33ZNlHTgvnuvn1oPwVSCLTK0IeE5g9txkDi_VOwy_PxqEXzMmst80pwX4ltx5GyHDJZDTvA3zxAGRYCQxYCrzt_qUHwWhNbVUAJBnzU0Wziv_n877O0AU4TczFlJBAqeMrqMmpmN9rYZ_kw1S3aKum8lQhn4gU8mC8pjHctI4empHpmntKX-VcMa4FIOwPxsjExSxCKZe1-pHerH6vNgcW8bgNQHgPu_xUlE_E0LFsZvMFsbei3ZdNEYrBMHmzOOx1_xDTQJN3ECuYFmtbPPkQb618iFcauI8M-kCPCbCFn6R-ckkMlhlvmcrOkIRIR_tgK5shkazfvJ88s2RLevXiMz_vNs0lg=w711-h947-no)

Pix 3
(https://lh3.googleusercontent.com/dkxwb1iQk2N5-ifj6mp1-mz5KpvMFW04YSvXt_XyK4c1gSRDUNI5HUwBazyunu7wkycvaPX3AgVVg3Do9Dktowa8ua8eBZmD5VT79b_lcyR6A4dY_Ictt59QnKilrEEsUTz_pO7EWIQvbC6lN74FzT1PiTO0rfdELyHdALwg4NBWF2oPSspIT_m_INe71bGXKYrw9kScABVc7npqCTnstWhVXHzG9CVrS8wQWBLbSDDZ4Ku83p6ZLDp5BkumfFoidvPjevp7dJd5uIVLHHN_Iow0bot9Wng3XOWi2UiPxiVjthjDhcgdCZVzv2akMmultiq8ic69asOsGKYDlbtVhlQGApnPAKFQMbAfYjOFTe0aRCriHzzLDoPYZWs11dahnGL0piQ9jV3yyoj79L88H281pipcBrjuyuAq4idKd-Zh0O7pfpY5Vfc_KiTEQqlvTAgIPzDqpB5xhgp7_-r8hJmoscag3mp7gMYQSfQ5ba2N3pVy9UKz42H8v0n__iFTzuRfrWvTvqbRKjHhisXZRNCjOwI6yCJ8cQdNsH8qZtUPgCdpWr2OA7oy4vgEWK4BMwmDTucqVlE0A3FoblbH7EOKs6qPdWy1d4rjYfuV4D1FiNVbwaTelipWxDlfCqmICvNnz7gG19LdFoNoxgcaExou0AEnU6hHvhT_uMyXVD1nDn1TfJo-3eePxGUWKdxat2Nc0rbQbbVwLOkDAQ=w1263-h947-no)

Pix 4
(https://lh3.googleusercontent.com/eKWawN1d0iaZ-nDi0cVqF0TfPgmwLhjzLEdWrC4Y5sL8Q3J8Z5FIYUsnIOY1JoDIHEfD8sC5UJEfaQ7T61hd_4VPQCGBtDW-3Hu_-YD7pceAuWtsrNRZHj-GvhOV6cf-n-TlHfNqrKf-IQ2-dQ2FH9SVDcGQLfqqFcX9sF_EEVN4Gf7HW3gjSXJWYOEmJGntVQzN2WK4LqtRIP_SO9KKt0DL0lo0SwUIjHB7mzQa_uNGW4K7G3jf-cyJicnTula892xebmU4txYVQOEIPqJd6t1sqQQp8qoE9e0g7KHCpGRJ9yC_IORmykDgcHbshCiSIne_mIORT1Efudfl7T3VRBcnNXaw0LxpBb_eUjQQyAaEOwujHz8VBt_8guIwJkN1lRDsNP7xhgwxIL9IXmbLyL03lYwCT9d-UyNaedR30_TFnmGUO-FC0CbXXMmjr_AjuuioNu2AmD_l4lkuR7DSRpoF3Yf3OROqxsuYGSOkTcj_f42oIU9v39Jg7FW2Bs3gonv-Zsl6ZBKaEmdq2yPuCXZOJuqY42C242jeixq_B-YbxL9PQ0XnJz4qNNqUP48OaoE4V6BDBNbkyEKWGRm-D1PmH1hGVZKXJo_Ao9upjW1-52lXNbr_wnbu45xbiGUspybbwjjyigXCYPREvpElZN-SbFXID1U-M6aORDGEEQgHiRSi9zIiFpUWrDpqFAVynS0HsW5jT3_B5VCBuA=w1263-h947-no)

Pix 5
(https://lh3.googleusercontent.com/ehCvKVBZ7f_ZN-5X4fF-izuzgAA_4lDhNTNxR28hHJO18jdk6jXbjPU_77pzQaw01pxN8UTe-TZ94Nvz8JQWKtnF-05w171M8CP6OMx463fjHYhHhNkjJKOHNMw6DJmrKFwuKOPFeF0d61QyPNOPZzl65tjyCWbDcrINNWbWGAt-gommDL6sKAezoueH5fR74LixX-QLVxm7jc_YajIOsVZdH46ngK-jG_CQghAUY8buyPjz8V8-COuRMO5ZbiRGjyYRmael--VuB_rdZ6rcEyH2rCUuZbCLZXkhktyQO0hoD5MHm847XiEVV5bryTdtUmqMUNtLHhc3jrlll42ujzDc9EQIpl8hPwQazBlqQE6XQLPbLdElAGaas0uaYIN3dNqnspIhqSUPS7pr98ETyy8mKKn8oakBNxtzAx8xaalINIzsJjMVqOw6-ZtM8knp3LiHfEWXdaSROzr9pkX7pW-PbUBtH6q1AVwBW43lYWKQMuMRHp3loYPPZUlHiOvGnxKifYEiEOLV2H6h2z4jkkSVsj1JXkDPv3Zi0r8jQDswEnPSiep-lVLJcoqxBa9zMT0bbkK37ycy1SwzVxTYu3ZRSfXPJeafzXWM1doMEgRFFzOhOz0k1Fi2wBkazJj_Hn5AlP8IPbBfVEB1noOoDzsSZsFceT8VHohQDwALV3eMBAziZyA3mOGrZcBfKfxvFKapuEl4b0fjok2LQQ=w1263-h947-no)

Pix 6
(https://lh3.googleusercontent.com/_Scbbw3PXpy-XIwbeWVYp7ldn3iIwsXY0B_nmEG-aRJ5nQEIME1L4vlK4YZmLZKyIjYqU2I5DNGanYapZY9RCq2Lm7ksDIZ5R7TmIEZnFAA-q2RqVa5YGkluPNPx8tMaZzuWI8FH3D1AT3A9M2Mu9eJ1GKVgQgynR7tBBGSnrqQxC6gshwyCP2qsa7fYT1Evss2N3ejipA9IQaDrB2YRjOUSWfDYkAdUmhHIX4cxwV_xFKVyRGqsDEh9PhCbB4izdFz2J80TzT2CJadM_x6vApzLXJYpvtdrDJhJQVhuIfYYCErV98AjrpWGRMBveYYFnw5sQCBQsLf0_FiGi5ysQHet719uHHZhDhCAhyKFUygppWOnpty67kA0HiJ2EzwWWROMYtuEVwqx5bejryPgJvtd-m3HdHTzXcJ4UiH87pCC_Mh_Paxz9C32RXWDLFvWDauA-uRcYgdNCEpAM6Wr8oM7-AiMpNTQZIBecHDSVuzHw77V1HfWweke4kBZNdbsQ5l1oFG7WIKiUzZtx8FeVAfWg1oIPVlqB4f2j9SVBhMERBG4m9E56iEi_4O0SR8Y-Fh9KyzVX6la3FDPkIBYgAXGlkLednYJbHVUUPgwL63H_KPBkOsOKRtJtj0kOUVAs7R_7vknGUHOViDv-LGFtpgEROz8deM_OxV6d3aPnz_iH5dWEB1KHA_AAnbiKj5kv3zflHQxpjWm--cHqQ=w1263-h947-no)

Pix 7
(https://lh3.googleusercontent.com/NE-vreL9IkqjBImaFkmJIslqyjmPhPte9IB6CA0pvb5gqSZzY-GenWdourCfV-d3qgO5FhUHbYjwCRPpZgwYw8Pg68LrO_9C3j2w8zpOH2jsNm-RGi4QxQmc8LN-TnLQyKnowGtfJsIn-0hpTBnVLXcAbBB_8zPBWJO4xuQH11OdVrha3JPx5aaBE3qyZitbRN4wSlOYz1Pv9RsE-KeXKdZHqaXi44BShYZMKsmqZt0hDv-KhGXfML7X-9Tb5k7yfZvIrVXYftQbZ-178HQReLESlec26b52K-BO_9sfs2RqFrXvVlkUwiFQk-ikXBdIT9Xk8U4waz57yZV3B-fW_dqwN1EOFPZEQAwA4GzPeDf1kKvNUqkznwbVEKDJWBGWMxrFXgcmXPtcEhs2DQM9gniRbpjUU1IOHlLZhIeDqEQDg1uWmk8AsNYUbOMLYwbvM1dB6KWaXKbBDmHLh62OxofmP3uCH7fuogfefAFCJFQlO4cPX4T_oKHCr3ToLL-vO14zJp1uR6XS3oadlj-5yD9t2HEmjZ7aQsQ4DekaIPjtF48W4dgTklMnl5mdfCd4-L5QQKsTgMLmnuMfDI272Znrmbt7Ia0BNf6yRkPqt_JFmeXZRfX-Fng6ySlE2B__3f2rnbh5e7zU3_q3V75qsl7D2KfNbXkZbfWK5clKulHwuT2SOAwtdNf35haburtMNfHkxs-Y_xCjBKHHuA=w1263-h947-no)

And last but not least, a video of the engine running.  This is with about 5 to 7 psi of air applied.

https://www.youtube.com/watch?v=hJ3J8GHIhyg

It runs well and very smoothly with very little vibration at this speed.  I do like the scale model fasteners and the brass accents on the engine.  What does everyone thing about the color of the flywheel? 

I did learn a LOT during the build of this engine.  Prior to this, I'd never made an eccentric assembly, nor had I done any cylinder lapping, nor had I drill/tapped any small holes of size 2-56.  So, I'm rather pleased about all that and it make me confident enough to start on the next challenge!

So this is it for this engine, enjoy!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: 10KPete on January 13, 2019, 07:14:45 PM
Sweet!! A beautiful engine that runs beautifully, Mike. An excellent job.
It's been fun following this build and I hope your next engine is more so!

 :cheers:

Pete
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: crueby on January 13, 2019, 07:15:14 PM
Excellent job on the engine Mike!!


I like the dark green on the flywheel, the darker colors look great against shiny metal.


 :ThumbsUp:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Admiral_dk on January 13, 2019, 07:42:37 PM
Chris and Pete has already mentioned the important details - so I will just tell you to enjoy the great result  :cheers:
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on January 13, 2019, 08:11:26 PM
The engine and base fit together like a glove Mike. Beautiful job on both!!

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Kim on January 14, 2019, 05:36:23 AM
Beautiful!  Love the color, and love seeing it run!  You should feel quite proud of your work here :)
Kim
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: sbwhart on January 14, 2019, 08:13:15 AM
Great Job Mike

It ticks over lovely  :whoohoo:

If any one would like a set of drawings just send me a PM with your email address and I'll mail them.

Stew
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: scc on January 14, 2019, 12:35:39 PM
Nice piece of work, looks and runs great. :ThumbsUp:      Terry
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Tennessee Whiskey on January 14, 2019, 01:57:29 PM
Really nice Mike. I’d say that you had a great weekend with these beauties and the Chiefs win 8) :ThumbsUp:

Cletus
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Gas_mantle on January 14, 2019, 03:02:28 PM
Great job Mike and I enjoyed following your build log  :)

The Potty Mill engines are a great design.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 14, 2019, 11:25:47 PM
All, thanks for everyone's very kind comments!  They certainly are encouraging! 

A few things i forgot to mention.

First,  huge thanks to Stew Hart for his excellent set of drawings!  They are really clear and easy to follow and of course his superb design is buildable for even a beginner like me!  i'd encourage everyone to give his engine a try! 

Next, there's one additional thing I'm going to do which is to have some small brass plaques made for each engine with the engine name, year of construction and my name.  This is mostly for posterity, but I think it will look good.  I saw someone else did this on their engines and I really liked it.  Unfortunately i don't remember exactly where I saw it at.

Finally, I've decided on my next engine project.  I'm going to order and attempt to build the PM Research #1 Steam Drilling Engine.  I like the looks of it and I want to give working with castings a go.  I anticipate the biggest issue will be workholding but I've started looking thru Bill Lindsey's build log of this engine and that will be a huge help I'm sure.  I might be crazy but I'm also going to start on a Webster build but I want to build a model of it in Fusion 360 so I'll interspace CAD work with shop work which I think will work OK.  Plus I'll start collecting the various pieces I'll need for the eventual build. 

Again, thanks to all for looking at my build and for all the encouragement and kind words!

Mike
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: b.lindsey on January 15, 2019, 12:31:06 AM
Mike, the PMR #1 is a nice engine. I have not been pleased though with my color choice in paint so as soon as things get settled down at the shop it will be getting a new paint job. It's still a nice looking and running engine though. Will certainly be following your build.

Bill
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Larry on January 15, 2019, 04:36:23 AM
Great job Mike. Love it ! I like Stew's engines and have built the Grasshopper and Vertical Cross Single. Have also built the PMR #1. I used that same flywheel on the Grasshopper.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: Jeff Michel on January 15, 2019, 11:01:47 AM
Excellent job, I enjoyed your build immensely.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on January 15, 2019, 11:41:54 PM
Very interesting build log and a great-looking engine.

In the photos on the previous page, the larger of the two oscillators caught my eye. Would you mind posting a little background on it? Or does it feature in another thread?

Thanks,

gary
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on January 15, 2019, 11:44:26 PM
Ah ok - I just found your build log on it - Elmer's #36 Reversing Wobbler.

That's my next read!

 :)
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: mikehinz on January 15, 2019, 11:48:39 PM
Ah ok - I just found your build log on it - Elmer's #36 Reversing Wobbler.

That's my next read!

 :)

Glad you found the build log! 

There's also this:

http://www.modelenginemaker.com/index.php/topic,8474.0.html

That's the Fusion 360 solid model plus a link to the drawings for the engine.  It's 2x size from the original plans and I can confirm that the drawings are pretty correct as I built it from the drawings that you can download and made any corrections as I went along.

I hope they are helpful!  I did enjoy building that engine and learned a lot from it.  It runs quite low at very low air pressure.

Thanks for taking a look at it!

Mike.
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on January 16, 2019, 06:45:19 AM
Yes - I noticed that one too.

Looking forward to reading them.

Cheers,

gary
Title: Re: Pottyengineering Horizontal Mill Engine - Imperial - Mike's 3rd Engine
Post by: gary.a.ayres on January 16, 2019, 07:06:52 AM
Ha... I just started reading the Elmer's wobbler thread and saw a comment from myself!

Must have started reading it back in August and then drifted away...

Picking up on it again now   :)

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