Model Engine Maker

Engines => From Plans => Topic started by: NickG on June 05, 2013, 11:04:13 PM

Title: Stew's Simple Mill Engine
Post by: NickG on June 05, 2013, 11:04:13 PM
Hi all, finally got back into the workshop after my hol and decided on Stew's Simple Mill Engine to break me back in; hopefully gently but we will see!

Although it is simple it still breaks some new ground for me - I have never made a double acting engine yet, all of my steam engines have been single acting oscillating engines although I have in recent years done some more complex stuff like a hot air engine and a few flame gulpers which have used similar techniques to what this will.

I am trying to show this build via tapatalk on my iPhone to avoid being in the workshop then on the computer writing things up so apologies if it isn't as coherent as it should be.

It is not my intention to go into much detail of machining as Stew has done that much better than I could, I will, in the main just give simple updates on the progress I'm making.

I am not following Stew's plans religiously as will be using, where possible what materials I have to hand. Oh, also, I am going to cheat and use my milling machine!

I started off gathering materials together, then machining the flywheel for which I had an RDG 4" casting. At first the flywheel was machining well but  I then made an arbor to turn the OD and things weren't quite right. It kept slipping on the arbor ( nut was a bit small ), I eventually realised this was due to a chilled spot on the outer rim. I kept tightening the nut to stop it slipping then got that sinking feeling when it turns far too easily and snaaapp! Threaded section on arbor was no more! Feeling pretty peeved I resorted to not a good practice and gripped the flywheel by the boss with flat end of tail stock chuck o keep it straight in jaws. To my surprise this worked well and was uncannily concentric - time will tell just how concentric! It was my intention to paint the flywheel Including the rim black - I used to think it was compulsory to have a polished rim but had seen one of Stew's and Jason's flywheels and they look the part painted too. Just as well as the chilled spot on casting was quite visible despite dressing with a file. Now having problems painting the damn thing, not sure whether the paint is taking to the cast iron well as it seems to be taking a long time to dry.

Next I cut out the base plate on the mill. The alloy I'm planning to use is somewhat thin but am not too worried as it will stiffen up once I start bolting bits to it and when it's fastened to the thick wooden base. Luckily I found z bit the right length with 3 square edges so I just had to cut the 4th!

Next job was the main bearings. I didn't have any 8mm plate so had to fly cut some 12 down to size. This took longer than I thought and made a bit of a school boy error not fly cutting a long enough length! Rather than fly cut more I managed to squeeze the bearings out in different orientations but this meant I only had 1 square edge so milling them to size also took much longer than it should have!

So far I am making it hard for myself and progress is slow but an enjoying being back in the workshop!
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on June 05, 2013, 11:15:14 PM
Well you seem to have gotten off to a good start Nick. I am here and will follow you on you venture. Looks good so far.

Don
Title: Re: Stew's Simple Mill Engine
Post by: sbwhart on June 06, 2013, 05:30:28 AM
Good start Nick

Fly wheel looks good with the S hooks.

Stew
Title: Re: Stew's Simple Mill Engine
Post by: Jo on June 06, 2013, 07:04:34 AM
I am trying to show this build via tapatalk on my iPhone to avoid being in the workshop then on the computer writing things up so apologies if it isn't as coherent as it should be.

......
So far I am making it hard for myself and progress is slow but an enjoying being back in the workshop!

Are you sure that your misses won't realise when you are writing this up that, whilst you may be sitting with her playing with your iphone, your heart is still in the workshop ? :naughty:

Nice to see you start another engine Nick :ThumbsUp:

Jo
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 06, 2013, 08:22:15 AM
Thanks guys and Jo - she did ask what I was doing frantically typing in bed  >:D so I thought I'd better own up but then she just laughed. Well at least I won't be accused of being anti-social and sat on the computer all night despite her being in bed anyway  :noidea:

Am trying to get in by 22:30 so only giving it 2 - 2 1/2 hours a night, the first night when I was having trouble with the flywheel it was 23:55 - lost track of time and then realised I'd been running the lathe at that time in close proximity to next door - hope they couldn't hear!  :Argue:

Title: Re: Stew's Simple Mill Engine
Post by: Jo on June 06, 2013, 08:32:39 AM
Thanks guys and Jo - she did ask what I was doing frantically typing in bed  >:D so I thought I'd better own up but then she just laughed. Well at least I won't be accused of being anti-social and sat on the computer all night despite her being in bed anyway  :noidea:

 :lolb: Caught on day one  :lolb:

Maybe I should make suggestions to your wife as to how to cure this little problem before it gets out of hand :mischief:.

Jo
Title: Re: Stew's Simple Mill Engine
Post by: Damau on June 06, 2013, 02:44:26 PM
Looking good Nick.  I will be following along on your build.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 06, 2013, 03:33:10 PM
Thanks Dale, I'm trying to keep the momentum (however slow) just so I don't bog down and get stuck in a rutt! Want to get through the project at a decent pace - for me at least!
Title: Re: Stew's Simple Mill Engine
Post by: b.lindsey on June 06, 2013, 03:37:56 PM
Great start on this Nick...I seem to be in one of those bogged down states myself at the moment.  I looked around briefly and found stew's drawings, but not a finished picture of this engine. Do you know of one that can be posted to see where you are headed?

Bill
Title: Re: Stew's Simple Mill Engine
Post by: sbwhart on June 06, 2013, 04:41:21 PM
Her you go

(http://i431.photobucket.com/albums/qq32/sbwhart/Lads%20and%20Dads%20engine/IMG_0156_zpsabfe4fc4.jpg) (http://s431.photobucket.com/user/sbwhart/media/Lads%20and%20Dads%20engine/IMG_0156_zpsabfe4fc4.jpg.html)

And the build log is here

http://www.modelenginemaker.com/index.php/topic,1801.0.html

And a video of it running her

<iframe width="420" height="315" src="https://www.youtube.com/watch?v=3hG9zZOqQ5o frameborder="0" allowfullscreen></iframe>


https://www.youtube.com/watch?v=3hG9zZOqQ5o

Stew
Title: Re: Stew's Simple Mill Engine
Post by: b.lindsey on June 06, 2013, 04:45:29 PM
THanks Stew!!

Bill

I was looking in bar stock from plans rather than from own design....doh!!! :hammerbash:
Title: Re: Stew's Simple Mill Engine
Post by: fcheslop on June 06, 2013, 05:23:28 PM
Looking good Nick, I bought one of those flywheel castings and had one devil of a job with it as well.
cheers
Title: Stew's Simple Mill Engine
Post by: NickG on June 06, 2013, 07:52:51 PM
Sorry, I should have put your pics on. Reminds me what I'm aiming for. I often find it hard to get motivated Bill. Thanks Frazer, not sure whether to try any more from there then, was thinking of a bigger one for a future engine.
Title: Re: Stew's Simple Mill Engine
Post by: fcheslop on June 06, 2013, 08:54:27 PM
Hi Nick, I know for certain I wont  :Lol: talk about blood sweat and tears :Lol:
 cheers
Title: Stew's Simple Mill Engine
Post by: NickG on June 06, 2013, 09:51:58 PM
:Lol: that was about the same for me - literally but won't go into that!
Title: Re: Stew's Simple Mill Engine
Post by: divided he ad on June 07, 2013, 08:00:42 AM
Good Start Nick  :ThumbsUp:


We're all watching now so expect plenty of  :stickpoke: if you slow down.....

Need plenty of  :stickpoke: and some of  :slap: myself.....  still haven't finished my rocking engine from 2 years ago!  :facepalm:




Still, will be good to see your progress.   :)

 



Ralph.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 07, 2013, 09:45:35 AM
Thanks Ralph - yep, I'll need plenty of those.

Seriously, 2 years for a rocking engine? You need more than a  :slap:  ;)
Title: Re: Stew's Simple Mill Engine
Post by: divided he ad on June 07, 2013, 02:19:25 PM
Quote
Seriously, 2 years for a rocking engine? You need more than a  :slap:  ;)

 :ROFL:

Yeah, I know... Time passes so very quickly!


One day  :old:







Ralph.
Title: Re: Stew's Simple Mill Engine
Post by: Tennessee Whiskey on June 07, 2013, 07:24:17 PM
It does fly by, but look at the beautiful glow you've shed on the world with your torches. It's all relevant.

Yalls Redneck,
Eric

Title: Stew's Simple Mill Engine
Post by: NickG on June 07, 2013, 10:47:30 PM
Quick update - I've been slowly continuing work on the main bearings and have finished them bar the top coats of paint. The dimensions did not
come out as perfect as I would have liked ( dials on the mill aren't great even when used in metric it seems!) The main holes are also slightly off centre, however the main thing is that the holes are in the same position relative to the bolt down holes! The crank will line up ok. Deviated slightly from the drawing, the base of the bearings are 36mm wide rather than 38 ( I didn't fly cut enough down to thickness!) and the bushes are 13 mm OD rather than 14 as didn't have a 14mm drill and don't have a boring head yet. Used an 8mm end mill to finish the bores as don't have an 8mm reamer. Finish is good but prob slightly oversize. This does not matter as I will be turning the crank due to lack of 8mm bar! Still making things difficult for myself - should have just gone and bought the metal!

Another pic attached with first coat of grey primer - for me things always look decent in undercoat but rubbish when finished!
Title: Re: Stew's Simple Mill Engine
Post by: swilliams on June 08, 2013, 12:56:01 AM
Looking good Nick.

Steve
Title: Re: Stew's Simple Mill Engine
Post by: vcutajar on June 10, 2013, 05:08:35 PM
Missed this build thread but now up-to-date.  Good progress there Nick. You are just like me.  My builds are very slow also.  But then again we do not have a deadline.

Vince
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on June 10, 2013, 07:14:24 PM
Hi Nick, just catching up on your latest and she's looking good. Any progress is better then no progress and we are not in a hurry here are we?

don
Title: Stew's Simple Mill Engine
Post by: NickG on June 10, 2013, 07:40:28 PM
Thanks guys, am just about to go out and do a little more. You're right, no time limit but I just get frustrated and want everything done yesterday for some reason!
Title: Stew's Simple Mill Engine
Post by: NickG on June 10, 2013, 10:08:34 PM
Painted the bearings the other day and they turned out reasonably well,nothing fancy just kept everything square as hate filing radii etc. Never been properly taught how to use a file so have never been any good at it.

Got a bit more done tonight, just the slide bars. I didn't have enough 1/4" square section steel but did brass. Nothing major here just mill them to length then drill holes in same place on each bar - the only critical thing being that in their pairs, the holes need to line up. Annoyingly, I am yet to find the centre of something accurately on this project, they are the same though which matters more!

Will Probably do the supports and spacers for the slide bars next.
Title: Re: Stew's Simple Mill Engine
Post by: arnoldb on June 11, 2013, 12:44:07 AM
Good going Nick  :ThumbsUp:

Quote
You're right, no time limit but I just get frustrated and want everything done yesterday for some reason!
::) Bah - we all want that  :)  The journey is a lot more fun - usually in retrospect though ;)

Filing....  Most likely you'll end up loving to hate it, or hating to love it...  The hating to love it bit seems strange, but there's something about wielding a corrugated bit of steel and rubbing it against other "stuff" to make bits come off that can be immensely satisfying  ;)

 :cheers:, Arnold
Title: Re: Stew's Simple Mill Engine
Post by: Jo on June 11, 2013, 07:25:27 AM
I find filing very easy and satisfying but having spent 6 months of my apprenticeship being taught to file might help  ;)

Filing radi is easy with a button. Then there is that old trick of using a marker pen to identify the high points that need filing and making sure you centralise your filing on the mark.

Jo
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 11, 2013, 12:46:01 PM
Probably something I should practise, fine with filing buttons and I can see less chance of messing up than trying milling with rotary table.
Title: Stew's Simple Mill Engine
Post by: NickG on June 15, 2013, 11:05:27 PM
Done a bit more - not a lot but never mind! I turned the supports for slide bars, little different to Stew's design because I had some 10mm 303 stainless to do them out of and thought it would be less metal to take off! I've also used 3mm threads in both ends.

The stainless is funny stuff, can achieve a really good finish but strangely it seems to like a fast feed, same seemed true when drilling it. It gets quite hot when turning it too. The only thing it didn't like was being parted off so I stopped promptly, sawed and faced instead - this meant a bit of faffing around measuring to get them all the right length. Chuck backstop would have been ideal!

I then realised I didn't have any 3mm screws long enough so had to make some studs! What a pita lol! I had some 1/8" stainless which meant even more of a pain having to turn them down in the collet chuck from the milling machine a little on each end first. Listen to me complaining - there were only 4 of them lol! Luckily 1/8" passed through the clearance holes I'd drilled.

Next was just some spacers - for this I decided it would be easier just to do from some round - drill a deep hole and part the 3 bits off to desired thickness to give a little clearance for the cross head material (1/4" sq steel). This time I used some 7mm mild steel hex - don't know where it came from but it cuts really nicely and parts off easily. You'll notice in the pic that the back left spacer is missing- this one will be done from square as it has a hole in it which acts as a valve rod guide.

A bit early for an assembly I know but had to do it to keep myself motivated!! I was quite impressed with the way the slide bars and supports went together everything seems nice and square. Just got to do the rest of the engine the same and it might be ok!
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on June 15, 2013, 11:30:33 PM
Pretty good progress from what I see Nick. She's shaping up nicely.

Don
Title: Re: Stew's Simple Mill Engine
Post by: Jo on June 16, 2013, 06:54:59 AM
I then realised I didn't have any 3mm screws long enough so had to make some studs! What a pita lol! I had some 1/8" stainless which meant even more of a pain having to turn them down in the collet chuck from the milling machine a little on each end first. Listen to me complaining - there were only 4 of them lol!

Nick: It takes time to appreciate the pleasures  :LittleDevil: one can have doing studs  :embarassed:

Coming along nicely :ThumbsUp:

Jo
Title: Stew's Simple Mill Engine
Post by: NickG on June 16, 2013, 08:07:56 AM
Thanks Don, Jo I think it's going to be a while before I appreciate studs! Hmm, what to do next? Think I feel a crankshaft coming on!
Title: Re: Stew's Simple Mill Engine
Post by: sbwhart on June 16, 2013, 08:16:34 AM
Nick

You still have 8 more M3 and 8 M2 studs at least to make  :stir: :mischief:

You can get metric stainless studding on ebay quite cheep just do a search

Stew
Title: Stew's Simple Mill Engine
Post by: NickG on June 16, 2013, 08:30:55 AM
Argh! I think for the cyl covers I can cheat though, the m3 screws I've got can have the heads chopped off and use with nuts. Not sure about the valve chest though, don't think the m2 ones be long enough!

that was weird, was just day dreaming about how to make the connecting rod!
Title: Re: Stew's Simple Mill Engine
Post by: Jo on June 16, 2013, 08:31:12 AM
Nick

You still have 8 more M3 and 8 M2 studs at least to make  :stir: :mischief:

You can get metric stainless studding on ebay quite cheep just do a search

Stew

 :o  :ShakeHead: The little pleasures that one gets in doing studs is character building  ;)

Jo
Title: Stew's Simple Mill Engine
Post by: NickG on June 18, 2013, 10:24:38 PM
I made a start on the crankshaft - the piece of metal I had long enough and closest to form was 3/8" dia - I thought it was 303 stainless but then realised it was magnetic, thought then that it might just be mild steel but it was nice and shiny and free from rust. It didn't turn like 303, was more like silver steel, gave a dull but good / smooth finish.

I had always meant to reset my tail stock on centre ever since I got the lathe but just lived with it. Since the shaft would have to be turned to 8mm over its full length I thought I better try to set it. Still not that happy, it seemed to vary about 1.5 thou over its 105mm length - don't know what is acceptable? It was in this case, managed to get a good sliding fit in the bearings and a nice push fit in the flywheel - this appears to have acceptable levels of wobble - at least on the rim, sometimes there's not much you can so with the way it's been cast.

I also made a nice big brass but (mainly because I didn't have a 6mm nut. Of all the methods people come up with to secure flywheels to the shaft Stew has come up with a nice simple but effective one here for model engines.

My only slight annoyance is that I didn't allow enough material to cut off the centre drilled end afterwards ;-(

When i did a quick assembly it was evident straight away the weight of the flywheel being outside the bearings. Must admit I prefer to see the flywheel between the bearings or with supplementary support, however the way stew has it seemed to be common practise. All traction engines are like this and they have heavy flywheels. Most hit & miss engines do too although they usually have 2 to balance things out. It will still be fine on a small engine like this and the  weight of the crank, con rod, eccentric etc will go some way to offsetting the mass of the flywheel.

Got to make the webs & pin now, loctite then cut out the centre of the shaft.

Title: Re: Stew's Simple Mill Engine
Post by: b.lindsey on June 19, 2013, 12:28:31 AM
Great update Nick...it coming along very well!!

Bill
Title: Re: Stew's Simple Mill Engine
Post by: divided he ad on June 19, 2013, 02:27:26 AM
Looking good Nick  :ThumbsUp:


Quote
My only slight annoyance is that I didn't allow enough material to cut off the centre drilled end afterwards ;-(

Personally I'd either leave it and answer all the "what's that hole for?" questions or more likely I'd fill it with a brass plug... I like to tart my creations up  8)

You could make a steel plug to hide it.... But that might be boring  ::)






Ralph.  ;D 
Title: Re: Stew's Simple Mill Engine
Post by: swilliams on June 19, 2013, 02:50:38 AM
Looking good Nick

IMHO 1.5 thou taper from tailstock misalignment is a little high, but still acceptable. You can always improve it if and when needed. I'm with Ralph, I wouldn't worry about leaving the centre drilled hole there.

Cheers
Steve
Title: Re: Stew's Simple Mill Engine
Post by: derekwarner on June 19, 2013, 03:41:36 AM
NickG.........300 series stainless steels can be magnetized by cold working/machining.......I have been trapped :Doh:

The draftsman specified a linear displacement transducer magnet spacer as AISI 304....I approved the Drawing  ....the machinist produced the spacer....the spacer was installed in the cylinder & the transducer produced erroneous ERROR signals.................  :zap:

The following is courtesy of GOOGLE......

"All austenitic grades have very low magnetic permeabilities and hence show almost no response to a magnet when in the annealed condition; the situation is, however, far less clear when these steels have been cold worked by wire drawing, rolling or even centreless grinding, shot blasting or heavy polishing. After substantial cold working Grade 304 may exhibit quite strong response to a magnet, whereas Grades 310 and 316 will in most instances still be almost totally non-responsive".

"The change in magnetic response is due to atomic lattice straining and formation of martensite. In general, the higher the nickel to chromium ratio the more stable is the austenitic structure and the less magnetic response that will be induced by cold work. Magnetic response can therefore be used as a method for sorting grades of stainless steel, but considerable caution needs to be exercised"

Hence ...we now only use BS1400 LG2 bronze for transducer magnet spacers ............Derek


 
Title: Stew's Simple Mill Engine
Post by: NickG on June 19, 2013, 06:51:22 AM
Thanks Bill, Ralph and Steve, I think I will just leave it (mainly because I can't be bothered messing on!) I remember seeing drawings at work with centre drill permissible etc though. will remember for next time!

To set the tail stock I just lined a centre drill up by eye with the pip on a faced piece of rod. I need to turn myself a centre and use the trick nipping a piece of sheet between head and tail stock centres. It could be out vertically I guess?

Derek, that's interesting - I do seem to remember buying some 304 because it was cheaper then someone telling me 303 was nicer. I don't think it will have been silver steel as I don't think I would have got any in that size, don't think the bar had a ground finish either, will have a look at the bit of parent bar that was left and try to get a decent photo.

Anyway, look like it will do the job for this.
Title: Re: Stew's Simple Mill Engine
Post by: Jo on June 19, 2013, 07:19:10 AM

To set the tail stock I just lined a centre drill up by eye with the pip on a faced piece of rod. I need to turn myself a centre and use the trick nipping a piece of sheet between head and tail stock centres. It could be out vertically I guess?

If you got it within .75 thou out by eye that was good going  :praise2:.

Really you should be using a between centres gauge and measuring with a dial gauge to set the tailstock. If you have not got a suitable gauge then turning a piece of work between centres and measuring also works it is just much slower....

It is more likely to be horizontal misalignment than vertical, unless you have some  :censored: under the tailstock.

Jo
Title: Stew's Simple Mill Engine
Post by: NickG on June 19, 2013, 03:34:50 PM
Unfortunately I don't have a 3mt live centre and my revolving one isn't that great as the point isn't very sharp! Got a few new 2mt ones so need a reducer. is the nipping a bit of sheet trick no good?! I don't have a test bar.
Title: Stew's Simple Mill Engine
Post by: NickG on June 19, 2013, 10:54:28 PM
Aaand on tonight's show, Nick files some metal ...

Fairly frustrating evening, still making it hard for myself! Tonight I wanted to do the crank webs & pin and finish the crankshaft.

I was actually quite pleased with myself for finding some steel only slightly thicker and slightly wider than I needed. A quick skim in the mill would sort this out. It needed skimming as it was chrome plated, otherwise I could have left it as the design is accommodating for minor dimensions such as this, as Stew intended.

Anyway, when I skimmed this unknown stuff it left quite bad machining marks as can be seen in pic - prob a combination of things, speed? I just tend to guess this on the mill :-/ Tool is a trusty solid tungsten end mill that was being chucked at work but I seem to use it for everything these days! Didn't use any cutting fluid, maybe the mill needs tramming in etc.

I was going to leave it but after a quick rub on some emery cloth I realised his bad they were and no amount of rubbing was going to get rid of them, considered flycutting but had already taken down to size do I decided why not try draw filing them - this took a few mins did each surface but looks much better.

Then marked out, cut off each end if bar and milled together to give sane length. After de-burring I stopped as was getting a bit late.

2 hours to get 2 small bits of steel the same size. Even my centre pop marks are in wrong position so will just use centre drill and dial on machine and see where that gets me!

I won't be putting the rad on as Stew's drawings call for, partly because I'll have to make an arbor and partly because I think it is kind of one of my OCDs, I only seem to like straight lines, don't really do curves otherwise I could file them!

Title: Re: Stew's Simple Mill Engine
Post by: NickG on August 02, 2013, 11:48:53 PM
Haven't done anything on this for over a month but I've been off work all this week and am all next so have been doing a couple of hours a night. Progress is very slow, I seem to be spending too much time taking metal down to size or squaring bits up. I also seem to be messing on trying to correct poor surface finishes from the mill too - I usually do the minimum possible, usually nothing at all from the lathe but from the mill there were lots of machining marks.

I finished the crank webs off but unfortunately managed a fairly sloppy fit on the shaft so have pinned them with rivets. Couldn't get the right fir on the pins either, one drill bit too tight, next one too loose so they're loctited too , hopefully it won't all start moving when i cut the centre out!

Also decided to do the con rod which was keeping me awake at night a bit! Basically I chickened out and decided to go for a version milled from flat rather than turned. The 4 jaw on the harrison is huge and i couldn't be bothered to get it out and set it up. Although it doesn't look as good as the original it's turned out OK I think.

 Had to file the rad free hand too, could have done on rotary tabke had it been set up but like Jo I've never used it. I cant really as no chuck compatibility at the moment. It would also have meant making an arbor. Could have used filing buttons but again would need to make 2 buttons and something to clamp them together so went for the mk 1 eyeball as Stew would say. It's partly hidden inside the crosshead anyway.

Next week should see increased capability in my workshop with the introduction of a shaper and a myford ML7. The myford is not as good as the harrison but if i purchase an adaptor i will be able to swap the chuck to the rotary table inc the 4 jaw chuck i got which i think has a myford back plate. Wil also be able to have the lathes set up for different things saving time and the shaper can be making things flat while I'm doing something else! Peoples lights will be starting to flicker in the street at this rate!

The news of the shaper got a mixed reception from my dad - he said he chucked one out when he was teaching!   He agrees it will give a better surface finish than the mill but the mill can do most things that can! Well at least it will keep me off the streets as my grandad used to say!

Don't worry about the nasty screws, they were not quite long enough to cut down for studs :-( really dont want to make any more proper ones but if needs must...
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on August 03, 2013, 04:09:48 AM
Glad to see you back on this one Nick. I would like to make it one day. Some progress is better then no progress keep it up bud.

Don
Title: Re: Stew's Simple Mill Engine
Post by: Jo on August 03, 2013, 06:58:52 AM
Nice to see some progress. But I am sure your misses is still suspicious of your sitting in bed at that time of the night playing with your phone :mischief:

Superglue is good for holding filing buttons in place  :naughty:

Jo
Title: Re: Stew's Simple Mill Engine
Post by: sbwhart on August 03, 2013, 07:02:30 AM
Good to see you are back at it Nick, I think its going to be a race between you and Lawrence/Dan as to who finishes first  :cartwheel:

Stew
Title: Re: Stew's Simple Mill Engine
Post by: NickG on August 03, 2013, 08:53:37 AM
Thanks all, good tip with the super glue. i'll keep plugging away, i haven't spent a penny on it which is good, it's all come from the scrap boxes. Good point Jo, it took me ages to write all that waffle lol, must keep it simple! Stew I was thinking about Lawrence doing it last night, must give him a ring to see how they are getting on!
Title: Re: Stew's Simple Mill Engine
Post by: vcutajar on August 03, 2013, 09:14:28 AM
I know the feeling Nick.  There are days when one spends time in the shop and at the end of the session it feels like there is nothing to show for the work done.

Vince
Title: Re: Stew's Simple Mill Engine
Post by: NickG on August 03, 2013, 10:47:19 AM
Yep, i should not have been so tight and bought fresh as Stew designed it to use stock sizes where ever possible which would make it much easier and less time consuming. Will get there though!
Title: Re: Stew's Simple Mill Engine
Post by: b.lindsey on August 03, 2013, 04:52:49 PM
Nice to see you back on this one Nick. Enjoy your week off!!

Bill
Title: Re: Stew's Simple Mill Engine
Post by: fcheslop on August 03, 2013, 07:53:06 PM
Looking well :ThumbsUp:
Im not a million miles from you should you need to borrow a test bar .Its 10/1/2 inches long
cheers
Title: Re: Stew's Simple Mill Engine
Post by: swilliams on August 04, 2013, 05:40:58 AM
Looking good Nick. Have fun with your new acquisitions!

Cheers
Steve
Title: Re: Stew's Simple Mill Engine
Post by: NickG on August 04, 2013, 03:36:16 PM
Thanks Bill, Frazer and Steve. The lathe is now sat in the garage but still in the trailer! It looks quite dinky compared to the Harrison but they are quite weighty ML7s. The garage will now need a bit of
a re-shuffle to accommodate the new machines. I was going to scrap the stand for the lathe and put it on a workbench but have now decided it's too good! I didn't realise but it's a genuine myford cast iron stand i think from something older which has had a couple of plates made to allow the ML7
to fit. Has a drip tray too.

Don't want to start doing anything with the tools yet though as I'll lose what little momentum I have on this engine!
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 14, 2014, 10:53:49 AM
Oh dear it seems to have been 8 months since I've done anything on this - but now I have just restarted and with some motivation I might just get it done for Harrogate show! I'll have to because I've said I'd put it on the stand! Well I've slowly been getting the new lathe and shaper operational and they are now working - nice machines. The shaper could clean up much better but I can't be bothered, have added a guard and nvr switch to myford along with quick change tool post, got a face plate and 4 jaw from David so it's now reasonably well equipped. Versatile having the two lathes, shaper and mill and finally set rotary table up which makes drilling bolt rings a piece of cake - well if they line up that is!

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/355CCD91-7958-4028-9110-3EEA86121E6C_zpsdj0frngw.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/355CCD91-7958-4028-9110-3EEA86121E6C_zpsdj0frngw.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/AB198CBC-8AF8-43D6-8A4E-A81EC51620A2_zpseri4zbla.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/AB198CBC-8AF8-43D6-8A4E-A81EC51620A2_zpseri4zbla.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/25B5993B-8196-48C1-8754-ADB716934108_zpswvvmdigl.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/25B5993B-8196-48C1-8754-ADB716934108_zpswvvmdigl.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/565A34AB-1FD3-4B3B-801C-B8114D2E80C7_zpssw2ko4ag.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/565A34AB-1FD3-4B3B-801C-B8114D2E80C7_zpssw2ko4ag.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/0B9AFFB3-854F-4211-B98E-681FBABDBC9F_zpsud2svx75.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/0B9AFFB3-854F-4211-B98E-681FBABDBC9F_zpsud2svx75.jpg.html)
Title: Re: Stew's Simple Mill Engine
Post by: Alan Haisley on April 14, 2014, 02:18:17 PM
With all that machinery you'll have no excuse to finish the engine now. Just remember that we are  :popcorn:

Alan
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on April 14, 2014, 05:00:02 PM
Ok Nick we are waiting bud.  :popcorn: You should love that Myford great machine.

Don
Title: Re: Stew's Simple Mill Engine
Post by: sbwhart on April 14, 2014, 06:55:58 PM
My word Nick you've quietly got together a nice range of machines.

No excuses now

  :stickpoke: :stickpoke: :stickpoke: :stickpoke: :stickpoke: :stickpoke:

Stew
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 14, 2014, 10:13:15 PM
True guys, My wife keeps telling me it's all a waste because I never use it so I'll have to get some use out of it! Don the story behind the myford is a bit sentimental, my grandad gave me his which is what first got me into the hobby but I naively sold it but always regretted it so when brother in law's dad said he was going to sell his, I bought it. I was never a great fan, I think because in those days (I was 16 or 17 I think) I didn't know how to set it up properly etc. Using the boxford at school used to give so much better results I thought it was the lathe at fault. This one however, with umpteen years extra experience seems pretty good so far!
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 14, 2014, 10:15:12 PM
The only extra things I would like for the workshop is some kind of power saw, maybe a decent pillar drill and a boring head - can do without first 2 though.
Title: Re: Stew's Simple Mill Engine
Post by: ths on April 14, 2014, 10:35:07 PM
That cast iron stand will give it a bit of rigidity, a good accessory in itself.

Hugh.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 14, 2014, 11:30:51 PM
When I agreed to buy it, I intended to scrap the stand as didn't recall it being any good, was going to bench mount it but when I got it home I thought the stand looked pretty useful. Seems it's from an ML3 looking at lathes.co.uk so it's got some adapter plates to let the 7 fit but as you say it's a pretty sturdy affair Hugh.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 17, 2014, 10:43:58 AM
Well, still plodding along with the cylinder. Certainly not rushing it but u have still forgotten to protect it from the chuck jaws leaving big indentations. I drilled the holes in one end long enough for the threaded holes and the two covers. Machined the detail on those then parted off. Had to put them back in the chuck to take a final skim off the parted face and in the case of the front cover machine the register. I did think of a method to make sure it all lined up but then I couldn't be bothered clocking everything in with 4 jaw as thought it'd take ages and I'd prob not improve much over the 3! Will be interesting to see if
It all fits! No pics of the covers yet. This was my method of ensuring the holes on the other end of the cyl were in the same orientation:
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/A5B8F719-14D4-437C-BBCB-0400ECF21D46_zpsq3doj3or.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/A5B8F719-14D4-437C-BBCB-0400ECF21D46_zpsq3doj3or.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/2EFA8BF9-1FB4-4CE6-B465-C6C206E9045E_zps3ynpjtrv.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/2EFA8BF9-1FB4-4CE6-B465-C6C206E9045E_zps3ynpjtrv.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/C1781E0F-7330-4E28-83A9-EC95FEEB4435_zps4fmmj04z.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/C1781E0F-7330-4E28-83A9-EC95FEEB4435_zps4fmmj04z.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/4121E52A-BE96-4DB4-B4ED-318CC381937F_zpsu1fzyntd.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/4121E52A-BE96-4DB4-B4ED-318CC381937F_zpsu1fzyntd.jpg.html)

Spotted them with centre drill then opened up to tapping size. The DRO on the quill is v handy for getting the depth right. Then used taper tap by hand just to start the threads off
Square and finished out of the machine. I hope that big blow hole in centre cleans up! Got two little 'helpers' now sometimes..
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/A32E52C7-D8D1-45F1-BCD9-A64D8A21F5EA_zpskeppvux8.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/A32E52C7-D8D1-45F1-BCD9-A64D8A21F5EA_zpskeppvux8.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/35471480-DF80-444D-BBD2-42F80196D0F8_zpsyqcdbvvi.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/35471480-DF80-444D-BBD2-42F80196D0F8_zpsyqcdbvvi.jpg.html)

Made these
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/8ADEE555-837B-4629-8F3E-A3DFF8630C24_zpsbuqp22il.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/8ADEE555-837B-4629-8F3E-A3DFF8630C24_zpsbuqp22il.jpg.html)

Any guesses from our friends across the pond(s) as to what these are?!

Back in the shop and starter boring the cyl.

The drills started wondering so it's a good job I found this tapered shank carbide tipped drill went gently and it was so rigid it picked its own centre rather than the earlier created wobbly hole. This is where I left things - the hole isn't quite big enough for my small boring bar and don't have a bigger drill ... Hmm ...

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/4E47ECDB-0FBD-4331-876A-C0A00D1D4551_zpscbrwvl7c.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/4E47ECDB-0FBD-4331-876A-C0A00D1D4551_zpscbrwvl7c.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/4D5F5199-C387-46BA-B293-85588F44D0DB_zpsa6lz59nn.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/4D5F5199-C387-46BA-B293-85588F44D0DB_zpsa6lz59nn.jpg.html)
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/4D5F5199-C387-46BA-B293-85588F44D0DB_zpsa6lz59nn.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/4D5F5199-C387-46BA-B293-85588F44D0DB_zpsa6lz59nn.jpg.html)



Title: Re: Stew's Simple Mill Engine
Post by: zimma on April 17, 2014, 05:28:20 PM
Yum Yum Yorkshire Puddings. Try making a plate sized one and fill it with meat, veg and gravy.

Graham (Originally from North Yorkshire!)
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 17, 2014, 06:11:33 PM
Yum! bigger ones I always find harder to get to rise up properly. I always have one first just with gravy for sun dinner!
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on April 17, 2014, 07:51:56 PM
Nick looks like you have a well equipped pit crew. Are those Muffins and what did you put in them? Good pit crew food though.

Don
Title: Re: Stew's Simple Mill Engine
Post by: Jo on April 17, 2014, 08:14:08 PM
Are those Muffins

 :lolb: Of the Yorkshire kind  ;).

Jo
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 17, 2014, 08:45:49 PM
They are Yorkshire puddings Don! Really they should be dished in the middle to hold gravy but these rose all over, never been able to get them perfect! It's batter mix same as pancakes or crepes (flour egg and milk) then stuck in the oven for 20 mins or so in probably what is a muffin tin with a bit of cooking oil or lard in each well heated first. May not sound the most appealing but It's a bit of an English speciality like fish 'n' chips! Equally as nice with jam or syrup on for a desert! Or cooked with sausage in them which is 'toad in the hole'!
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 24, 2014, 09:57:32 PM
I found a boring bar small enough and started boring the cylinder out to size.

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/A53F127C-D4CE-4BF1-8216-C01FABDCBC95_zpshkhvbswd.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/A53F127C-D4CE-4BF1-8216-C01FABDCBC95_zpshkhvbswd.jpg.html)

Prior to this I had spend some time stripping down, cleaning and adjusting an adjustable reamer but the boring operation gave such a good finish  I decided to leave it and take it all the way to size. It turned out a nice fit for both covers.

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/B48CC505-D837-438A-A5A8-3C9B21856C39_zps04jsctxb.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/B48CC505-D837-438A-A5A8-3C9B21856C39_zps04jsctxb.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/52C25A15-7998-418B-8772-C4B4984D30B0_zpssoba4fap.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/52C25A15-7998-418B-8772-C4B4984D30B0_zpssoba4fap.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/3EEF3AC7-BEFB-46FF-9FCB-A6EC35EEFF15_zpsvzmhqimr.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/3EEF3AC7-BEFB-46FF-9FCB-A6EC35EEFF15_zpsvzmhqimr.jpg.html)

And this was the first time I've got the mating parts with a rig of bolt holes to line up!!

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/11A48C6F-9110-43DF-975E-8F29600DB880_zps2xgqn7y0.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/11A48C6F-9110-43DF-975E-8F29600DB880_zps2xgqn7y0.jpg.html)

Then it was off to the shaper to machine the flats. I calculated how much needed to come off to leave me the 16mm wide flat for the valve chest - the mounting flat I had to make smaller - went for 10mm wide as I blindly thought I'd like to put a ring of 6 holes (carried away with the rotary table lol) - this means one is at the bottom leaving little meat to mill off! I should know by now that most things are designed the way they are for a reason! Anyway, there's plenty of meat left with a 10mm wide flat and I have some 10mm thick steel which will need to be 14.25mm high to give me the correct centre height. Should still look ok I reckon.

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/5FA2006F-11B7-4F41-B77F-E9D8890053E4_zpsfyauncra.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/5FA2006F-11B7-4F41-B77F-E9D8890053E4_zpsfyauncra.jpg.html)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/050E6204-4327-44D7-A1B1-06ED49D947D2_zpsczgdqfxe.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/050E6204-4327-44D7-A1B1-06ED49D947D2_zpsczgdqfxe.jpg.html)

Title: Re: Stew's Simple Mill Engine
Post by: Jo on April 25, 2014, 09:55:47 AM
 8) Nice to see you using your shaper, must use mine more.

 :o but were you not just a little brave getting near that moving shaper with your camera? My shaper has in the past given me a black eye and that, thankfully, was not the ram

Jo
Title: Re: Stew's Simple Mill Engine
Post by: ths on April 25, 2014, 10:31:02 AM

My shaper has in the past given me a black eye and that, thankfully, was not the ram

Jo

Then what was it??

Hugh.
Title: Re: Stew's Simple Mill Engine
Post by: Jo on April 25, 2014, 10:44:23 AM
 :ROFL: It was me being a silly fool and reaching down the side to pick up something I had dropped just as the power feed moved the handle round which as usual I had left on the end of the shaft so that I could wind it back after and it caught me  :facepalm:

The guys in the office were very good no one asked how I had got that shiner  :-[

Jo
Title: Re: Stew's Simple Mill Engine
Post by: Stuart on April 25, 2014, 11:26:48 AM
Nick

I am not from Yorkshire but you are doing those puddings wrong

Mix as you have said pour the mix in the roasting pan put a trivit over it and roast the joint (beef ) over the top that way the meat juices will impregnate the pudding

Those were the days when I was a carniviour doc said drop of the meat for health reasons

Stuart
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 25, 2014, 03:02:25 PM
I enjoyed using the shaper for the first time Jo, it gives a great finish and nice flat surface. Just after I took the photo something weird started happening, it was giving an uneven surface but then realised the tool wasn't tight and slipping down, caught in time before it ruined everything! Just took the pic with the i phone so wasn't like I was looking through the view finder lol!

Stuart I've heard people cook them in the beef juice but didn't know how! Yum!
Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 27, 2014, 01:46:27 PM
Why is there always something that gets in the way?! I needed to clock in the vice and tighten it up on the milling table before I did the next operation as is last had the rotary table set up on it - need another milling machine Jo lol! Anyway, it was going surprisingly well, just by chance I got it square within 0.01mm or something, went to tighten it up and the tee but appeared to turn to mozzarella before my (http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/16021712-F17C-441C-8458-7EDFAE5BE5FB_zps6ut2xtoh.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/16021712-F17C-441C-8458-7EDFAE5BE5FB_zps6ut2xtoh.jpg.html)

Tried another tee nut and that was the same just felt like getting to between nipped / tight ish and just fell apart - last one was the same. Great, spent next couple of hours making a new one. On first inspection they appeared to be different failure modes:

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/05296E3C-EE3D-47CC-8EE7-525C56F3CFC2_zpsh9741rvi.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/05296E3C-EE3D-47CC-8EE7-525C56F3CFC2_zpsh9741rvi.jpg.html)

But had a closer look later and realised what had happened. The stud didn't go to the bottom of the tee nut which meant it was trying to simply pull the rest of the nut away from the wider bottom but shearing it through its weakest point. This definitely wouldn't have happened had the stud gone right to the bottom. I still think they were made of cheese mind you but more like mature cheddar than mozzarella. This still doesn't really explain why it's been ok up to now (maybe fatigue?) and why the other side was and still is ok. Have sorted a new set if studs which go right to the bottom now though. The new nut isn't a proper tee just a flat bit if metal the right size without the top bit but this is much stronger stuff anyway, the thread will probably be the weaker point now but plenty strong enough.

With this sorted I clocked the vice back in.

Next job was to drill and tap the holes for the valve chest. Thought I'd do this by coordinates the old fashioned way counting the turns as no DRO!

 (http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/2808E298-9BD5-4DB6-85CF-2A80CE7CF572_zpso4uyhdot.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/2808E298-9BD5-4DB6-85CF-2A80CE7CF572_zpso4uyhdot.jpg.html)

Seemed to work pretty well, centre drilled first then went back to drill to depth then start the tap off in each hole. Didn't bother with taper tap in small hole like this as it'd prob just pull out. Could have done to grind the point off to get a few more threads but it's ok.

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/67859D0A-F838-41FC-A39A-EEB56A4BF869_zpsmnjru2m5.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/67859D0A-F838-41FC-A39A-EEB56A4BF869_zpsmnjru2m5.jpg.html)

Looks like I'd drilled the ports in between doing this.

Finished tapping off by hand, Jo would say these 2mm taps are massive but small for me and easy to snap!

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/36B27696-F80A-4289-A77D-F8D6EE497AB7_zpsmkqxyfxu.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/36B27696-F80A-4289-A77D-F8D6EE497AB7_zpsmkqxyfxu.jpg.html)

Back into the mill on its end to drill the ports from end of bores. There was 1mm of meat either side so not too bad. This went well, pretty easy with this straight port design over traditional angled ports. Good simple cylinder design.

Finally mills the 2mm deep pocket to allow steam / air through.

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/8567B218-B03C-4726-B84C-E932FE74BA9E_zpsymoyi6um.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/8567B218-B03C-4726-B84C-E932FE74BA9E_zpsymoyi6um.jpg.html)

Completed cylinder except for mounting holes.

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/6D52670E-8B0E-403B-8945-15C17C61497B_zpsxkpvi7tu.jpg) (http://s.photobucket.com/user/NickG24/media/Mobile%20Uploads/6D52670E-8B0E-403B-8945-15C17C61497B_zpsxkpvi7tu.jpg.html)

Title: Re: Stew's Simple Mill Engine
Post by: NickG on April 27, 2014, 01:49:55 PM
1.5mm either side not 1mm!
Title: Re: Stew's Simple Mill Engine
Post by: arnoldb on May 01, 2014, 09:32:16 AM
Good going Nick  :ThumbsUp:

Looks like those T-nuts were hardened but not tempered afterwards...

Kind regards, Arnold
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 01, 2014, 06:50:30 PM
Yeah could be Arnold, they had a structure I wouldn't have expected from normal drawn steel inside, looked more like a cracked casting! Chinese junk I think.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 10, 2014, 08:35:34 PM
Hi all, been burning the midnight oil in attempt to make some progress on this engine it seemed like a box with a few bits a couple of weeks ago and it seemed the finish line was miles away.  :headscratch:

Anyway, here are a few pics of progress  ;D

Forgot how convenient using the 4 Jaw was for making small components flat! This is bringing the valve chest Down to size.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/4362D99B-0518-492A-BAC2-6D70DDD25ABF_zpsrlmt1xd2.jpg)

Setting up for the offset bore - I centre drilled in the mill then set the centre mark running true using this technique - I was sceptical but it was pretty quick to get it running true within a couple of hundredths of a mm.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/0A28DDC2-4FBC-4A5C-B790-14EC986B6C20_zpsqanswoae.jpg)

I didn't have any hex the right size for glands so thought I'd try something else new and try the rotary table on its side to drill tommy holes. Was planning on doing 6 but duh ... The jaw of the chuck was in the way on 3 of them so 3 it was! Collet chuck would be useful for this sort of thing but I'd need a 2mt one, beginning to think that would be quite useful actually.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/41387792-0F3C-48B0-981E-7A358E52E8F5_zpswshmchaf.jpg)

This was making one side of the pivot for the valve / eccentric rod - I did this a little differently to stews, decided to make the valve rod shorter and not bother with the guide. It should be ok as it is a piston valve so mainly guides itself and it has the gland - I did that differently too, mine is just a guide as it is inside admission piston valve it isn't absolutely necessary. I can see why Stew did it with the guide though - good practice and the longer rod makes it much easier to set the timing and totally takes the criticality out of the length of the valve and eccentric rods.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/CBAF3259-1E24-44E2-8CE9-04E8E07BF359_zps2q2qgfja.jpg)

No action shots of these parts but thought they came out ok! Not dimensionally perfect but something I could adjust for on assembly and all a nice fit.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/3D485C08-0CF0-459C-98FB-6076AE981F2B_zpsaunxlazo.jpg)

Cast iron piston on its rod is hidden inside the cyl for a test fit - good finish and fit, no lapping or anything can,t be bothered with that molarky!
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/9B9B6BB7-D991-4FC8-A9BD-2FD9333ADCBE_zpsop5nwmuu.jpg)

Back to the valve chest, finished off, cap and inlet made.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/EEBF7F69-7080-4138-8CE6-348754A3D2AB_zpsstxgsrgr.jpg)

Pivot finished
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/90363F59-7D5F-4121-A3FD-3AF31C9528F3_zpsy5v1s5l3.jpg)

Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 10, 2014, 09:06:56 PM
Was getting towards the home straight at this point thought id do the base then at least I could plonk all the bits on it for Harrogate.

Nothing to fear about the brown stuff if you just treat it like a bit of metal!  :Lol:
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/5773710A-37F4-4045-BE98-6F1C21C5DBE0_zpscxg1iy5e.jpg)

Genius ...
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/5CA39C28-68A1-4886-B06B-22BE15C6DC05_zpsqelwasae.jpg)
Apart from my first attempt had the screws through a softwood button in the middle and the cutting force proceeded to rip the screws through the wood and take a chunk out of the end of the base!

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/8BCB7229-AC43-4FC6-9298-A61F022BD226_zpsxixty66l.jpg)

Flycutting cut out for flywheel lol always thought of this but never thought it'd work ... It did. White stuff is glue where the wood has had a joint down it at some point in its life.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/BF7529E5-2F1E-4505-849F-81F88F57D2A2_zps8122o11c.jpg)

This was risky - measured and calculated all the points for holes, marked for sanity check but done by coordinates using dials ... So need a dro!
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/5731562F-AED5-411A-8D10-EB7DD10FA9E3_zpsfgyn4yio.jpg)
This was a struggle working out so late at night after a day at work.

Another good reason for drilling base on wood - holes spotted through for clearance for screw heads on underside. Finished base with a bit of teak oil. Oh forgot to say I acquired a new toy for brown stuff from dad ... a router. This was much easier and faster than milling all the way around the edge and getting steps to line up!
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/979BA968-9E90-4F95-BE25-13F0818CC006_zpsym3vpz36.jpg)

Coat of primer on base - this paint vie been using is pants, seems to take weeks to harden, some sort of enamel, maybe need to stove it !
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/BCAB0B80-CF44-4D4D-98BF-0CB3792A05FD_zps60nempaw.jpg)

Eccentric - I decided to use a slightly different design here with a plate and a screw, think it was Elmers engines I'd seen it on. Drilling the offset hole in 4 jaw, then I could simply turn a shoulder, part off and part off a 2mm thick piece for the plate.
(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/571B1499-6F5B-427F-989B-DF6B9F7C33FF_zpsqfqm0vou.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/22EE2ACD-F1DB-4D6B-A911-258B1300FFE2_zpsoetsvrgm.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/6B6A8ACA-C01B-4BB9-980A-CFA544AE8820_zps2wrja4wm.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/5C69AC94-34D1-4132-8A5A-E67AFB780A14_zpse90nlh5j.jpg)
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 10, 2014, 09:32:37 PM
Phew - worked until midnight on Thursday and Friday night - absolutely knackered but finished just in time for the show - that'll teach me to enter an exhibit when it's just a box with a fee bits in it!

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/A74B6113-3B5C-484C-ACF7-EA431756BDB7_zpsudbindue.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/A2DAF5F9-A561-422B-B104-6D224D274A78_zpsssbvkb9p.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/39BBF51C-1890-40A9-AD21-905438BFF088_zpsxjkluloh.jpg)

(http://img.photobucket.com/albums/v287/NickG24/Mobile%20Uploads/16716980-C2C2-4C5D-87AF-2B5CCEEAE3CC_zpsmhwvyvcy.jpg)

I changed the configuration a little, when I made the crankshaft it was to stews prelim drawings which had an error and it ended up too long with a gap between where the bearing and flywheel go. So I spaced the bearings out and decided to put the eccentric between the crank and bearing on the flywheel side to fill the gsp. This meant turning the cylinder around. I also turned the valve chest the other way up as I think before I bored it I realised it was a marginally better fit or lined up better with the ports that way before I bored it. This makes the inlet a problem, I was planning to have a pipe going straight down hen through the side of the base but ran out of time! This made getting a pipe on it v difficult today as the inlet was just a random this'll do sort of size and is a bit long.

It is all a bit stiff but I can confirm as of a few hours ago that it's a runner !  :whoohoo:Took about 15 psi as it's tighter than I would have liked - combination of binding on piston / rod and valve rod. I probably didn't get the machining sequence quite right so as to get no runout. Because I used stock sizes for piston rod and valve I relied on the concentricity of the chuck and collet chuck which with the fits I had wasn't good enough.  It'll loosen off if get chance to run it but sorry no vid for a while as I don't have a compressor  :( it was thrown together in a bit of a hurry in the end, gaskets are poor and really the baseplate is too think - 3mm aluminium which I thought would be ok when screwed down and all bits bolted to it but you can see it flex.

Oh, also, stud police should look away now, some are too short, some are too long but it's just cheap and cheerful fasteners! I found some nice (dare I say it, cap screws) for the con rod which were just the right length.

Enjoyed the project, lots of firsts for me and probably the most complex project I've done so far despite being a beginner's engine. Lots of learning points too - I was a bit down hearted last night when assembling as nothing seemed to be going right but after a bit of fine adjustment this morning I got it to a reasonable level of friction. Hopefully it'll bed in eventually. The flywheel has a bit of  a wobble due to my crankshaft fiasco but not going to dwell or start remaking parts, onwards and upwards and learn lessons for next time.

Thanks to Stew for designing another nice engine and sharing the plans - will have to show Lawrence when am back, I expect he's onto his next project by now!


Cheers  :cheers:

Nick
Title: Re: Stew's Simple Mill Engine
Post by: zeeprogrammer on May 10, 2014, 10:10:18 PM
Congrats Nick!
Looks good. That's a lot to do in a couple of days.
I'm liking the color and the base.

But...there's just one little thing missing. Just one.

A video!  ;D
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on May 10, 2014, 10:13:31 PM
Wow! You have been busy Nick and a fine job of it to bud.  A video would be nice.  :stickpoke:
But I do like.............. :praise2:

Don
Title: Re: Stew's Simple Mill Engine
Post by: Jo on May 11, 2014, 08:03:06 AM
 8) Well done Nick she looks very nice  :ThumbsUp:

I wonder if a set of castings has caught your eye as you next engine :naughty:

Jo

Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 11, 2014, 08:08:22 AM
Thanks Zee and Don, got there eventually but took nearly a year looking at the start of the post!!! for some reason when I've looked at this on tapatalk this morn there's only my latest post on, I had split it into 2 but there now seems to be a load missing :-( never mind. The paint was annoying because as I was handling components to assemble was getting finger prints and bits running off etc. as I said, I never thought to get a vid on the one run it's done and it will be at the exhibition today but may go to retrieve it from club on tues and try to sort a better inlet to get a vid / run it in a bit.

Ps just checked on website and post is there phew! Zee all that last bit was over a couple of weeks but didn't have time to update!
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 11, 2014, 08:12:19 AM
Thanks Jo, just saw your reply. Possibly the DT will be my next engine although they still scare me. At Harrogate yest there was a new set of castings that caught my eye at Blackgates - a horizontal and vertical engine with 1" bore, set of 15 castings and drawings for £69 ... Later find out they only did 5 sets of each to see how they went and the price is bound to go up. They weren't the best, bit rough around the edges but nonetheless a bargain at that price.
Title: Re: Stew's Simple Mill Engine
Post by: fumopuc on May 11, 2014, 08:16:07 AM
Hi Nick, that is looking very nice. Well done. Have fun at your show.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 11, 2014, 08:20:31 AM
Thanks Achim, show was good, I went yesterday as you would expect, some incredible stuff there - all the more impressive when I've just struggled to make something so simple!
Title: Re: Stew's Simple Mill Engine
Post by: ths on May 11, 2014, 12:20:39 PM
Great work Nick, and good to see your take on Stew's design. Hugh.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 11, 2014, 12:26:59 PM
Thanks Hugh, the changes were mainly just to suit what material I had. Couple of bits of metal used were a bit suspect and it reiterated to me that it's usually easier when you know what it is you're machining! next project I think I'll buy material to suit!
Title: Re: Stew's Simple Mill Engine
Post by: sbwhart on May 11, 2014, 04:07:32 PM
Hi Nick great job, are you planning to post a video?.

I like the colour scheme  black with brass that's my favourite combination.

Cheers

Stew
Title: Re: Stew's Simple Mill Engine
Post by: b.lindsey on May 11, 2014, 04:32:45 PM
Very nice Nick, I like the base and color choice too, simple and "engine" looking!!  I hope you can post a video too as time permits.

Bill
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 11, 2014, 04:35:28 PM
Yeah I got the colour scheme from one of your other engines! Think it was the Simpson and
Shipton. Yeah will get it back on Tues and get a video during the week somehow! Haven't got my own compressor but think club have got gone or failing that will use dads.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 11, 2014, 04:37:33 PM
Thanks Bill, using the router for the base was a doddle although I did manage to scorch one edge! I squared it up on the milling machine first.
Title: Re: Stew's Simple Mill Engine
Post by: Kim on May 12, 2014, 02:38:21 PM
Very nice work on your engine Nick!  :ThumbsUp: I really like it.  I can relate to it taking a year to do a simple engine!  That's my kind of time frame for this work.  Yours turned out very nicely.  You don't need to worry how long it takes.  It takes what it takes, and as long as your having fun, what does it matter?  (This is what I tell myself! :)).
Kim
Title: Re: Stew's Simple Mill Engine
Post by: fcheslop on May 12, 2014, 04:11:32 PM
Nice engine Nick :ThumbsUp:
Soooo whats next .
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 12, 2014, 09:10:14 PM
Thanks Kim, good point mine never go to the time frame I expect! Cheers Fraser erm, undecided - got the double Tangye castings but not sure I'm up to the job. Want to
Finish an electric loco I started for the boys first to get it out of the way but also want to rebuild a steam loco I have and build an I.c engine as haven't made one yet but have always wanted to. What do you reckon?!
Title: Re: Stew's Simple Mill Engine
Post by: fcheslop on May 12, 2014, 09:28:13 PM
Go for what ever shouts build me :ThumbsUp:
Title: Re: Stew's Simple Mill Engine
Post by: arnoldb on May 17, 2014, 08:33:28 PM
Good going Nick - nowt wrong with that engine  :ThumbsUp: :ThumbsUp:

You're in the same boat as me - my dad also gave me a router, and it's a handy bit of kit for making engine bases - but like you I've had to resort to the mill for wood-working on many occasions  :Lol:

Video ?  :stickpoke: ;)

It's good to see that you're enjoying your new shop!

Kind regards, Arnold
Title: Re: Stew's Simple Mill Engine
Post by: NickG on May 18, 2014, 04:40:02 PM
Thanks Arnold, I know I know - video! I'm usually the first to want I show my stuff working but unfortunately this one isn't going to run on lung power! Might be able to take it down to the club and get one there, failing that I reckon I'll soon have the compressor from my dad!!
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 13, 2014, 09:40:25 PM
Sorry, this is a terrible video of it running powered by a weed killer bottle but it's the best I can do at the moment. It needs a good run as it is all pretty tight, only turned over for a few short bursts!

https://www.youtube.com/watch?v=_dL-apwzGQM
Title: Re: Stew's Simple Mill Engine
Post by: Johnmcc69 on June 14, 2014, 01:21:37 AM
That's great Nick!! She's a runner!!

 John
Title: Re: Stew's Simple Mill Engine
Post by: sbwhart on June 14, 2014, 06:23:34 AM
Well that's a different way of getting air to her, I'd thought of using a space hopper as an air cylinder to increase pressure you would just have to sit on it  :Lol:

Looks a good runner Nick  :whoohoo:

Great job

Stew
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 14, 2014, 12:07:18 PM
Ha, yeah I couldn't think of anything then have been weed killing recently and thought it might work! Space hopper is a good idea!! Runs ok but is still v tight!
Title: Re: Stew's Simple Mill Engine
Post by: Ian S C on June 14, 2014, 12:37:39 PM
I.v got a 3 litre sprayer, it runs any of my little wobblers, but did not have the volume required to run the Stuart Turner S9, but that's quite a big engine, 1 1/2" stroke, 1 1/2" bore, double acting.        Ian S C
Title: Re: Stew's Simple Mill Engine
Post by: Kim on June 14, 2014, 04:01:32 PM
Congrats on a runner Nick!  It looks great!
And using the sprayer pump is a brilliant idea! I'd never thought about that before.
Thanks for sharing the video!
Kim
Title: Re: Stew's Simple Mill Engine
Post by: Alan Haisley on June 14, 2014, 04:18:31 PM
It's pretty and it runs.  :praise2:
Title: Re: Stew's Simple Mill Engine
Post by: Maryak on June 15, 2014, 04:43:40 AM
Congrats on a runner Nick!  It looks great!
And using the sprayer pump is a brilliant idea! I'd never thought about that before.
Thanks for sharing the video!
Kim

Me 2  :ThumbsUp:

Best Regards
Bob
Title: Re: Stew's Simple Mill Engine
Post by: fumopuc on June 15, 2014, 06:09:29 AM
Hi Nick congratulation for this runner. The idea to use the weed killer spray pump is brilliant. Some years ago I have  run an engine by a normal small kitchen steam cleaner with success, but the following conflict with the rest of my family will let me never try it again.
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 15, 2014, 11:50:58 AM
Thanks chaps, hopefully next year at Harrogate it will get fully run in on the compressor! Gaskets probably aren't great, there's nothing in the piston rod gland and flywheel has a wobble but it runs ok and plenty of new learning points so reasonably happy.

Ian, yes the spray tends to run out pretty quick and I could only just pump fast enough to sustain it so with a 1 1/2 x 1 1/2 no chance!

Achim, haha I can see how that wouldn't go down well!
Title: Re: Stew's Simple Mill Engine
Post by: Don1966 on June 15, 2014, 02:56:07 PM
Congrats Nick just finding you video. She runs pretty good to me bud and looks great. I like........... :praise2:


Don
Title: Re: Stew's Simple Mill Engine
Post by: Stilldrillin on June 15, 2014, 03:16:24 PM
Nicely done Nick!  :ThumbsUp:

I wouldn't have thought of a spray pump......  :praise2:

David D
Title: Re: Stew's Simple Mill Engine
Post by: NickG on June 15, 2014, 07:22:53 PM
Thanks Don and David!
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