Model Engine Maker

Engines => From Plans => Topic started by: 90LX_Notch on August 19, 2018, 07:28:54 PM

Title: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 19, 2018, 07:28:54 PM
My next build has begun.  It is George Britnell's Inline Four Cylinder Over Head Valve Internal combustion engine. 

This will be a long term build due to work and kid related activities.  If updates are sparse please inquire with a post.  It helps me to find shop time knowing that someone is following along.

Engine Block:

The block is 6061 Aluminum and was first squared.

Somehow the pictures of the more difficult side are not on the camera.  I was stumped for awhile as how to get the .062 radius that is called for at the bottom corners and transitions.  My .125 ball endmill did not have the required length of cut.  I finally realized that if I angled the mill's head at 45 degrees I could machine and blend the required radii. 

Fortunately, I do have the pictures for the easier side.  I scribed the necessary lines and began to whittle away at the block.  Once the required angle was roughed, the engine block was transfered to a fixture plate that allows it to be set for angles in the mill's vice.  This particular angle fixture design came from one of the contributors of the "Shop Made Tools" thread at  Home Shop Machinist.  Once the angle was set the the block was indicated and clamped to the fixture with c-clamps. 

Once both sides were machined I started to do some hand blending with sandpaper and stones.  I still to do more blending but will hold off until the engine block is completed.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 19, 2018, 07:31:21 PM
More pics
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on August 19, 2018, 08:28:25 PM
Good start on the block Bob. I will be here for the duration, no matter how long it takes :)

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 19, 2018, 10:51:37 PM
Thanks Bill for jumping onboard. 

I'm excited for this build.  This is such a cool little engine.  I was blown away by George's video of it when I started in this hobby nine years ago.  We all marvel at George's work; but, to actually build one of his engines to print, really opens one's eyes to just how skilled he is.  To say it's humbling is an understatement.  My skills are going to get pushed beyond their limit.  But, that is the only real way to build skills.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Tennessee Whiskey on August 20, 2018, 12:22:46 AM
 :popcorn: and  :DrinkPint: in hand: I’ll ride along too Bob.

Eric
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gbritnell on August 20, 2018, 01:19:19 AM
Bob,
Needless to say but if you have any questions please don't hesitate to ask.
I'll be following every step of the way.
P.S. You will want to put the cam hole in before opening up the crank pockets.
gbritnell
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 10KPete on August 20, 2018, 01:20:56 AM
I think it's safe to say that many of us have a seat for this show!

 :ThumbsUp: :popcorn: :DrinkPint: :ThumbsUp:

Pete
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 20, 2018, 01:30:58 AM
Glad to have you along again Eric.

Thanks George I appreciate it.  I've been able to figure out everything so far.

Thanks so much Pete.  I am happy that you coming along again for this one.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: zeeprogrammer on August 20, 2018, 01:53:36 AM
As I said in another thread...I'm watching.  :popcorn:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on August 20, 2018, 07:53:15 AM
I will be following along as well  :ThumbsUp:  :ThumbsUp:  :wine1:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: crankshafter on August 20, 2018, 08:31:19 AM
Bob
I'm in for the ride ;)

CS




Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: deltatango on August 20, 2018, 08:48:19 AM
Hi Bob,
I'm following this one as well. It doesn't matter how long it takes!
David
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 20, 2018, 08:23:35 PM
Zee, Roger, crankshafter and David thank you for signing on for this journey.  Your support, as in the past, is greatly appreciated.  I'm hoping to make some progress this week and post it over the coming weekend.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: fumopuc on August 20, 2018, 08:25:06 PM
Hi Bob, me too, will wait for each new step of this build.
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Sleddog on August 21, 2018, 12:22:48 AM
I've got my chair slid into position too. Right next to the popcorn :popcorn:
Looking forward to following along.

Jack
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Dave Otto on August 21, 2018, 12:27:16 AM
Hey Bob,
Looking forward to following along with your new project.


Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 21, 2018, 11:39:40 AM
Achim, Jack and Dave, thank you for joining in.  It's going to be a long ride.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 26, 2018, 04:16:19 PM
Engine Block continued:

Unfortunately, I didn't get any shop time this past week.  Yesterday, I was able to get a little time in and did some layout work for the next machining operation.  I am hoping to get some time in this afternoon to actually do some machining.

As far as the layout goes, I thought I'd post a picture of my Brown and Sharpe 570 vernier caliper in action.  It is an old vernier that I picked up that has two holes in it that are for setting dividers.  It provides an easy way to set an accurate radius for layout work.  I usually don't do layout work and just machine off of the dials from datums.  For this particular venture, I have the layout lines to serve as a check and balance to hopefully prevent a machining blunder.
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gbritnell on August 26, 2018, 06:05:35 PM
HI Bob,
Even though I have digitals on my machine I always give myself layout lines for reference.
gbritnell
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 28, 2018, 08:53:44 PM
George they are a big help with the intricacies of this part.

I literally got called into work Sunday right when I was about to go into my shop.  I was able to get in the shop a little Sunday night and installed a toolmaker's button.  The button will allow me to indicate accurately on the rotary table to mill the pocket for the timing gears.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 03, 2018, 10:11:36 PM
Engine Block continued-

After the layout, the block was tapped 5-40 and a Toolmaker's Button was installed.  The Button was then carefully moved into position.  The Engine Block was then setup on an angle plate and mounted to the Rotary Table.  The Button was then indicated true to the Rotary Table; finally, the RT was indicated to the spindle.  Then it has just been a lot of cranking of the handles and whittling away at the aluminum.  This feature is probably about 90% finished.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on September 03, 2018, 10:28:36 PM
Looking great Bob. Glad you are finding some shop time.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 03, 2018, 10:32:52 PM
Thanks Bill.  Thank goodness for this long weekend.  We had a wedding on Long Island that chewed up most of it.  Luckily I was able to get in the shop this morning and machine what I posted above.  Now I need to get off of this computer and get back at it.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: zeeprogrammer on September 03, 2018, 10:54:12 PM
I got really confused by the photo of engine block.
I don't recall your posting a picture of the project and my googling left me even more confused.

Can you point me to a picture of what you are building?
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 04, 2018, 12:54:17 AM
Carl a video is worth a million words.  It is George's four cylinder.  I am currently machining the front of the block.  The pocket is where the timing gears will reside.

https://www.youtube.com/watch?v=yYKUlcy-g1w

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: zeeprogrammer on September 04, 2018, 12:56:54 AM
Fantastic!
And thanks. That's going to be a fun engine!  :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 04, 2018, 08:50:33 PM
Block continued-

Once all of the pocket was milled with the 3/16 endmill that I was using, I moved onto the od of the pocket that protrudes beyond the block.   I calculated the wall thickness and used my Starrett 220 Multi-Anvil Micrometer to verify the dimension.  Next, the bottom edge of the block was indicated square to the table.  This allowed me to position x and y in order to cut a .355 radius inside the pocket.  The radius is required for the crank timing gear.  I used my boring head to cut the radius.  The process was repeated, and a .434 radius was cut for clearance for the water pump.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on September 04, 2018, 10:08:21 PM
You are on a roll Bob!! Always like following your builds.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 05, 2018, 01:19:56 AM
You are on a roll Bob!! Always like following your builds.

Bill



Thanks Bill!  You made my day!  I was able to even get a little shop time in this evening.  I'll post the pictures tomorrow.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Tennessee Whiskey on September 05, 2018, 07:44:05 PM
I’m here also Bob. Looks like you are moving right along. ‘Fraid you’re going to have to find something larger than a pill bottle to take this one to shows in though 8)

Eric

Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 06, 2018, 11:34:40 PM
Thanks Eric.  Maybe a shoe box to transport this one.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 06, 2018, 11:41:37 PM
Block continued-

The tangent points of the two internal radii needed to be milled in a straight line along with the outside of the wall. In order to align the radii, two ball bearings and tool blank were used.  This worked well and the tangents were sucessfully blended.  Next the outside of the wall was milled. 

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: zeeprogrammer on September 07, 2018, 12:13:21 AM
Neat!
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on September 07, 2018, 12:57:26 AM
Yeah, neat trick Bob. Have to file that one away.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Dave Otto on September 07, 2018, 01:13:50 AM
Nicely done Bob!

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 07, 2018, 02:07:28 AM
As always, thank you gentlemen for your support. 

I posted the bearing trick in "Tip and Tricks" with a writeup.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on September 07, 2018, 08:45:48 AM
Off to a great start  :ThumbsUp:  :ThumbsUp:  :wine1:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 09, 2018, 04:27:52 PM
Block continued-

The timing case feature is now complete, sans the threaded holes for the cover and some additional handwork.  The .062 radius on the outside back edge was done with a lathe tool that was mounted in a fly cutter.  The spindle was locked in position and the Rotary Table was cranked and acted like a Planar with the tool being fed in small increments.  This allowed the cutter to cut right up to the corners without trailing away as would happen if the tool was turning in the spindle. 

The outside of the small radius for the wall, which was machined in the above post were the tangent was milled, was done in a similar fashion.  The boring bar was mounted 180 degrees out from normal as if to cut an od with the boring head.  The boring head was carefully turned back and forth by hand.  After each cut, Z was increased .010 and the motion was repeated until the depth of the wall was fully cut.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 09, 2018, 04:28:52 PM
Thanks Roger for your support.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on September 09, 2018, 06:57:52 PM
Good to see you getting some shop time Bob. The block is coming along well.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 17, 2018, 03:18:12 AM
As always Bill, thank you for following along.

For a couple of different reasons I put the block on hold.  My allergies have been bad and the block requires more concentration than I am able to muster at this point.  Secondly, I have the Rivett 608 up on blocks incase the basement floods as Florence moves this way.  I was planning on boring the cam tunnel next and was going to set it up on the Rivett with an angle plate bolted to the faceplate. 



Crankcase breather-

In order to keep this build moving, I picked off a part that I could get through with my allergy situation.  I started the crankcase breather assembly by making the flange.  I started with a piece of .750 diameter aluminum and roughed out a blank.   The blank was then mounted to the .187 dia. expanding collet that I used for the flywheels in the "Tiny I.C." build.  The collet was used to face the back of the blank and was then transfered to a Vee Block, which was setup on the Rotary table.  The bolt holes were drilled along with one hole into the collet that allowed the blank to be pinned to help prevent it from moving during milling. The basic profile for the flange was then milled.  The smaller radii were filed by hand.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Art K on September 17, 2018, 04:03:44 AM
Bob,
Just in case I haven't chimed in yet I wanted to let you know that I'm following along. I have a great respect for George and it is great to start to see people building his designs. Great work so far.
Art








Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Kim on September 17, 2018, 05:48:29 AM
Nice little part there, Bob.
Sorry about the allergy situation.  That's no fun at all. Hope it gets better soon!
Kim
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 17, 2018, 10:49:42 PM
Thanks Art for following along as well as your kind compliment.

Thanks Kim.  Yeah, allergies are not fun at all.  I try very hard not to take anything for them and usually they clear up within a day or two on their own.  The fall is a particularly bad time for me. 

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: zeeprogrammer on September 17, 2018, 11:41:16 PM
 :popcorn: Following along.

Try not to sneeze in the shop. Those small parts will fly.
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Art K on September 18, 2018, 12:12:14 AM
Bob,
I started taking Wal-itin by my doctors recomendation it's Walgreen's generic version. Other wise I'd be blowing my nose all summer, oh yeah and sneezing to.
Art
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 24, 2018, 12:16:11 AM

Block continued-

The cam tunnel calls for a .312 diameter hole, 4.523 deep.  In order to get good geometry, the engine block was setup on an angle plate on the faceplate of the Rivett.  A toolmaker's button was used to locate the center point of the block.  As of right now, I am about halfway through the block with a .250 pilot hole.  It is taking an extremely long time to drill the pilot because the lathe is in backgear and the surface speed is far below what a .250 drill requires.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 24, 2018, 12:17:17 AM
Thanks Art for the tip.  Unfortunatly, there aren't any Walgreen's near me.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on September 24, 2018, 12:56:31 AM
That's quite a set up Bob!! Hope the allergies are better now.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 25, 2018, 12:16:28 AM
Thanks Bill.  My allergies were bad Friday and Saturday.  They were good yesterday.  I should have quit while I was ahead though.  I had a little mishap with the block. The boring bar rubbed and the block shifted on the angle plate.  I believe it is recoverable.  I just have to add an extra step to the plan that I had in mind.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gldavison on September 28, 2018, 04:20:12 PM
Hi Bob

 Just caught up on this build. Excellent work so far. I'll be following along. Did George have a build thread on this engine? I need a project for this winter, and this looks like a good one. So I need plans.

Gary
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gbritnell on September 28, 2018, 07:03:37 PM
HI Garry,
There is no build thread as it was made long before I had a computer or digital camera. I do have the drawings. Send me a personal email and I'll give you the particulars.
gbritnell
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 30, 2018, 11:42:29 PM
Thanks for following along Gary.

It will be nice if you pursue this engine also.  If we can get a third person (come on Bill), it will be the "Tiny" builds of a couple of years ago all over again.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 30, 2018, 11:43:50 PM
Unfortunately, I couldn't squeeze in any shop time this weekend.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on November 26, 2018, 03:06:17 AM
Well, it has been close to two months since I last posted in this thread.  Life has gotten in the way of any shop time.  However, I was able to get in the shop today and made a .250 diameter by six inch long boring bar.  The bar uses #44 (.086) drill rod as an insert tool bit.  I proofed it on a piece of 7075 aluminum using the above setup (faceplate and angle plate) and successfully bored a .300 dia, 1.5 inches deep.  Unfortunately, when I went to take a picture, the camera batteries were dead.

Hopefully, I can get more shop time in and start to move forward with this build.  Unfortunately, this winter is already stacking up to be bad.  We had a 10" storm hit us last Thursday and I have been called out several times since, for icey road conditions.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on November 26, 2018, 11:18:08 AM
I hear ya buddy!   Stick with it, it'll come back and winter wont last for ever....... 8)

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on December 16, 2018, 08:16:09 PM

Thanks for looking in Dave.


Block continued-

As mentioned above, I made up .250 dia boring bar.  It worked well enough to get the job done.  The cam tunnel is now through the block. 

With Cabin Fever fast approching I have decided to put this build on hold (as though I was making any real progress) and try to finish up an engine that I started on years ago.  If I pull that one off in time for CF it will be a pretty neat little engine.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on December 16, 2018, 10:09:02 PM
Man I love that lathe......parts look good too!

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Dave Otto on December 16, 2018, 11:41:36 PM
Nice work Bob, and yes what Dave said, I sure wouldn't mind having that lathe in my shop.

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on December 17, 2018, 12:03:36 AM
Your setups always amaze me too Bob. The block is coming along.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on December 17, 2018, 10:34:42 PM
Thanks for following along gentlemen.

Dave & Dave, yes, I love that lathe.  It is the crown jewel of my machines.

Bill, the setups aren't really that amazing.  I use to read a lot of old time machinist type stuff.  Those guys had amazing setups.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Art K on December 18, 2018, 03:09:13 AM
Bob,
Sorry I missed the memo explaining what lathe you have & why everyone is raving about it. :thinking:
Art
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on December 18, 2018, 03:21:41 AM
If the link works Art, this is when I bought it.  It is a Rivett 608 on the original oak cabinet.

http://www.modelenginemaker.com/index.php/topic,4646.0.html?PHPSESSID=s8nnihdaloa8lt7c8ujqj0cvd1

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 15, 2019, 12:05:25 AM
Wow, four months since I lasted worked on this.


Block continued-

A .250 diameter ball endmill was used to rough out the location for the crankshaft.  (The long range plan is to mill the pockets that that will form the webs of block, then install the caps.  The caps and block will then be drilled and bored to the finished diameter.)

The oil holes were drilled and reamed to .0625.  I chose to ream the holes because I can insert dowel pins in them for locational purposes for future setups.

I am currently in the process of drilling and tapping the 2-56 holes for the caps.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Art K on April 15, 2019, 03:16:56 AM
Bob,
Glad to see you are back at it, more than I can say for myself. Been busy after all.
Art
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 22, 2019, 02:24:38 AM

Thanks Art.  I am glad also.  It is so nice to be making some progress on this engine.


Block continued-

The 2-56 holes for the caps were finished up and the milling of the pockets began.  A .500 drill was used to rapidly remove some of the material.  Next a .500 endmill was used to rough out the pockets.  I currently have one of the pockets roughed out and have begun the second pocket.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on April 22, 2019, 09:55:35 PM
Good to see you back on this one Bob.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 23, 2019, 09:23:19 PM
Thanks a Bill, as always, thank you for your support.  Hopefully, updates will be more frequent now that plowi season is over.  I get busy after Memorial Day because of the pools opening; but, it is nothing like plow season.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Don1966 on April 24, 2019, 02:18:09 AM
Looks like your off to a good start Bob I will Be following along!..... :ThumbsUp:


 :popcorn:
Don
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on April 24, 2019, 01:55:16 PM
Bob, not to divert your thread, but you had mentioned some problems with the Tiny IC engine. Have you done any more with that and has it improved. I have found a start up method that works well on mine after it has been sitting (even overight) and still allows for hand starting. If interested let me know and I will send it via PM.

BIll
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 25, 2019, 10:59:31 PM
Thanks Don.

Bill- re Tiny, it'll just about to start, then foul the plug.  My plan is to make a new plug for it.  I would still be interested in your start method.


-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 30, 2019, 09:58:53 PM
Block continued-

Not as much progress as I had hoped for this past weekend.  I roughed out two more of the pockets.  I do have a good reason for the small amount of progress.  I had an opportunity to buy a mold maker's tools at a great price. 

I've been going through them and cleaning them.  I am also determining what I am going to keep and what I will have to sell.  I can't justify holding onto to tooling that is bigger than what my machines can hold.  I also don't need doubles and triples of measuring tools.

I'm very happy.  I did get some items that have been on my wishlist for sometime.  (Large roll cabinet (9 drawer Craftsman), gauge block set, 0-1/8 Albreicht drill chuck, angle block set, etc.)

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on May 01, 2019, 01:03:54 AM
Looks like a good score Bob. Have fun going through it all :)

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on May 01, 2019, 11:20:18 AM
Glad to see you back on this one  :ThumbsUp:  :ThumbsUp: That looks to be a good catch  :)
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 02, 2019, 01:27:59 AM
Thanks Bill.  Going through it is more of a pain than anything.  I already pulled out the "wow" stuff.  Now it is the, do I really need this stuff.

Thanks for checking in Roger.  It is a good catch for me.  It brings me that much closer to my ultimate shop. 

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 07, 2019, 01:46:28 AM
Block continued-

I did manage to get a small amount of shop time this weekend.  I finished roughing the last pocket and proceeded to finish part of the pocket.  The pocket calls for .125R corners; so a .250 end mill was plunged at the correct locations minus .005 to allow for a finish pass.    A .100 step was left on the bottom of the pocket for a .090R fillet that will be milled next.  The pocket should be .720 and and I am at .719 with gauge blocks.  I can definetely live with that.  If I can hold that for the other three pockets I will be very happy.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on May 07, 2019, 01:23:52 PM
Good to see some progress Bob. Were the gage blocks part of the new acquisition or did you already have them?

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 07, 2019, 10:01:37 PM
Bill the gage blocks are part of a set that was included in my recent tool purchase.  They are so nice to have on hand.

-Bob


Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on May 08, 2019, 02:05:40 PM
Thanks Bob, I thought they might have been a part of the tooling acquisition. Have always wondered how much I might use a set of those but don't have any currently.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 14, 2019, 12:51:38 AM
Block continued-

I was able to sneak into the shop this Mother's Day and make some progress.  I used the Zero Setter that I made a couple of years ago and swapped in a .250 endmill that has a .094R.  The Zero Setter allowed me to re-establish 0 in Z after changing tools.  The pocket was then finished to the correct depth and the .094R was machined at the bottom of the pocket.  Both the X and Y coordinates  were milled .001 less than in the previous operation so that finished walls were not touched.

The Zero Setter was used and the tools were then changed and the next pocket was milled leaving a .100 step.  This is the first project I have actually used the Zero Setter on and have to say that I am very pleased with it.  I was able to go to my target depth after a tool swap as though the original tool was still in the machine.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: ozzie46 on May 14, 2019, 01:33:21 PM
Did you do a build log on the zero setter? I can't seem to find it.

Ron
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Ye-Ole Steam Dude on May 14, 2019, 04:05:23 PM
Hello Bob,

Some really nice work and the build is looking good.

Have a great day,
Thomas
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 15, 2019, 10:58:01 PM
Ron-
Thanks for looking in.  I didn't post a build thread for it, just a completed project thread.  It is just two pieces besides the indicator.  A body that was machined for the indicator to slip into and a "pad" to fit over the indicator plunger.  If you have any questions or need any clarification do not hesitate to ask.  The only thing that I found from using it, is that if you rezero the Z dial during use; when you zero the indicator before changing tools you must note what the Z dial reads and set the next tool to that reading during the change.
http://www.modelenginemaker.com/index.php/topic,5824.0.html

Thomas-
Thank you very much for the encouraging words and for checking in.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: ozzie46 on May 16, 2019, 12:47:51 AM


 Thanks Bob.

Ron
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on June 08, 2019, 08:18:00 PM
Last week I was able to finish the pockets as well as the lifter pockets.  Things have been hectic so I was unable to post an update.  Today I began the lifter bores, a pretty straightforward operation.  Well, pooh happens.  Somehow, a .187 endmill cut a .215+ diameter stepped hole.  The required diameter is .203.  As far as I can figure, poor chip evacuation is the cause. 

I believe I can save the block by the use of bushings for the two bores that were machined.

I'll post pictures once I calm down.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Admiral_dk on June 08, 2019, 09:51:21 PM
Commiserations Bob

Been there and done that - or in my case has tried making a hole in a certain diameter and ending up with a very rough one somewhat bigger because of poor chip removal as you said  :facepalm:

Best wishes for the repair

Per
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on June 09, 2019, 12:46:54 AM
Per-

Thanks for the wishes.  I drilled the bores oversize and pressed in some plugs.  I'm going to let the Loctite set overnight and try again tomorrow.


-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on June 12, 2019, 01:59:48 AM
Block continued-

The same .250 endmill with .094R was used to finish the crank pockets.  It was also used to mill the lifter pockets.  As noted above the next operation was the lifter bores.  I used a two flute endmill with a high helix that yielded terrible results.  Two plugs were turned and pressed into the bad bores.  The pocket was once again milled. 

For a change of pace, I made a 5/16 diameter boring bar and ground a tool that will be necessary for a future operation on the block.  A test cut on a piece of scrap yielded a positive result.

-Bob

Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on June 17, 2019, 10:56:38 PM
Block continued-

The lifter bores were spotted with a .187 diameter endmill.  I am leaving them at that for now because I don't have a .203 diameter reamer. 

The next feature that needed machining were the "windows" that provide oil to the main bearings.  George calls for the use of a .625 diameter Woodruff cutter.  Of course I don't have one, so I made the boring bar and toolbit mentioned above.  The bit was then set for a .625 diameter swing.  Then the fun began.  The tool was side plunged in X axis at the required location.  Then it traveled for .100 in Y axis and was backed out.  The tool was then lowered .030 in Z and the same cut was made as just mentioned.  This sequence was repeated for eight "windows".  For the amount of time that I have in this part, I was scared to death using this homemade setup.  But, it worked.

Next, the cylinder bores for the sleeves were located and bored.   These bores will be used for locational purposes for future machining operations. I ran into a problem with too much chatter from my boring head.  To rectify the problem, I ground a tool and used the 5/16 diameter boring bar directly in the spindle.  I have done this before with excellent results.  The hardest part is setting the tool to swing for the required diameter.

The last operation for this setup was drilling and tapping eleven 0-80 holes that the oil pan will bolt to.  Tapping this small is not difficult with the correct tools.  A spring loaded Fisher Machine Micro Tap Guide was used along with a simple knurled disk tap wrench.  The Tap Guide is reversible with both a pointed tip and a center drilled tip.  This allows for the use of different style taps.  Thanks to Marv for the disk tap wrench idea.  This helps to limit torque and reduce tap breakage.

It was nice to finally remove the Block from the table of the BenchMaster.  It has been setup on there forever.

Onto the next setup.
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on June 18, 2019, 01:12:37 AM
Impressive work Bob!! Glad you found some shop time.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gldavison on June 18, 2019, 01:53:08 AM
Hi Bob,

I made a 4 flute reamer from the same drill rod the lifters were cut from. Drilled the hole with a #8 drill them reamed with the home made reamer. Lifters fit perfectly. You're coming along. Looks good.

Gary
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on June 18, 2019, 08:18:08 PM
Thanks Bill.  I can never thank you enough for your constant support.

Gary, I had considered making a D bit reamer; the thought of making a four flute never crossed my mind.  I recently bought a dividing head.  A fluted reamer might be a nice way to christen it.  How is your build coming?   

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on June 26, 2019, 01:01:20 AM
Block continued-

A fixture plate that allows for angles was setup in the Clausing 8520.  The idea for this fixure came from the Home Shop Machinist website's thread: Shop Made Tools.  The 22 degree angle was set using angle blocks and an indicator.  The fixture was then indicated along X.  The Block was loosely bolted to fixture through the cylinder bores.  The Block was then indicated to the fixture and tightened down.  Toe clamps were pushed up against the side of the Block as a security measure in case the block tried to shift during machining.

The same .250 diameter, .094R endmill was used to finish milling the pockets and the 22 degree sidewall of the block.  As I moved to each pocket, a simple shop made indicator holder was used to indicate the center of each pocket.   This holder clamps to the spindle and allows the tool to remain mounted.  This allowed for the Z axis setting to be left unchanged, which was important to blend the walls and floor of each pocket.  (It wouldn't have made sense to use the Height Setter, to swap one tool and the indicator, back and forth multiple times.)

The bottom of the block is now done.  Next up will be the top and it's details.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on June 26, 2019, 01:41:44 AM
Always love seeing your setups Bob. The block is really coming along.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on November 30, 2019, 05:51:55 PM
Well, it's been five months since any updates to this build.  I have been able to get in the shop recently and get some machining done.

Block and Top Plate-

Pictures one and two show a fixture plate that I machined for the next sequence of operations to the Block.  There is a .125 radius channel machined the length of the plate.  This allows for two .250 broken end mills to locate the crank bore parallel to the X axis of the mill.  A .0625 reamed hole is located in the center of the channel and allows for the plated to be indicated.  A corresponding dowel pin was inserted into the Block and the Block was located onto the fixture plate with the dowel sitting in the reamed hole. The Top Plate was then placed on the Block and clamped with a simple strap clamp.

George dimensioned the Block features from the Crank centerline in X and the Block centerline in Y .  This fixture allowes for a perfect 0,0 in relation to those centerlines as previously machined.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Ye-Ole Steam Dude on November 30, 2019, 06:26:41 PM
Hello Bob,

Very neat   :popcorn:

Have a great day,
Thomas
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on November 30, 2019, 06:29:56 PM
Block continued-

A fixture plate that allows for angles was setup in the Clausing 8520.  The idea for this fixure came from the Home Shop Machinist website's thread: Shop Made Tools.  The 22 degree angle was set using angle blocks and an indicator.  The fixture was then indicated along X.  The Block was loosely bolted to fixture through the cylinder bores.  The Block was then indicated to the fixture and tightened down.  Toe clamps were pushed up against the side of the Block as a security measure in case the block tried to shift during machining.

The same .250 diameter, .094R endmill was used to finish milling the pockets and the 22 degree sidewall of the block.  As I moved to each pocket, a simple shop made indicator holder was used to indicate the center of each pocket.   This holder clamps to the spindle and allows the tool to remain mounted.  This allowed for the Z axis setting to be left unchanged, which was important to blend the walls and floor of each pocket.  (It wouldn't have made sense to use the Height Setter, to swap one tool and the indicator, back and forth multiple times.)

The bottom of the block is now done.  Next up will be the top and it's details.

-Bob

Looks great bob!!!
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Dave Otto on December 01, 2019, 01:31:34 AM
Looks good Bob,
Glad to see you back in the shop!

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gldavison on December 01, 2019, 01:46:47 AM
Hi Bob

Excellent work.  Glad your back at it.

I have all the parts made but not assembled. I plan to powder coat block and pan before finial assembly. Working on a mounting and then will start on the radiator.

Gary
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on December 01, 2019, 02:26:12 AM
Thank you gentlemen for your support.  Hopefully I can keep moving forward with it. 

Gary I look forward to seeing yours.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on December 08, 2019, 06:39:53 PM
Block and Top Plate continued-

To make certain that the Top Plate couldn't move, the first four of ten 3-48 holes were drilled and tapped.  Screws were then threaded inserted inorder to clamp the Top Plate.  This allowed for the strap clamp to be removed.  Next, two .0625 dowel pins were located and inserted.  Two of the 3-48 holes required a .125 counter bore.  An endmill was used to accomplish this.  The cylinder bores were then rough bored for locational purposes.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Admiral_dk on December 09, 2019, 11:24:02 AM
Nice to see progress Bob  :ThumbsUp:    :cheers:    :popcorn:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on December 09, 2019, 06:06:24 PM
Good to see you back on this  :ThumbsUp:  :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on December 13, 2019, 01:36:05 AM
Thanks Admiral_DK.

Thanks Roger.  I've been following along on your two cylinder build.  I don't get to post much these days but, I still try to follow people's builds.


-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on February 07, 2020, 07:42:13 PM
Block continued-

The first picture shows the block with the Top Plate removed.  With the Top Plate removed, the next feature to be machined are the pockets that will form the water jackets.

A .500 diameter endmill was used for the initial roughing.  The overall finished depth of the water jackets is 1.040.  The rough depth was to 1.035.

Next a .250 diameter long reach endmill was used.  The water jackets, like the crank web pockets, call for a .094 radius at the bottom.  A .100 ledge was left where needed at a depth of .930. This allowed for the use of a .094 radius .250 diameter endmill to cut the botom radii.

edit- I had some problems with uploading my pictures.  The second picture is the Top Plate removed.
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: b.lindsey on February 08, 2020, 01:41:21 PM
Good to see an update Bob. Looks like some of this recent weather has been keeping you busy outside the shop, but happy to see you are finding some shop time as well.

Bill
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on February 09, 2020, 04:11:15 AM
Thanks Bill.  Yes, the weather has been keeping us busy. 

I have a couple of other pictures that I need to post.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on February 11, 2020, 12:08:36 AM
Block continued-

The water jackets were plunged with a .375 end mill to rough them out.  As above, a .100 ledge was left.  Then a .250 long reach end mill was used to finish the walls.  Next, a .250 ball end mill with a .094 radius was used to finish each pocket.  This created the .094 radius that transitions from the floor to each wall.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on March 08, 2020, 10:16:12 PM
Block continued-

The block has 10 holes for the head bolts that have a .099 radius brow around them within the water jacket.  The only way that I could do this was with the rotary table. 

The rotary table was centered to the spindle and my universal fixture plate was then clamped to it.  The setup procedure was as follows: a center was placed in the spindle and lowered into a bolt hole.  The block was then clamped to the fixture plate.  The block was then indicated parallel to the x axis.  A .250 diameter long reach end mill was used.   X was adjusted .240 (.099R+1/2 the endmill diameter + .016) for the first pass.   The endmill was plunged to a depth of .946 and brow was cut.  Next, X was adjusted to .224 for the final pass.

A .250 diameter endmill with a .090 corner radius was next used at a depth of 1.040. X was adjusted to .225 so the endmill would not rub the wall as it cut the .090 radius at the bottom of the water jacket.

What I love about this, is no one will ever see all this work once the top plate is in place with the cylinders pressed in.  I could have left everything with sharp corners; but, that would not have helped me improve my skill level which is what this is all about.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Vixen on March 08, 2020, 10:30:25 PM
Some nice work there, all done the traditional way by turning the handles.  :ThumbsUp: :ThumbsUp: :ThumbsUp:

Mike
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Dave Otto on March 09, 2020, 02:18:41 AM
Nice work Bob, enjoyed the update!

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: nj111 on March 09, 2020, 09:10:57 AM
Impressive rotary table work, thank you for these posts. All looks spot on!   Also, love the indicator holder - I shall be copying that idea. Nick
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gbritnell on March 09, 2020, 11:51:47 AM
Good to see you getting more time on the build. It's coming along great! The block is the most time consuming part of the build.
gbritnell
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: michelko on March 09, 2020, 03:00:58 PM
Unbelievable what can be done with conventional machines  :cheers:

Regards Michael
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: awake on March 09, 2020, 03:05:11 PM
Wow! That is incredible work. How many hours did it take? Or should that be how many days? (If I were attempting this, I'm certain it would be, how many weeks!)
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on March 09, 2020, 04:17:45 PM
Very nicely done  :praise2:  :praise2: That's a lot of swarf  :wine1:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on March 10, 2020, 12:07:09 AM
Wow, thank you all for your kind words.

nj111- That holder also slips onto the spindle of the mill to allow indicating without removing a tool.

George- Yes it is.  A lot of planning involved along with all of the machining.  The head will eat a lot of time also.

awake- Each hole took around a half of an hour once I got the process down.  I have over 100 hours into the block.
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 13, 2020, 01:47:46 AM
Block continued-

I've been deemed an essential employee so progress continues at slow pace.

The lifter pocket on the side of the block was milled using a 3/16 endmill.  The block was clamped to an angle plate for this operation.  Bolts that have been faced on the head were used like jack screws.  They were used with tee-nuts in the mill's tee-slot along with a jam nut to add rigidity to the setup.  The block was then flipped over and the water passage hole was drilled along with the 0-80 mounting holes for the coolant tube.  Next, the location for the crankcase breather was layed out on the 22 degree slope of the block using a spring loaded tap guide as a scribe.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Zephyrin on April 13, 2020, 08:43:41 AM
incredible skills with the rotary table, for doing this pocket, certainly a lot of concentration while turning the wheels...
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 14, 2020, 11:11:01 PM
Thank you Zephyrin.  I wouldn't say incredible, just alot of planning with the rotary table.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Craig DeShong on April 15, 2020, 02:08:02 AM
Very nice work Bob.  :popcorn: :popcorn: :popcorn:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: scc on April 15, 2020, 11:22:26 AM
Absolutely beautiful machining Bob :praise2: :praise2:        My attempts at accurate handwheel turning are far below yours.......inadequate concentration ::)         Love this build :popcorn: :popcorn:            Regards     Terry
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 17, 2020, 01:12:12 AM
Thank you Craig.

Thanks Terry.  I have notes by the machine indicating the direction the part is being machined based on what the numbers on the dials are doing. 

 My notes look like this:

Cut to Left X minus
Cut to Right X plus
Cut to Back Y minus
Cut to Front Y plus

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: fumopuc on April 17, 2020, 06:39:53 AM
Hi Bob, very impressive.

Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 21, 2020, 11:49:47 PM
Thanks Achim for your continued support.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 21, 2020, 11:50:06 PM
Main Caps-

I decided to take a little deviation and start on the main caps.  The rough shape was milled and then setup on an arbor in the lathe.  A Dremel was used to profile the required .275 radius.  I've posted about this technique before, but in a nutshell, the Dremel is set on the tangent and is run back and forth until the profile is produced.

Next, the profiled bar was setup in the mill and a .014 slitting saw was used to slice off the caps.

The caps will be drilled in the mill.  The same fixture plate that was used for locating the block will be used.  A .250 pin that sits in a radiused groove in the fixture is used to locate the caps.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 04, 2021, 03:48:18 PM
Well it’s been close to a year without any updates.  I did continue to work on this but just didn’t post anything for some of the reasons that were brought up in the “Lack of response to posts” thread.  But, a major factor was that my technology had become very outdated.  It was ten times harder to move, convert and post pictures.

 The attached picture is a “family” shot.  The oil pan and main caps are done.  The timing cover is done.  The tappet cover is done and the water pump is half done.

I do have some pictures of each part being machined if there is any interest. 

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Vixen on April 04, 2021, 04:44:59 PM
 :ThumbsUp: :ThumbsUp: :ThumbsUp:

Just to let you know it's looking good.

Mike
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on April 04, 2021, 05:51:19 PM
That's some machining to be proud of  :praise2:  :praise2:  :wine1:

I am interested in function, I don't have the patience for finishes like that  :(
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 04, 2021, 06:09:43 PM
Thanks Mike, knowing your work, that is a great compliment.

Thank you Roger.   The finish isn’t all that hard to achieve. Sandpaper to remove tool marks and green Scotchbright for the final finish.  I try keep the same stroke direction to give a grain appearance.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: kuhncw on April 04, 2021, 06:13:07 PM
Bob,

Nice work.  Photos of a few more parts being machined would be interesting.  I always learn from the setups others devise to hold parts.

Chuck
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Admiral_dk on April 04, 2021, 09:09:41 PM
Looks really good to me + nice to see that you still progress with this engine.

You mention that the finish is only 'sandpaper' - but it still requires the correct technique or you end up with a lot off lines criss crossing each other in odd angles ...  :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gldavison on April 05, 2021, 12:44:08 AM
Beautiful work Bob. I begin to wonder if you were still going to work on this. I understand about life getting in the way of the hobby. I check in every day hoping to see some progress.
I'm with Rodger on the finishing part. I'm just interested in seeing the work run when I get done. Maybe if I live long enough the better finishes will come along.

Gary
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 05, 2021, 01:59:54 AM
Thank you Chuck.  I will start posting pictures.

Thank you Admiral for your continued support.

Thank you Gary.  Hopefully, I can get some momentum going.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 05, 2021, 02:24:59 AM
Main Caps continued-

A .250 diameter pin was placed in a collet.  A driver was threaded onto the Atlas 618 spindle and a previous attempt at the main caps was placed on the .250 pin.  A lathe dog was clamped onto the assembly.  This setup created a fixture to screw the main caps onto for facing.  The caps were then faced on both sides to the proper width while maintaining alignment with the caps center line.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: MJM460 on April 05, 2021, 04:08:22 AM
Hi Bob, that looks like a good secure way to machine the faces square.

I am another who reads every post and would be most interested two see how you did those more complex parts.

MJM460
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: fumopuc on April 05, 2021, 07:42:37 AM
Hi Bob, I have been a very long time familiar with this time issue between, life, work and shop time.
So I do understand your situation very well.
But for me it doesn´t matter if it is a long term or a short term project to watch.
Your project itself is very interesting and I do read every post with pleasure.
 


Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 05, 2021, 11:03:18 AM
MJM and Achim thank you both for expressing your interest in further posts.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 05, 2021, 11:27:18 AM
Rear Main Cap-

This was a “fun” part to make.  I goofed a couple along the way. 

A one inch bar was placed in a collet in the Rivett 608.  A register was turned for future indicating.  The cap requires a .275 radius; so, a .550 diameter was turned.  A .250 diameter bore was also turned at the same time.  The dividing head was setup in the Clausing 8520 and the bar placed in the chuck.  The register was checked and the milling started. 

Five axis is a big buzz word in the cnc world.  This is a manual five axis setup.  A .375 endmill was used to mill away half of .550 diameter establishing the required .275 radius.  Next, the part was indexed and both the sides and width were milled..

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 06, 2021, 11:33:51 AM
Rear Main Cap continued-

The mounting holes were drilled and the height of the pads were milled.  Next the profiling of the .275 radius was done with a small endmill by taking light cuts and indexing by hand.  Once the radius was completed, the dividing head was set to 45 degrees and the side of the pad was milled.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 10, 2021, 11:13:45 PM
Rear Main Cap continued-

The Main Cap was then sawn from the parent bar.  It was then placed on the same fixture as the other caps in the Atlas 618 and faced to size.  Next came some light handwork with sandpaper and Scotchbright.

I included a picture of the completed Main Cap flanked by two screwups.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Don1966 on April 10, 2021, 11:27:32 PM
Bob I would say it’s a long time coming but hey buddy your getting there all great work.... :Love:



 :cheers:
Don
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Art K on April 11, 2021, 03:16:29 AM
Bob,
Great progress on the engine. Had to play catch up, life is in the way. I liked the process you used to make the rod caps, Have to file that away for future reference.
Art
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Admiral_dk on April 11, 2021, 12:30:59 PM
Except from the screws it looks exactly like a full size engine  :praise2:

Can you get matching bolts or are you forced to do those yourself ?

Per
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 11, 2021, 05:15:55 PM
Don thanks for still tuning in.

Art thank you and I’m happy that you have filed that process away for future reference.  That has always been my hope that people find some useful nugget from these posts.

Per, I usually windup making the bolts because it is the only way to get the correct look.  However, I have a few small socket head cap screws that I have used to hold the oil pan and timing cover on.  I really like the look that they provide and McMaster Carr sells them from 0-80 and up in different lengths. 

-Bob

Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on April 12, 2021, 02:32:27 AM
Thats a fine looking block!....Coming along great Bob

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.l
Post by: Dave Otto on April 12, 2021, 02:50:57 AM
Beautiful work Bob!
Great to see you posting again.

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 12, 2021, 11:54:44 PM
Dave and Dave thank you both for checking in.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on April 24, 2021, 12:05:34 AM
Oil Pan-

A parallel was indicated and clamped to the Benchmaster’s table.  The aluminum blank was banked against it.  Two J&S clamps were used to secure the blank to the table and two toe clamps were used as stops as an insurance policy.  The pocket was then roughed out.


-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 04, 2021, 03:25:48 AM
Oil Pan continued-

The pan required a five degree angle for the side walls.  The head on the Clausing was set to five degrees and both inside walls were milled.  The pan was then moved back to the Benchmaster and a long reach endmill was used to rough the sides and the lips.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Vixen on May 04, 2021, 01:29:00 PM
Hello Bob

It's nice to see more, well executed, 'old school' milling.  :ThumbsUp: :ThumbsUp: :ThumbsUp:

Mike
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on May 04, 2021, 04:54:59 PM
Still following and enjoying  :ThumbsUp:  :ThumbsUp:  :wine1:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 30, 2021, 05:20:00 PM
Thank you Mike and Roger for your continued support.  I apologize for taking so long to reply.  Work has been crazy in preparation for the Summer Season.

-Bob


Oil Pan continued-

The outside sidewall was milled with a 5 degree tapered endmill.  (By luck the endmill was in a toolbox purchase that I had made years ago.)

Next a .125 radius cutter was used along the bottom edge of the Oil Pan.

The Pan was then clamped to an angle plate and a .660 gage block stack was inserted into the clearance pocket for the Rear Main Bearing Cap.  An edge finder was used to pickup the blocks in order to determine the centerline of the pocket. 

Next a .375 endmill, followed by a .500 endmill, was used to rough out the required .275 radius for the Rear Main Bearing Cap.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gldavison on May 31, 2021, 02:35:53 AM
Hi Bob,
 I like the way you figure out how to set things up. Makes me think you were a professional machinist in another life. 

 Excellent job on the documentation  and the machining.  Keep it coming.

Gary
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 31, 2021, 10:36:48 PM
Gary thank you so much for that compliment. 

I was never a professional machinist.  I was an inspector for a few years checking complex machined parts.  That gave me a solid foundation for “thinking outside of the box” with setups.  It also gave me an understanding of geometric relationships of features which is probably the biggest catalyst for my setups.

 I was also a CNC operator one summer in college and for a brief period (wife’s maternity leave) eleven years ago.  Those jobs exposed me to different workholding techniques.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on June 01, 2021, 11:30:21 PM
Oil Pan continued-

In order to get the required .275 radius a 5/16 boring bar was used.  The tool bit was set .118 above the boring bar’s centerline (5/16=.312, .312/2=.156, .156+.119=.275).  To make this setting, the bar was placed in a collet in the Atlas 618 lathe.  An indicator was set to zero on the diameter of the bar.  The carriage of the lathe was then moved to where the indicator touched the tool bit.  The bit was then adjusted.

Next, the boring bar was placed directly in the spindle of the BenchMaster mill and the radius was machined.  I’ve found this method to give a chatter free finish when compared to that of my boring head.

-Bob

Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 23, 2021, 03:00:56 AM
Engine Block continued-

The Top Plate was made and assembled to the block.  A spigot was turned in a collet and the faceplate was installed on the Rivett 608.  The block was then placed on the spigot and clamped to the faceplate.  The Top Plate was then bored and counter bored.  A shop made plug gage was used for checking both diameters.  After the four bores/counter bores were completed, each Top Plate bore was indicated true and the bottom of the block was bored.


-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on August 23, 2021, 03:23:03 AM
That's looking great Notch!!!       It warms my heart to see it being done on a 608!!!

What's the bore and stroke on that?

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 23, 2021, 11:26:21 AM
Thanks Dave.  The 608 is my baby.

.750 x .875

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gbritnell on August 23, 2021, 12:00:07 PM
It's coming along great!
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: RReid on August 23, 2021, 02:46:04 PM
That's one sweet looking little engine block! :ThumbsUp: :popcorn:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 23, 2021, 10:12:30 PM
Thank you George.  I’ve always had immense respect for your builds.  Building this to print has increased that respect a great deal more.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on August 23, 2021, 10:15:15 PM
Ron-

Thank you for “tuning in”.  I don’t post much but check the site daily and follow most threads.  Nice job on the radial and congratulations on a fine runner.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on August 24, 2021, 01:17:13 PM
Very nicely done  :praise2:  :praise2:  :wine1:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Vixen on August 24, 2021, 04:03:11 PM
Hello Bob,

Thats some very impressive machining on the cylinder block. I am full of admiration of you guys who do it all on the handwheels.

Cheers

Mike
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 01, 2021, 11:17:37 PM
Roger and Mike thank you both for your continued support.

Unfortunately, I was unable to get into the shop this weekend; therefore, I have nothing to post.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 21, 2021, 11:11:30 PM
Block continued-

An arbor was machined to accept the rough sleeves. The sleeves were then a simple turning job. Note, the bore is not to finished size.  This will be done later in the lathe.

The plate was removed and high temp RTV was lightly dabbed around the block’s top surface.  The plate was then reassembled and any RTV that oozed out along the outside of the block was wiped clean.  I was pleased with result of the seal created along the inside of the water jacket (photo 5).

The sleeves were then coated with Ford Teflon Assembly Paste and pressed into the block.

This was a bitter sweet moment.  My best machine work is now entombed within the block, never to be seen again.


-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: RReid on September 22, 2021, 12:33:36 AM
At least those are some good pictures for posterity of your never-to-be-seen-again machining. Beautiful work! :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on September 22, 2021, 12:47:46 AM
There were pictures!!!! It happened....and it happened with a 608!..... :cheers:

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 23, 2021, 10:25:02 AM
Thank you Ron and Dave for your continued support.  Hopefully I can get some momentum going and knockout some more parts.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Don1966 on September 23, 2021, 11:10:50 PM
Awwww more progress kept it coming Bob! …. :Love:



 :cheers:
Don
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 03, 2021, 05:48:51 PM
Thanks Don.  Happy to see you checking in.


Progress Report-

Last week I decided to start on the head.   In the process of squaring the material, a sliver of cast iron went into my left eye.  I can usually get foreign objects out of my eye easily; this however, took a few hours and needless to say “killed” any productive shop time.  Luckily my eye is fine and I am working on the head today. 

I will try to post how today goes later.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: crueby on October 03, 2021, 07:57:22 PM
Glad you got it out safely - that can be really nasty!   Though when I first saw the picture I thought THAT was the sliver...!
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Kim on October 03, 2021, 11:37:11 PM
Yes! Glad you got it out of your eye.  Did you have to go in somewhere to get some help?

I noticed that you've got your name stamped in that metal work area in that picture (toward the bottom).  Very personalized!   ;D

Kim
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 04, 2021, 10:54:05 PM
Chris-
Lol.  That would have really hurt.  Thanks for dropping in.

Kim-
No, I considered going to the E.R. at one point but kept at and was able to remove it.  My eye was very irritated for quite awhile.  The stamping on my bench includes my wife’s name and the year we were married.  It was just something I did one day when I had the stamps out for something else.  Thanks for checking in.



Head-
The head is made from a block of cast iron.  The block was squared.  The side walls requires a 6.08* angle.  A parallel was clamped to the table, the sine bar was placed against it and indicated.  The head was then placed against the parallel and clamped to the table.  The parallel was then removed.

George drew the walls of the head without bottom radii.  After pushing myself with the engine block with blended radii I decided to add radii to the head.  A step was left for the radius to be cut.  A shop made single lip cutter was used to cut the bottom radius.  The cutter took me awhile to make.  I’ve had my single lip cutter grinder for close to a year now but haven’t it used it much.  The cutter is a 3/16 diameter with a 1/32 radius.

As stupid as it sounds, I had quite the feeling of satisfaction watching the radius form as the cutter machined away the cast iron.

-Bob


Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Dave Otto on October 05, 2021, 01:32:11 AM
Nice progress Bob!
I recently acquired a Deckel SO grinder and have been working through it. It is in pretty good shape but filthy and neglected. I'm just about finished with it, it will make a nice addition to my shop.

Dave 
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on October 05, 2021, 02:18:32 AM
Oh man!   Engage Safety Squints!


Sorry to hear that bud!   Glad it turned out OK.....tell me about that cute depth gage?....hmmmm? 8)
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 05, 2021, 03:51:58 AM
Dave O.- The single lip cutter grinder is a very handy addition.  The Chinese knock off of the SO doesn’t have a real .001 resolution vernier scale which makes putting an accurate radius on the tool a pain.


Dave P.- That gage is a Z axis setter that I cobbled together.  In the picture it is sitting on the head and a stack of gage blocks.  In the picture I am setting the radius cutter.  By doing this, the cutter is set to the plane of the step of the head that the gauge is sitting on.  I also used a gauge block stack that corresponded to the height of the step to keep the gauge from tipping and giving a bad setting. 


Thank you both for checking in.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gbritnell on October 05, 2021, 12:16:32 PM
Slow but surely Bob but it's coming along great!
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on October 05, 2021, 05:18:26 PM
Looking good  :ThumbsUp:  :ThumbsUp:  :wine1:

You were luck with your eye. Many years ago I had been doing some grinding and was sweeping the bench off afterwards. By one of those chances a small piece of metal was flicked up by a bristle and went behind my normal glasses and into my eye  :( My wife was out somewhere, I didn't feel that I should drive, I would have had a long wait for a taxi and an ambulance seemed excessive (possibly not where eyesight is concerned  :headscratch: ). I got my most powerful magnet, put some clingfilm on it and stuck it in my eye. The chip came out without any damage  :)  :)
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 07, 2021, 12:39:48 AM
Thanks George.  My only shop time is usually on Sunday.  I just keep chipping away at this build.  I’ll get there one day.


Roger- The sliver got by my glasses and wound up under my eyelid, very near the eye socket near the eyebrow.  Usually, I blink into a glass of water to remove objects from eyes.  I eventually got it, but it was by far the hardest thing I ever have had to get out.

-Bob

Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 10, 2021, 11:29:48 PM
Well….

A setback has occurred.  I allowed myself to get distracted for one second and I turned the handle the wrong way.  More than likely this is a catastrophic “f’up”.  The hurt area becomes a .100 thick wall for the valve cover.  The endmill traveled .065 into it.  I can bore a hole, turn a plug, press the plug in and machine it flush with wall.  How it will look is questionable.

At this point, I’m just aggravated with myself and don’t know what path I’m going to take (fix it or start over).

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Kim on October 10, 2021, 11:34:36 PM
 :facepalm:

Very sorry to hear that Bob!  I've certainly done that before and it is frustrating.

I certainly feel for you.

Kim
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Don1966 on October 10, 2021, 11:44:37 PM
Been there and know how you feel just take a step back and relax. Then when the head clears regroup. At least that’s what I do because tools start to fly if I don’t. Decisions decisions Bob you’ll get it done….


 :cheers:
Don
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on October 10, 2021, 11:47:04 PM
What part was that Bob?

Feeling it man!.....Sorry to see that

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 10, 2021, 11:57:16 PM
Thanks guys.  It’s the head.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on October 11, 2021, 12:10:27 AM
Well   Tell ya what.     the only people who don't make mistakes are those that never do anything....


You have nothing to lose by trying to put a plug in, that reaches up to the top surface, and then machining it back...  You could thread it, but not sure you need to, especially without looking at the print.

Love is a wonderful thing, but Loctite is forever!!!   8)......but not tonight

Ifn I was you....I'd walk away for the evening and come back with a better mood....I know I get pissed at myself when I do it.

Dave


Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: gbritnell on October 11, 2021, 12:56:16 AM
Bob,
As long as it doesn't affect the structural integrity of the part plug it. One thing to consider is if you use a round plug just make sure that any intersecting edges are Fairley close to right angles otherwise you stand the chance of chipping the sharp corners. I have patched many parts in my career.
gbritnell
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 11, 2021, 01:09:38 AM
Thanks Dave and George I greatly appreciate your input.

I couldn’t just walk away from this.  I have already begun the repair.  I blued the mistake and turned the spindle by hand  until a scratch mark appeared.  Then I moved over another .001.  Next, the endmill was plunged to depth.  Then it was dinner time and I’m now watching a movie with my wife.  I’ll pick this backup at another time.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on October 11, 2021, 01:57:56 AM
Way to go Bob!    and I'm glad you're watching a movie....You internalized a plan...and you are acting on it....nothing bleeds stress off better than that!

Goodonya mate

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: eccentric on October 23, 2021, 07:05:29 PM
Bob,

What purpose do the indicated slots in the block provide?  Do they equalize crankcase pressure between the cylinder sections?  Are they for ease of assembly later?  And why are they needed on the ends of the block and not just between the cylinders.  They do not look straight forward so there must be a good reason.

Probably a simply explanation, but it has me scratching my head.
(https://www.modelenginemaker.com/index.php?action=dlattach;topic=8373.0;attach=130131;image)

Thx

Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 23, 2021, 07:25:05 PM
Eccentric-

Excellent question, George’s design uses a splash oil system.  Those slots allow oil to the main bearings. 

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on October 23, 2021, 07:27:09 PM
 :popcorn:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: eccentric on October 23, 2021, 07:38:56 PM
Oil to the main bearings, that makes sense. i see the oil feed holes to the bearings now.   ;D   :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on October 25, 2021, 03:12:20 AM
Head continued-

Last weekend was the Jacktown show; so, I was unable to get into the shop.   This weekend was chock full family functions but, I did manage to get some shop time in.  I made a plug out of cast iron and pressed it into the head.  A toolmaker’s clamp was used to apply pressure against the plug, holding it firmly against the “boo-boo”. 

Under any other circumstance, I would feel confident that the repair would work after machining.  Unfortunately, after reviewing the print, the “boo-boo” is right where the spark plug hole will be located.  Time will only tell.  I do have an idea to help increase the odds and will be incorporating it into the “fix”.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: eccentric on December 13, 2021, 07:03:40 PM
Bob,

I am working on my main bearing caps and have been studing your methods. Yours are beautiful, here is a picture:

(https://www.modelenginemaker.com/index.php?action=dlattach;topic=8373.0;attach=125370)

I noticed you have not machined the o-ring notch in the main bearing cap or the cylinder block.  Was this a conscious decision?

Thanks, Greg
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on December 13, 2021, 09:08:34 PM
Greg-

Yes it was a conscious decision.  I plan to machine the o-ring groove with the cap and block assembled.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on February 07, 2022, 12:00:18 AM
Breather assembly-

Unfortunately, I did not take many pictures.  The tube was made from a solid piece of 3/16 aluminum.  The bar was bent while still solid.  A vee-block was set up in the four jaw chuck in the Atlas 618.  The bar was then drilled and bored. 

 The flange was done on the rotary table from a turned part.  The cap was a simple turning job.  The insert for the cap was turned, then milled with a ball endmill.  The bolts were turned from a piece of steel that was milled into a hex with the Spin indexer.  A 1-72 die was used for the threads.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on February 07, 2022, 12:41:48 AM
Nice progress Bob!    I see the Atlas!....Where's the Rivett?!!   8)

Hope things are well my friend...

Dave
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on February 07, 2022, 01:16:18 AM
Thanks Dave.  All is well.  It’s winter, so my machining progress slows to a crawl.  We’ve been getting a lot of small winter events that we still have to go out for.  I’ve been called out the last seven weekends, we were out both Christmas Eve and New Years Eve.  It’s just one of those winters.  Thankfully I made it to Cabin Fever this year.  I was out the next day plowing.

The Rivett is still here.  I had to make a set of gears for the carriage feed.  I use the Atlas much more because I can leave it full of chips.  Whenever I use the Rivett, I meticulously clean and oil it.  The Atlas is a  “winter beater car” and the Rivett is a classic high end automobile.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: steamer on February 07, 2022, 01:25:15 AM
Thanks Dave.  All is well.  It’s winter, so my machining progress slows to a crawl.  We’ve been getting a lot of small winter events that we still have to go out for.  I’ve been called out the last seven weekends, we were out both Christmas Eve and New Years Eve.  It’s just one of those winters.  Thankfully I made it to Cabin Fever this year.  I was out the next day plowing.

The Rivett is still here.  I had to make a set of gears for the carriage feed.  I use the Atlas much more because I can leave it full of chips.  Whenever I use the Rivett, I meticulously clean and oil it.  The Atlas is a  “winter beater car” and the Rivett is a classic high end automobile.

-Bob

 :ThumbsUp: :ThumbsUp: :ThumbsUp: :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 08, 2022, 12:03:55 AM
I haven’t updated in awhile.  I made all the 0-80 socket head cap screws for the timing cover, side cover and oil pan. It took awhile to develop the tooling and process, but I am happy with the results. 

I’m currently planning on returning to the head.  I am going to try and salvage the head that I had started on.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Admiral_dk on May 08, 2022, 10:25:43 AM
Oh man they are tiny - did you make them from stock or modify a bigger screw ?    :cheers:

Per
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 08, 2022, 10:38:14 AM
They are made from bar stock Per.  The threads are die cut.  The recessed hex is .050 (1.27mm) across the flats. 

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Admiral_dk on May 08, 2022, 12:25:08 PM
OK and the recessed hex is where it get tricky or did you have a tool for this too  :thinking:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 08, 2022, 01:14:23 PM
Per-

I used shop made tooling.  The hex was created by center drilling .045 (1.143) deep with a .032(.812) diameter tipped center drill.  Then a .043 (1.092) shop made single lip endmill was used as a boring bar to bore the hole to .046 (1.168) diameter.  This produced a “flat” bottomed hole .045 (1.143) deep.  Next a shop made broach was used to make the hex.

The broach was guided through a sleeve ensuring that it was centered to the screw which was screwed into a lower section.  An arbor press was used to push the broach into the screw.

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Kim on May 08, 2022, 03:33:30 PM
Wow! That is quite the elaborate process to make your own SHC Screws!  That must have taken some time to do that!  I'm very impressed!

And then you blackened them? They look very good, whatever you did!

Were you unable to source 0-80 SCHS? Or did you just want the challenge?   That is just amazing work!

Kim
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: RReid on May 08, 2022, 03:37:26 PM
I'm very impressed, not least because they are so tiny. I just love posts like this that show what can be done with relatively simple, and shop made, tooling. :ThumbsUp: :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Admiral_dk on May 08, 2022, 10:45:53 PM
Like RReid and Kim - I am more than duly impressed  :praise2:   :praise2:

I knew it could be done, but these are the smallest of it's kind I've seen so far  :insane:    :cheers:

Per
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on May 09, 2022, 12:54:05 AM
Thank you Kim, Ron and Per for the compliments.

I did it for the challenge and to see if it could be done.  I now have the capability to produce any kind of fastener, based on any combination of features.  Also, I want be able to say that the engine is entirely built from scratch; except, for five screws that hold the top plate down.  The screws were blackened  by heating them and dipping them in virgin olive oil.

When it is all said and done, they are very expensive screws. 

-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Roger B on May 10, 2022, 05:52:10 PM
Splendid work on the screws  :praise2:  :praise2:  :)
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Vixen on May 10, 2022, 08:43:29 PM
Splendid work on the engine. The screws are pretty good as well  :praise2: :praise2: :)
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: Zephyrin on May 11, 2022, 08:33:47 AM
excellent work, certainly the best one can achieve with so simple and shop made tooling...
so much thoughts and skills in these simple tools, impressive !
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: justindewoody on January 23, 2024, 12:48:59 AM
Any updates on this build?
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on January 23, 2024, 03:02:32 AM
I should do an update.  I’ve just been crawling along on a remake of the head.  I get very little shop time these.  I’ve been very busy with my youngest daughter’s activities. 

Thanks for inquiring justinwoody.

-Bob
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