Model Engine Maker

Engines => Your Own Design => Topic started by: Brian Rupnow on March 19, 2019, 07:49:08 PM

Title: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 19, 2019, 07:49:08 PM
You fellows may remember---When I was chasing down helical gears for the sideshaft hit and miss engine I built, I bought a pair with 2:1 ratio off Ebay for $12.00 which is about $90 less than I paid for a set made in USA. I used the made in USA gears from Debolt to build my engine, but had the Ebay Chinese gears left over. I watched a YouTube video of an Edgar Westbury engine called the "Centaur" and was very impressed with the valve and sideshaft arrangement on it. Grandma was right--Idle hands truly are the devil's workshop. I was bored this week, so I've been messing around designing another sideshaft engine which uses the Chinese helical gears, and a valve arrangement similar to the Centaur engine. It's not a hit and miss engine--just a 4 cycle open crankshaft engine with a throttled carburetor. I might never build it, but it is interesting.
(https://imagizer.imageshack.com/img923/3079/r3XqOf.jpg)
(https://imagizer.imageshack.com/img924/6721/BQPlp8.jpg)
(https://imagizer.imageshack.com/img921/2483/Sp7ffe.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 19, 2019, 07:54:21 PM
The engine has a 1" bore and a 1.375" stroke and is air cooled. I will probably design a fan on the side opposite from the sideshaft and drive it with an o-ring drive belt from the crankshaft.
(https://imagizer.imageshack.com/img921/2192/SdFOP2.jpg)
(https://imagizer.imageshack.com/img924/7830/aGYvHM.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 19, 2019, 07:58:58 PM
The main chassis of the engine is interesting. It is hogged out of a block of 2" thick 6061 aluminum.
(https://imagizer.imageshack.com/img923/91/mMAVZm.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: gunna on March 20, 2019, 05:56:09 AM
......I might never build it, but.......
Yeah, I believe you Brian.
Keep up the good work.
Ian.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on March 20, 2019, 02:05:43 PM
Brian,
Oh no, you will build it, just a matter of time. :mischief:
Art
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 20, 2019, 03:29:55 PM
Of course, if you have an air cooled cylinder, it's always a good idea to have a cooling fan. I dug around in my "odds and ends" drawer and found the perfect size plastic fan. I also dug around in my aluminum box and found a scrap of 2" aluminum large enough to make the main engine body from, and a piece of 3/4" material large enough to make a base. I spent a couple of hours this morning putting in all of the tapped holes and clearance holes to put this thing together.
(https://imagizer.imageshack.com/img924/7257/9piB8E.jpg)
(https://imagizer.imageshack.com/img923/3930/d48nRI.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Jasonb on March 20, 2019, 03:33:35 PM
Looks like the flywheel will clash with that big gear.

Given the problems you had getting fuel up to the last engine why not put the intake at the bottom and exhaust at the top?
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 20, 2019, 04:07:11 PM
The gear doesn't clash with the flywheel (the flywheel web is offset). I may change the carb and exhaust around.-Not sure yet. It only becomes an issue if the tank is in the base of the engine.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Jasonb on March 20, 2019, 06:15:28 PM
Just looked like it came further than the web even with the offset, looks like over half way to me and offset less than half.?
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 20, 2019, 07:25:49 PM
Good eye Jason.--I can slide the flywheels to whatever I need for clearance. How the heck did you make that flywheel transparent?
(https://imagizer.imageshack.com/img921/3330/h6oGmo.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Jasonb on March 20, 2019, 07:48:33 PM
That should do the trick

I did not make it transparent, just drew a black ring around the gear.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 20, 2019, 08:19:35 PM
Ah heck--Thought maybe you had X-ray vision like Superman or something. Hmm--I don't know if you guys had Superman comic books on your side of the pond.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 20, 2019, 10:59:16 PM
Here is a link to the gears on Ebay. They are brand new.
https://www.ebay.com/itm/1M-30T-15T-Metal-Helical-Wheel-Gear-90-Pairing-Bevel-Gearing-Set-Kit-Ratio-2-1/292889142228?hash=item44318da3d4:m:msI2ys09LGNo7RpCbMsH8Dg
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 21, 2019, 01:17:11 AM
I've just done one of those things that drive machinists crazy. This main chassis for the engine is up on my mill right now, and I've just realized something about the counterbores for the ball bearings. The counterbores won't be put in until the bearing caps are made up and bolted into place. I don't see any way to machine it like this. I can open the hole to full size on one side and then fit the boring bar down thru it to counterbore the other side, but unless I'm missing something I can't put a counterbore in both sides.  Its not critical that it have the web left in the side of the hole to back up the ball bearing, but it would have been nice. I know I could resort to some old time voodoo and mount it to the lathe saddle and make up a boring bar that gets assembled in place to do the counterbores, but I prefer not to do that.
(https://imagizer.imageshack.com/img923/886/J5B3LJ.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on March 21, 2019, 03:11:33 AM
Could the thin web on one or both sides be added as a longer plate recessed into the side?
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Jasonb on March 21, 2019, 07:17:23 AM
Just make the web smaller, it only needs to stand 1/16" above the bearing diameter to give a face for the side of the bearing to contact. That would be easy to do with a boring head and suitable tool feeding upwards on one side and down on the other so all can be done at one setting.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Admiral_dk on March 21, 2019, 11:12:22 AM
It can be done with one of those boring bars between centers Jason sometime uses ….

ARGH - I just noticed that Jason himself answered on the next page where my reply appeared too….  :facepalm:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 21, 2019, 09:28:12 PM
That didn't go too badly at all. I have a multitude of holes to tap, and I'm still thinking about the counterbore issue, but I like the way the piece turned out. About 90% of it was "Lay out the shape on a piece of 2" material, bandsaw close to the line, then mill to the line".  Tomorrow I will think some more about the counterbores and tap all the holes.
(https://imagizer.imageshack.com/img922/5504/QQ0UoI.jpg)
(https://imagizer.imageshack.com/img922/6656/J8vZoP.jpg)
(https://imagizer.imageshack.com/img922/6953/cnDVpJ.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 21, 2019, 11:08:08 PM
I've figured out the counterbore. I can do both sides with a brazed carbide boring tool in my boring head. The crankshaft is 3/8" diameter. The clearance hole around the shaft is going to get opened out to 5/8" diameter. The counterbore for the bearing is 0.906" diameter. The shank on the brazed carbide boring tool is .425" diameter. The only part that of this that sucks a bit is that I can't do both sides in one set-up. I have a 5/8" reamer which will be used to put the clearance hole thru all. That way I can "pick up" on the reamed hole when I flip the part over to do the other side.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on March 22, 2019, 12:37:29 AM
Brian,
Quote
Oh no, you will build it, just a matter of time. :mischief:
Ok maybe not. You already have a major start and are troubleshooting the next step. At this rate you'll have this done next week. :ROFL:
Art
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on March 22, 2019, 01:07:07 AM
Wow, missed checking in and its half built!


 :popcorn:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Jasonb on March 22, 2019, 07:05:07 AM
Brian, if you make a holder like the one being used in the attached photo you can grind up a tool that will do both sides in one setting.

Much like this cut on the inside of an enclosed crankcase

(https://img.photobucket.com/albums/v156/jasonballamy/Hit%20n%20Miss/1-3rd%20Monitor/IMAG2345_zps4c3359ec.jpg)

Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 22, 2019, 06:51:11 PM
Todays work involved tapping all the holes I had drilled yesterday in the main chassis and fabricating a pair of bearing caps. Those bearing caps have a lot more work in them than you would think at a casual glance. Why is the half hole in the bearing caps a different size than the half hole in the main frame?--That comes from making changes on the fly and not writing them down on the drawing as I do them. It doesn't really matter. They are clearance holes around the crankshaft and still have to be drilled out to a larger size before things are finished. Tomorrow I will tackle the bores and counterbores. Every fifteen minutes I have a different plan on how I'm going to do it--Probably won't know myself until I'm actually doing it.
(https://imagizer.imageshack.com/img922/595/wjJWyb.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 23, 2019, 07:24:42 PM
So--Here we have the main chassis and baseplate set up in the milling vice. The top hole has been drilled thru and reamed to 0.750". The bottom hole (which will be on the sideshaft side of the engine) has been drilled and reamed to 0.4375" diameter.  The boring tool fits down thru the .750" clearance hole and has counterbored a 0.906" diameter hole x 0.312" deep into the inside face, to hold the ball bearing.
(https://imagizer.imageshack.com/img922/7719/VyOVd4.jpg)
(https://imagizer.imageshack.com/img922/7720/JO2y4L.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 24, 2019, 03:33:51 PM
I'm not really sure of what it is I'm doing, but that has never stopped me before. To put the counterbore in the other side of the engine chassis, I need some kind of "setting master" to set the boring tool to the diameter I require. I don't have any practical way to do that when the boring tool is in the part, so I will do it in the lathe. I have just turned a "setting master" from mild steel, one end of which is bored to the size required for the bearing and the other end turned to be about 0.010" smaller than the 7/16" hole which the boring tool must pass thru. It will become clearer as I post more pictures.---I hope!!
(https://imagizer.imageshack.com/img922/1443/nLVNte.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 24, 2019, 04:27:14 PM
So--Here we have me setting the boring bar (held in the headstock chuck) to the inside diameter of the "setting master" which is held in the tailstock chuck. Also a picture of the counterbore cut into the second side of the engine chassis. It worked out perfectly.
(https://imagizer.imageshack.com/img922/2493/SD3uU5.jpg)
(https://imagizer.imageshack.com/img923/4096/qnNoQ0.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 24, 2019, 04:33:54 PM
And last but not least, the two sealed ball bearings at home in their counterbores. You will note that the non sideshaft side has a much larger clearance hole than the sideshaft side. That is because with the large clearance hole cut into the side of the chassis for one of the helical gears, I didn't want to take any more material away than I absolutely had to.
(https://imagizer.imageshack.com/img921/8080/P4rU2s.jpg)
(https://imagizer.imageshack.com/img922/8810/UiSd7h.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 24, 2019, 08:19:44 PM
I found a piece of 1144 stress-proof steel big enough to turn a one piece crankshaft from. I'm thinking about bolt on counterweights. The model I show here is doable, but I'm not terribly impressed by the look of it. Has anyone seen bolt on counterweights on another model?  If so a picture would be appreciated.
(https://imagizer.imageshack.com/img922/1135/tc0dAF.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on March 24, 2019, 08:29:58 PM
Never seen that done, though it would make fabrication much easier. I have seen bolted on weights on loco drive wheels and such.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on March 24, 2019, 10:17:40 PM
Brian,
The plans for the Upshur vertical single suggested one of those round Woodruff keys as a counter weight. I wasn't comfortable with that.
Art
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Dave Otto on March 25, 2019, 02:14:33 AM
Why go to all the work of making the counter weights and then drill them full of lightening holes?

Dave
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Jasonb on March 25, 2019, 07:07:42 AM
And on a similar note having the two "straps" come past the main crankshaft axis will further counter the effect of the counterweights. If you stick with copying the centaur design then all the added weight is on the side of the shaft where you actually want it.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 25, 2019, 01:27:46 PM
Dave auto--More for "pretty" than for functionality.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 25, 2019, 05:49:18 PM
Here we have the first video related to this engine, showing the action of my $12 helical gears from China. I am very pleased with the action, and more than pleased with the price. The gears are made in China and sold thru Ebay. They are metric "modulus" gears rather than diametral pitch gears, but that means very little to me as they only have to mesh with each other.
https://www.youtube.com/watch?v=zp5dyim6WaQ
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on March 25, 2019, 06:40:49 PM
Those gears work great!

The module vs DP spec is just two different ways of measuring the same thing, sort of like than inches vs millimeters. Simple to convert from one to the other:
Module = 25.4 / DP
and

DP= Module / 25.4
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 25, 2019, 10:36:45 PM
The camshaft housing has a 1" long oilite bronze bushing in each end. The shaft is 3/8" diameter, the hole inside the square piece is 1/2" diameter. There is an oil hole to squirt a bit of oil into the cavity to keep the oilite bushings lubricated. I finally had to break down and spend some money today--beyond the cost of the $12 helical gears. I was right out of 2" diameter cast iron to make the cylinder from, so I bought a 12" length today at my local metal suppliers for $45.00. I only need about 1/3 of the length I bought for this engine, but I'm sure there will be more engines in future.
(https://imagizer.imageshack.com/img924/7673/iajbtG.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 26, 2019, 05:20:48 PM
Oh Yeah---we got cast iron cylinder!!!!
(https://imagizer.imageshack.com/img924/5866/YOSeKj.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 26, 2019, 11:15:21 PM
I had a piece of 1144 stressproof long enough to make a crankshaft from. Since you can only buy this stuff in rounds, I always find it difficult to machine the first side flat as seen in the picture. Today I made up a wooden "fence" to mount on my bandsaw, and trimmed the first side off, then mounted it in my mill and took it down to size. Now that I have one flat side, I can mount that flat side to my mill table and mill down the opposite side to end up with a piece of bar stock.  With a steel straight edge held against the flat side now, there is no visible warping or bending. If you tried that with a piece of cold rolled, or even A36 mild steel, it would look like a banana now.--I did find out one other thing today about my gears--they are hardened. Harder than the devil's horn. I was going to open the crankshaft gear out to 3/8", but I tried it with a file first, and a file just skates off it.  Not wanting to ruin a drill or reamer, I decided to leave it at 8mm. They come with a stock bore of 8 millimeters (0.3150"). The only real difference that makes to me is that the flywheel on the gear side will have to have an 8 mm bore.
(https://imagizer.imageshack.com/img922/504/bsHH0Y.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on March 27, 2019, 02:13:19 AM
Brian,
I realize you already trimmed the stock to make a flat crank. But why not do two centers turn the crank throw then the mains to the ID bearing size then machine the counter weights in the opposite side. No need to bolt on counter weights that may or may not fly off at some point in time.
(http://listerengine.com/coppermine/albums/userpics/10019/RawJan11_363.jpg)
This is the end result of my Upshur crank, after some adjustments to make it fit inside the case.
Art
PS, It will spin at 7500 rpm
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 27, 2019, 12:22:11 PM
Art--The stock I had wasn't big enough to do that with. I know it looks good, but there would be a lot of machining if the original stock was large enough to turn both the crankshafts and counterweights form one solid piece.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on March 27, 2019, 02:20:32 PM
Brian,
Now that makes prefect sense.
Art
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 27, 2019, 02:37:06 PM
Now we have the round 1144 stressproof steel reduced to a flat-bar. The edges are still rounded, but that's okay. I had to remove a 3/8" depth of material from the rounded side. I can only comfortably take a 0.015" depth of cut in steel with my mill, so that's a lot of cranking back and forth. There is a little tip in this picture. If your milling vice is narrow like mine is at 3" and you are concerned about setting up a longer piece to keep it perfectly parallel to the mill bed, then block the ends up with 1 2 3  blocks and parallels so the piece is truly level, and just use the vice to squeeze it there and keep it in place. A couple of good raps with a dead blow hammer make certain that the piece didn't lift up at one end or the other when you tighten the vice.
(https://imagizer.imageshack.com/img921/9983/U7g1Vl.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on March 27, 2019, 02:41:11 PM
 :popcorn: :popcorn: :popcorn:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 27, 2019, 05:29:57 PM
This is the part of crankshaft turning which had by far the highest "pucker factor". I got thru it okay--I'm always thankful for that. I'm off to Tim Hortons to buy a bagel, and then if I'm lucky I'll get the two ends done this afternoon.
(https://imagizer.imageshack.com/img922/2752/LwJYZR.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on March 27, 2019, 06:29:18 PM
Great start on the crankshaft - did you saw away part of the slot first, or just do it all on the lathe?
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 27, 2019, 08:01:36 PM
I drilled a 7/16"hole thru so it would be about 0.060" shy of the journal, then sawed out the bit on the side away from the journal.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Herk on March 27, 2019, 09:15:12 PM
4 cylinder Willys/Jeep engines used bolt-on counterweights from late WWII through end of production in 70's.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 28, 2019, 02:58:12 PM
This morning we have a finished one piece crankshaft. It looks good, and has minimal run-out. I'm not a big fan of turning between centers, but for pieces like this crankshaft it is really the best way.
(https://imagizer.imageshack.com/img922/9076/cQpga2.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 28, 2019, 05:07:37 PM
4 cylinder Willys/Jeep engines used bolt-on counterweights from late WWII through end of production in 70's.
Thanks Herk--I've got it sorted now. Each counterweight will be held in place by one socket head capscrew. The counterbored hole for the capscrew will have a brass plug Loctited into it to hide the hole.
(https://imagizer.imageshack.com/img923/1103/e6Sg0A.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 29, 2019, 06:56:29 PM
Drove 185 Km up north to see my 98 year old mother today. She was ill around Christmas time, but is up and about and doing much better now. My metal supplier was supposed to be sawing off two pieces of 5" diameter cold rolled for me today to make flywheels from, but he never got to it. Ah POOP!!!--That's okay. I have material to make a connecting rod and piston over the weekend.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on March 30, 2019, 04:53:29 PM
And now you know how I spent my Saturday morning. There is nothing really difficult about counterweights, but there is a lot of fussy set up. They look nice in my opinion, and they clear everything when the crankshaft is rotated.
(https://imagizer.imageshack.com/img923/665/HpTBjh.jpg)
(https://imagizer.imageshack.com/img921/2144/ftPaHn.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 01, 2019, 01:38:11 AM
Not a whole lot to show today. I had to drive down to Orangeville with my pickup truck and move some furniture for one of my kids. When I got home this afternoon I decided I should do something, so the engine now has an ignition cam and the large o-ring pulley that fits on the crankshaft to drive the cooling fan. I haven't put the groove into the o-ring pulley yet, because I don't have anything to bolt it to, to mount it in the lathe. Once I get the flywheel for that side done, I will drill and tap the holes in one side of the hub, mount the pulley, and then turn the groove.
(https://imagizer.imageshack.com/img923/6426/It74jC.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on April 01, 2019, 02:39:07 AM
Looking good Brian.
Art
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Roger B on April 01, 2019, 08:09:31 AM
Only just caught up with this build, excellent progress  :ThumbsUp:  :ThumbsUp:  :wine1:

I have used bolted on balance weights on my last two engines.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 02, 2019, 12:10:57 AM
If someone told me they spent a whole day machining a con rod, I would accuse them of being a slacker. However--I spent from 10:00 this morning until 5:00 this evening  making this one from bar stock. Why so long?--Jeez, I don't know, but it did. Maybe I'm slowing down in my old age.
(https://imagizer.imageshack.com/img923/9791/XcDBGd.jpg)
(https://imagizer.imageshack.com/img923/3395/q9t01U.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: b.lindsey on April 02, 2019, 03:05:13 PM
It's really progressing well Brian. I like the look of the counterweights too especially done in brass!!

Bill
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 02, 2019, 03:41:08 PM
Today has been declared "Flywheel Day". I have two slices of 5" diameter cold rolled which cost me $25 in total. there is going to be a ton of machining in these, so I expect tomorrow and possibly the next day also to be "flywheel days".
(https://imagizer.imageshack.com/img921/5448/ESQJfG.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 02, 2019, 03:42:11 PM
Thank you Bill. I'm always glad to know someone is watching.---Brian
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 02, 2019, 05:52:53 PM
This is the first set-up for machining. The entire face has been machined to take off 0.030" because the pieces are cut 13/16" wide and I want the finished flywheel to be 3/4". the center hole has been drilled and reamed to finished size. The cavity in the face has been machined to full depth closest to the hub using a 0.120" wide cut-off tool. This is a time consuming operation, as you have to plunge 0.010", then traverse until the slot is about 0.400" wide, and keep repeating that. The slot is made 0.400" wide to allow my smallest brazed carbide boring bar to enter the slot. I will show it in the next post. I have lightly machined what will be the outer limits of the recess in the side, just to give me a visual when I begin to use the boring bar.
The outside diameter of the flywheel hasn't been touched yet. The cut off tool has been ground to have some of the "heel" removed so it doesn't rub on the side of the flywheel when taking the plunge cuts. So far, it is the only tool I have used.
(https://imagizer.imageshack.com/img921/1698/iJAmxW.jpg)
(https://imagizer.imageshack.com/img923/8872/m2WM0n.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 02, 2019, 06:55:15 PM
The second machining step involves using a brazed carbide boring bar mounted in the toolpost. I find that what works best for me is running the lathe about 170 rpm and advancing the tool into the pre-made slot about 0.010" at a time, then cranking out towards yourself until the tool reaches the maximum diameter that you want the cavity to be. Every time I do this I vow that I'm going to make an adjustable stop so that I don't have to watch the dro so closely.  After the boring tool had reached the bottom of the slot, I removed it and did a clean-up pass with a HSS tool to remove any ridges. Then I used strips of 180 and 250 grit garnet paper (which I buy on a roll) to clean up my tool marks a little more. This side is finished now, so I can flip the flywheel around and repeat this on the other side. The o.d. of the flywheel hasn't been touched yet.
(https://imagizer.imageshack.com/img923/4928/ft6neO.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 02, 2019, 09:16:35 PM
The last step, after the recess is machined in both sides of the flywheel is to hold the flywheel in place by expanding the chuck jaws inside the outer rim, and machine the outside diameter to a nice finish. The last steps of course, will be to put in the "lightening holes" and a couple of set screws and a keyway.
(https://imagizer.imageshack.com/img921/3784/HilWJ0.jpg)
(https://imagizer.imageshack.com/img923/8894/O0Q1LX.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 03, 2019, 12:05:00 AM
I looked in my broach kit for the appropriate broach for a 3/8" hole, and I see that some ham fisted bugger has broken my 3/32" broach!! Then I went online to search for a replacement. Happens they have them at Fastenal. Hey!!! my kid works at Fastenal.-C'mere kid!!!--Can you get one of these things for me?--Sure Dad.--Somebody up there loves me!!!
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on April 03, 2019, 03:47:59 AM
Brian,
Quote
Maybe I'm slowing down in my old age.
Nah.. It's just careful attention to detail, wonderful looking rod by the way.
Art
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 03, 2019, 06:27:38 PM
Both flywheels are turned now, but still need cosmetic holes, keyways, and set screw holes. You can see in the pictures how I kept both flywheels equally spaced about the center of the cylinder. This required a very large cavity in the gear side flywheel, but it clears the large helical gear by about .025", which is what I had planned.
(https://imagizer.imageshack.com/img924/9692/hZP7SL.jpg)
(https://imagizer.imageshack.com/img921/3241/UidhvV.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 03, 2019, 10:04:34 PM
Once the holes are drilled in the flywheel webs, they really start to come to life. I can't do much more on them now, until I get a new broach.
(https://imagizer.imageshack.com/img923/579/daKVYu.jpg)
(https://imagizer.imageshack.com/img921/992/5SHjDh.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on April 03, 2019, 10:10:59 PM
Those holes really change the look a lot!

 :popcorn: :popcorn: :popcorn:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 04, 2019, 03:51:40 PM
All the things I have done so far are just repeats of parts and operations that I have done many times before. The exciting part for me is about to begin, up at the cylinder head end. I have actually made the rocker arm and exhaust valve and sideshaft cam on my previous sideshaft hit and miss engine, so that's not entirely new either. The overhead intake valve and rocker mechanism will be "sorta/kinda" new to me. I am not going to commit at this time about the position of the fuel tank. There is room enough to squeeze one under the cylinder, but after all the issues I had with my previous engine has made me a bit leery of fuel tank positions. The cylinder head, although not terribly complex, is going to be "interesting".  It can be made from a length of 2" x 1" aluminum bar.
(https://imagizer.imageshack.com/img923/9175/EGLzwA.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 04, 2019, 09:46:03 PM
I've been setting here studying the two raised bosses on the face of the cylinder head in the above picture. They look nice, and they both serve a function. I'm just not 100% sure that I can make them. If I made them rectangular they would still function, but it wouldn't look nearly as nice. But--if I make them rectangular, I can set the part up on my mill table and use the boring head with a reversed boring tool and round the perfectly circular boss down to the surface of the longer raised portion.--Then how do I get the corners rounded on the longer raised portion?
(https://imagizer.imageshack.com/img923/266/V1c5zI.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 05, 2019, 12:00:42 AM
Okay--Minor design change here. That round boss was only there to give enough material to screw in an exhaust pipe. I have removed the boss completely and went to a flange mounted exhaust pipe. This lets me change the other long boss to be circular, which gives me sufficient thickness to screw the sparkplug into and makes machining a lot easier. Now it can be done on the lathe with my four jaw chuck.
(https://imagizer.imageshack.com/img923/2470/Dbnvy8.jpg)
(https://imagizer.imageshack.com/img923/930/0BoIq6.jpg)
(https://imagizer.imageshack.com/img923/1200/bHWrNs.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 05, 2019, 03:04:55 PM
The block which will become the cylinder head has been machined to correct overall dimensions. It is set up in the four jaw chuck, and the first cavity machined into one side. This is the side which fits against the cylinder, so the recess just formed fits over a register turned on the end of the cylinder. While it is still in this set-up, I have drilled a 3/16" hole thru, so that when I flip it over to machine the far side I can pick up exactly the same center. eventually that 3/16" hole will be opened up to accept a sparkplug with a 10mm thread on it.
(https://imagizer.imageshack.com/img924/9950/1Bhl08.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Craig DeShong on April 05, 2019, 03:14:55 PM
Brian, I bought those same gears off Ebay awhile back and was shocked :o at the size of them when received.  They were way to big for the contemplated project. Looks like you found a use for them though.  Following along as always  :popcorn:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 05, 2019, 05:03:24 PM
Part has been flipped over in the four jaw, and machined so as to leave the boss which the sparkplug fits up against. This is the last "on center" work that I have to do, so before I tear down this set-up I will drill and tap the sparkplug hole.
(https://imagizer.imageshack.com/img921/6610/A16fr3.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 05, 2019, 07:23:33 PM
The burn chamber has been milled. My gimpy back is starting to talk to me, so I'll finish this cylinder head off tomorrow.
(https://imagizer.imageshack.com/img924/2939/skDNb5.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 06, 2019, 05:23:50 PM
Jeez--I may have to rebrand this engine as the "Cyclops".
(https://imagizer.imageshack.com/img921/6249/v29i1U.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 06, 2019, 10:03:32 PM
Hi Craig--Glad you stopped by and said Hi. I kind of got the cart ahead of the horse here. I really should have built the piston next, but I was so intrigued by the shape of the cylinder head that I had to make it first. Your engine is looking very good, I follow your posts quite closely.---Brian
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 07, 2019, 07:19:52 PM
Todays offering to the machining Gods is a big beautiful cast iron piston. It was machined to about .001" larger than the bore of the cast iron cylinder, then "wrung" into the cylinder with 600 grit aluminum oxide paste. The cylinder bore was honed with a 3 stone brake hone, but not lapped. It is self lapping when "wringing" the piston into the bore with aluminum oxide paste. The piston pin is a bit of 3/16" cold rolled steel, held in place by a set screw in the piston.
(https://imagizer.imageshack.com/img921/4306/nttCh4.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 07, 2019, 09:49:18 PM
The idea of "wringing" a piston into a cylinder works like this. . The theory is that you turn the piston to be about .0005" to.001" oversize. Then using a loop of 220 grit sanding strip, work it back and forth on the piston until the piston just begins to fit into the cylinder, but not go in all the way.  At that point the cylinder is held in the chuck, and the piston is mounted on a T handle and coated with 600 grit. With the lathe on its slowest speed, you hold the T handle and work the piston in and out. This is scary as hell, and you have to be ready to instantly let go of the T handle if it grabs. Each time you try to move the piston into the cylinder, it will go in a little farther, as the grit wears away some of the piston o.d. and some of the cylinder i.d. You keep working it until the piston will pass completely through the cylinder. What you end up with is for all intents and purposes a zero clearance between the piston and cylinder. The hardest part of this procedure (other than the fear of getting wrapped up in your lathe) is turning the piston to the correct diameter. If you leave the piston too large, it grabs, jerks the tee handle out of your hands, and makes you crap your drawers. If you take off a thou too much, then you have no material to "wring" away.
(https://imagizer.imageshack.com/img923/1681/XUHM6t.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 07, 2019, 11:02:50 PM
Almost all of the small semi-diesel model airplane engines are made this way with no rings at all. They rev so high that compression doesn't have time to leak down around the piston. I can run my engines without a ring when they are made this way, but I have found that for really slow running engines that they work better with one Viton ring.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 08, 2019, 06:01:32 PM
Today the magic beast has grown a set of antlers---well, not really. Those are the pivot towers for my inlet and exhaust valve rocker arms.
(https://imagizer.imageshack.com/img924/9291/A0YfKq.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 08, 2019, 10:58:41 PM
I was just doing some research on recommended valve lift for the cam design on this engine. I found a site that recommended that valve lift should be roughly equal to 12% of the cylinder bore on a 4 cycle engine. This engine has a 1" bore, so it seems that a total valve lift of 1/8" (0.125") should be about right. This is not cast in stone, since I can design  cam lobes to give whatever lift I want. This engine will be a slow revving engine. I would appreciate input from other model engineers on this. I know that on my model hit and miss engines with atmospheric intake valves that the exhaust valve lift is almost 0.170", while the valve lift on my 1" bore flathead engine that was featured in The Home Shop Machinist magazine is only 0.080".
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Rustkolector on April 09, 2019, 06:10:27 PM
Brian,
I am only commenting here from from my experience with the slow speed (600 RPM) 1" bore multi-cylinder throttled engines that I have built. I used .375 dia valves usually with >.050" lift with very soft valve springs. These engines will easily rev well beyond 1000 RPM and will carry significant load at slow speed. These were both OHV and L-head configuration engines. You have to keep in mind that, comparatively speaking, slow speed engines have plenty of time for cylinder fill on the intake stroke, and that the only intake restriction will be the carb throttle opening.
Jeff
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 09, 2019, 07:29:12 PM
Rustkolector--thank you for your input. You must have had a pretty radical cam to get 1/2" of lift.---Brian
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Admiral_dk on April 09, 2019, 08:24:59 PM
It has happened to me too Brian, but read again :

Quote
.050" lift
vs. your
Quote
1/2" of lift

I think for a man who keeps on saying that he will not build any more engines for while - you are quite productive  ;D
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 09, 2019, 08:27:11 PM
My bad---Read the post wrong. 1/16" lift fits more with many other engines in the same size class that I have seen.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 09, 2019, 09:31:51 PM
Today was rocker arm day. They are brass, which will look nice with a bit of polishing. The size of these little things in no way reflect the amount of work that goes into making them!!!
(https://imagizer.imageshack.com/img924/426/KMKNjE.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 10, 2019, 09:33:07 PM
Lots of little fiddly bits done today. The cam contact rollers and fork, and the fan bracket. I hope to make both cams tomorrow.
(https://imagizer.imageshack.com/img923/373/7nnzv5.jpg)
(https://imagizer.imageshack.com/img921/6489/5S0j3H.jpg)
(https://imagizer.imageshack.com/img923/9492/zSO8Fg.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Johnmcc69 on April 10, 2019, 10:36:58 PM
Great looking engine Brian!

  :popcorn:
John
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 10, 2019, 11:31:47 PM
Thanks John. It is a very interesting engine. I was just saying to my wife this evening that I'm glad the weather is finally starting to warm up, because I'm getting tired of playing every day in my machine shop.---Brian
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on April 10, 2019, 11:47:48 PM
Thanks John. It is a very interesting engine. I was just saying to my wife this evening that I'm glad the weather is finally starting to warm up, because I'm getting tired of playing every day in my machine shop.---Brian
Hopefully that big snowstorm in the Dakotas is going to miss you? It is heading northeast, but may go northwest of where you are.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 11, 2019, 08:02:52 PM
The cams came out without any problems. They are simple flat sided cams and were very easy to machine. I had far more trouble and fussing with that brass pulley at the fan. I have to quit and figure out what comes next. I think I'm down to the valve/valve housings. They will be made as sub assemblies, then inserted into the cylinder head like I did on the previous hit and miss engine.
(https://imagizer.imageshack.com/img923/1193/4dHXzq.jpg)
(https://imagizer.imageshack.com/img923/2307/avRJNK.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 12, 2019, 04:27:40 PM
I had a very exhausting morning.--Oh, that's a horrible pun--I made the exhaust pipe and flange this morning. I should be making valves, but I need a break from machining things. The temperature outside is almost 60 degrees F and the glacier in my front yard is almost gone.  I think I deserve a coffee from Tim Hortons, maybe even risk a big sugary donut. If I still had my hot-rod this would be the day for its first spring ride. Maybe a good dose of sugar and a drive around town will restore my creativity and I'll do the valves later today. ---Brian
(https://imagizer.imageshack.com/img924/8042/lbgW4o.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 12, 2019, 05:43:59 PM
Went to Timmys, had a big coffee and an apple fritter, then went down to Partsource and bought a sparkplug, points, and a condenser. I use the same units on all of my engines. Cost is +/- $28 Canadian. Went to Kawartha Dairy and bought a small bag of curd to munch on.---Everything I like is either illegal, immoral, or fattening!!!
(https://imagizer.imageshack.com/img924/3293/LwHhIf.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 12, 2019, 08:35:50 PM
This afternoon I whittled out two valves. I keep my exhaust and intake valves the same size and length. I use plain cold rolled steel to make them from. They have not been trimmed to "finished length" yet. One interesting thing in this picture is the small piece of material setting between the valves. It is a scrap piece of cold rolled steel with a 0.125" hole reamed thru it. When I machine my valves, I leave them about .002" oversize. I work that last .002" down with a strip of aluminum oxide paper. I have learned from past experience not to trust my micrometer for the final diameter of the valve stems. Instead, I try and fit that piece with the hole reamed in it as a fitting guide. When the valve stems are reduced to the point where that piece will slide all the way up the valve stems, I know they are finished and will fit well into the reamed 0.125" holes in the valve cages.
(https://imagizer.imageshack.com/img923/4141/7gGF6F.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 13, 2019, 09:10:00 PM
Nothing spectacular going on today. I did make up proper pivot pins for both rocker arms, and a small retainer bushing on the back sided of the fan shaft (which doesn't show up in this picture anyways.) One thing that I did do, and that I like very much--I took off the rectangular sideshaft bracket, mounted it in the four jaw chuck, and turned a round boss and a taper on the end of it. This was a purely cosmetic thing, but it really adds to the overall look of the engine, I think.
(https://imagizer.imageshack.com/img921/1801/Tw0LDy.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 14, 2019, 10:08:35 PM
Its been a horrible cold, wet, nasty day today, with light traces of snow and lots of rain. I had an inventor come this morning to discuss a new project he has in mind, and after he left I turned two valve cages and two valve spring retainers. I dug around in my box of assorted springs and found two springs the right diameter, but I'm not sure at this point if they are strong enough.  Tomorrow I will use my George Britnel valve seat cutting tool to cut the seats into the cages, cross drill the end of the valves for a retainer pin, lap the valves into their respective seats, and maybe press the assembled valves and cages into the cylinder head.
(https://imagizer.imageshack.com/img921/9990/fHgQBv.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 15, 2019, 06:05:29 PM
The valve modules have been completely finished. All appropriate holes have been added and the valves have been shortened to finished length and  lapped into the seats before the modules are pressed into place. The valve cages were coated on the outside diameter with #638 Loctite before being pressed. The valves shouldn't have to be lapped any more, but if they need to be I can remove the spring and retainer and attach one of my finger chucks to the valve stem to spin it for a re-lap. The cylinder head is currently in a vice, which is closed enough to raise the valve faces up of the seats. That is "just in case" I may have got some Loctite on the valve faces. I don't want to Loctite the valve faces to the seats.
(https://imagizer.imageshack.com/img924/6387/CFXr4I.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 15, 2019, 10:31:37 PM
I knew that sooner or later I was going to have to cut keyways in this crankshaft, and today was the day. These keyways are just a little bit different, because they don't run out to the end of a shaft. I thought that they were called "pocket" keyways, but they are actually called "feather" keyways. I had to go across town and buy a couple of new 3/32" endmills because the one I had was broken. Not being able to find any pertinent information other than the correct name, I made it up as I went along. I ran the mill at 1150 rpm, poised the endmill over what would be the extreme end of the keyway, then very cautiously plunged to full depth--which in my case was about 0.053". This went well, so after plunging a total of four places I increased the depth from "0" to 0.053" in .005" increments and moved the table in x axis very slowly and cautiously from one end of the keyway to the other, with lots of squirt on cutting oil. All went well, I didn't break the endmill, and I have my keyways finished. I am still waiting for my broach to arrive so I can cut the keyways in my flywheels.
(https://imagizer.imageshack.com/img924/5498/Ox5UtL.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 16, 2019, 01:19:30 AM
My broach came in today, but there was a problem. The one I ordered was a plain HSS broach, for $75 Canadian. The one that came in today was the right size but was TIN coated and costs $135 Canadian. Tomorrow will be negotiation time. I am not going to pay $135 but I don't want to wait for another two weeks to get an uncoated broach in. Apparently they come from some place in Virginia.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Craig DeShong on April 16, 2019, 12:53:14 PM
Great progress Brian.  Following along.  :popcorn: :popcorn:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 16, 2019, 03:44:23 PM
The engine is very close to being finished. This morning I am "running it in" with power provided by an old 1/2 hp. electric motor. Running an engine in is not intended to take out any major binding in an engine. That is something that has to be addressed with more machining on something. This type of run in is to address all the minor binding points.--Con-rod big end to crank journal, sideshaft to bushings, wrist pin to piston, and any "stickiness" in the valve train.
https://www.youtube.com/watch?v=A7glIfsXP9w
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 16, 2019, 07:35:59 PM
Today yields a set of ignition points installed and the valve module retainers finished and installed.
(https://imagizer.imageshack.com/img923/1323/NjMqSj.jpg)
(https://imagizer.imageshack.com/img923/9732/haAu6b.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Roger B on April 16, 2019, 07:42:23 PM
Not long now  :)  :ThumbsUp:  :wine1: We also had more snow on Sunday  :( R+D department closed.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 16, 2019, 11:06:58 PM
And now I'm snookered!! The wrong broach has been returned and I have to wait a week for the correct one to be shipped up to me. My intent was to make the first trials of this engine using a Traxxas Pro 15 carburetor, but my local hobby shop has stopped handling them and they can't even special order one for me. I do have a piece of the broken 3/32" broach here and I may try to use it with shims. Depending on how the coming week turns out, I may make another carburetor while I wait for the correct broach to arrive.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 17, 2019, 02:57:51 PM
In order to have something to do, I went ahead and drilled and tapped the flywheel hubs for set screws. One set screw goes directly over the key and the other is 90 degrees offset. This is where my old "Tilt-a-whirl" vice really shines. Due to the fact that the hubs very seldom stick out past the width of the flywheels, these set screw holes must be drilled at an angle. I have a digital protractor which I use to set the vice to whatever angle of tilt I want and then drill the set screw holes. It helps a great deal if you have an extra long centering drill and an extra long tap.
(https://imagizer.imageshack.com/img923/5826/aWh05U.jpg)
(https://imagizer.imageshack.com/img923/18/kyllJh.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 18, 2019, 02:58:19 PM
Of course, like all my i.c. engines, I have to have a starter hub. This hub will bolt to the face of the flywheel. Since the crankshaft is relatively small on this end (0.3150") I want to keep any torque forces from outside to be as close to the supporting crankshaft bearing as possible. I will probably make this up today. Also you will see at the far end of the engine a red wire clamp. I don't have it correctly positioned yet, but it is there to hold the "hot wire" which goes to the ignition points so that it doesn't rub on the flywheel and short out.
(https://imagizer.imageshack.com/img921/8808/aDtB6C.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 18, 2019, 09:06:08 PM
There!! That's enough playing for today. Now, if I ever get my crankshaft keyways cut, I have something to engage with my variable speed drill to try and start this thing. At the last minute I decided to put a small flange on the outer edge of my starter hub. If I want to use the starter hub as a power take off pulley the flange will help keep a belt in place.
(https://imagizer.imageshack.com/img921/2088/gfEP6l.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 20, 2019, 04:06:16 PM
Every engine running old school ignition points need a condenser to keep the points from arcing and burning out. Its especially good karma when you get to hide everything in behind the flywheel.--It doesn't always happen that way.
(https://imagizer.imageshack.com/img921/174/EbcVj5.jpg)
(https://imagizer.imageshack.com/img924/313/gUPaOe.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 21, 2019, 12:53:40 AM
In order to have something to pass today, I set the valve timing and ignition timing this morning. Ringo had suggested that a pneumatic fitting that would screw into the sparkplug hole would be a good way to check for leaking valves before even trying to start the engine. What a great idea. I made one for my earlier hit and miss sideshaft engine, and this one has the same C6 sparkplug, so I thought I'd put some air on the fitting and see what was up with this engine. The exhaust valve didn't leak at all. The intake however leaked like a sieve. I pulled the cylinder head, relapped the intake with 600 grit aluminum oxide paste, then reassembled everything.--It still leaked like a sieve. Tore it down again and relapped the intake, first with 320 grit, then after a laquer thinner cleanup I lapped it again with 400 grit. Then after a second cleanup, I lapped it again with 600 grit. That fixed it. I'm getting a definite "bounce back" now when I spin the flywheels by hand.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Johnmcc69 on April 21, 2019, 01:55:40 AM
 :ThumbsUp:
 :popcorn:
 Real nice work Brian! Not much longer.

 Should be a sweet little engine.

 John
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Art K on April 21, 2019, 02:19:21 AM
Brian,
I may not say much but I have been following along. I must admit that I like the 4 jaw treatment to the side shaft housing elegant or aesthetically pleasing are terms I would use. Won't be long now.
Art
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 21, 2019, 03:11:17 PM
Its time to think about a gas tank. Space is really at a premium here, and I don't want a big external tank to mess up the lines of the engine. The tank I have shown in pale green utilizes the last bit of free space and still leaves clearance between the top of the tank and the underside of the cylinder, so as not to interrupt the breeze coming off the fan. The outside dimensions of the tank are 2" x 1 1/2" x 2 1/2" long. This will hold quite a lot of gas, and the main part of the body can be built from a section of 2" x 1 1/2" rectangular tubing with endplates welded into it. You will also note that I have used a Traxxas Pro 15 carburetor--Not because it is better than a home built one, but because it will be quicker to get a running engine than taking the time to build another carburetor right now.
(https://imagizer.imageshack.com/img921/1024/JHj2di.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 21, 2019, 09:03:59 PM
I scratched and scraped around in my "stuff you should never throw away" drawer and found a piece of 2" x 2" x 3/16" square tube and some oddments of 1/8" plate. The bandsaw cut one side off the square tube and yielded a 2" x 1 1/2" channel which will become the top and two sides of the tank. The three pieces of plate in the picture will become the bottom and two endplates for the tank. A gas tank could be made from much lighter material, but this stuff is FREE!!! When it's all welded together and painted, nobody will know. Jury is still out on the filler neck and cap.--And Oh yes--If you look under the cylinder you will see a block of wood cut to the size the finished gas tank will be. I really didn't want to make a tank that wouldn't fit after I got it finished.
(https://imagizer.imageshack.com/img924/7793/PuEc1z.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 22, 2019, 08:17:54 PM
Don't laugh!! This is the very latest in "blow your guts out leaktesting". The pail of water is out in my main garage. Works great.--Submerge gastank in pail of water. Put brass fitting in mouth. Blow your guts out and look for bubbles. Keep resoldering until there are no more bubbles. The neoprene tubing, pipe plug, and coupling all unscrew from the gas tank filler pipe. At the moment, the gas tank has no leaks. After sanding and cleaning it up ready for paint, it is my sincerest hope that no more leaks are found. The outfeed to the carburetor is going to be a bolt on affair. The mousetrap is not part of this apparatus. Caught one mouse in the pantry last night, and placing the trap on my side table is good wifes subtle reminder to set it again tonight.
(https://imagizer.imageshack.com/img923/4444/wAD2o1.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 23, 2019, 01:37:27 AM
And a lovely thing it is, indeed!!  It fits into the space that was available, it doesn't foul the blades of the cooling fan, and that rather ridiculous long filler spout neck coming out of the tank at a 10 degree angle ends up in the correct spot. Far enough away from the sparkplug to prevent arcing to it, and convenient to fill.
(https://imagizer.imageshack.com/img923/1459/wmzIig.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 23, 2019, 08:47:20 PM
Nothing too outrageous today, but progress none the less. I made up the aluminum fixture which bolts to the side of the gas tank. This piece bolts to the side of the gas tank and the actual fuel passage is sealed with a rubber o-ring between the gas tank body and this aluminum part.  The gas tank is threaded for the bolts, and the bolts will be coated with J.B. Weld as a sealing agent. I did fabricate and install an anti flowback valve, same as on the sideshaft hit and miss engine, with a 3/32" diameter ball. I was able to drill and tap two of these holes in the gas tank with my existing tooling, but had to order an extra long drill and #4-40 tap to get the other two which fall directly under the long filler spout. The goopy looking stuff is J.B.Weld which has to dry 24 hours before I do much clean-up on it.
(https://imagizer.imageshack.com/img921/6225/yb9E6d.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Johnmcc69 on April 23, 2019, 09:17:21 PM
 :ThumbsUp:
 Nice fab work on the tank Brian!
 I really like the brass filler cap.

 John
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 23, 2019, 11:13:08 PM
John,--That brass cap is just a common pipe cap, purchased from the hardware store. They are kind of a plain, ugly thing as purchased, but they clean up very well on the lathe. I just screw them onto a pipe nipple, hold the pipe nipple in the lathe chuck, and re-profile the outside of them.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 24, 2019, 04:25:30 PM
The gas tank has been mounted to the base. Taking a picture of this is about the same as taking a picture of a black cat in a coal bin, but you can see enough of what I'm doing.  This was one of the times where I didn't want to put the holes in the baseplate before hand. A fabrication like the gas tank might have the bolt holes exactly where you want them on cad, but there is more of a chance that they won't be. This was an opportunity to set the finished gas tank in place and mark thru with transfer punches. I have only one extra length drill, and fortunately it was smaller in diameter than the #5-40 thread tap drill. So--set the tank up, transfer punch holes, use my one and only extra length drill to drill thru the base, then set the base on its side in the mill vice and drill thru from the other side with the correct size tap drill, then tap from the wrong side (thankfully my taps were just long enough to go thru the 3/4" baseplate), then tear down the setup and put the bolts in place. Fortunately I didn't have to remove the cylinder to do any of this, but I did have to dismount the sideshaft housing.
(https://imagizer.imageshack.com/img924/471/p24MxF.jpg)
(https://imagizer.imageshack.com/img924/4854/jLKN5F.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 25, 2019, 11:16:05 PM
Sing Hallelujah brutha--My new broach finally came. During the past week while I've been waiting for the new broach to show up here, I have went ahead and finished all of the little things that I normally might not have done until the flywheels were broached and the engine test fired. So--Tomorrow may be the day!!!
(https://imagizer.imageshack.com/img921/4255/Vih6Bf.jpg)
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 26, 2019, 02:21:36 AM
Flywheels are broached and all is well. Nothing broke, flywheels and keys are assembled on crankshaft. Now I can go to bed.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 26, 2019, 08:05:38 PM
So here we go guys and girls. We have a runner. I still have a few adjustments to make, but overall I'm very happy. It took very little to get it running. I am confident enough at this point to sell a complete set of plans for this engine for $25 Canadian funds. On a scale of 1 to 10, with the Webster being a 1 and Malcolm Strides Lynx being a 10, I would classify this engine at about a 5 in terms of difficulty to build. Contact me if you wish to buy a complete set of engineering drawings as .pdf files. I will be doing more adjusting and tweaking, and will be back with a better video, but there will be no more changes to the engine itself. I have a Traxxas Pro 15 carburetor on right now, but will include a complete set of carburetor drawings with the engine in case you wish to build your own carburetor.---Brian
https://www.youtube.com/watch?v=spr0AHILQ_s
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Johnmcc69 on April 26, 2019, 08:22:56 PM
 :ThumbsUp:
Excellent Brian!

 John
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on April 26, 2019, 08:49:24 PM
Terrific!   :ThumbsUp:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 26, 2019, 09:53:07 PM
And here we have the engine running after a bit of "tuning up".
https://www.youtube.com/watch?v=fycK-IioAbQ
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Admiral_dk on April 27, 2019, 11:19:04 AM
A very fine runner Brian and I must say that it does slow very well  :cheers:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: MJM460 on April 27, 2019, 11:42:49 AM
Hi Brian, congratulations on another great runner.

You never cease to amaze me.  It was already 20 March this year when you posted that you were playing around with an idea to use some helical gear that you had.  Now, only 27 April, you have designed and built an excellent runner.  You must be quietly sharing that alternative universe with Chris.

But now, what would it be appropriate for that engine to drive?  Such a nice engine needs to earn its keep. 

MJM460

Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 27, 2019, 05:11:28 PM
Thank you, fellows. I am very happy that this motor came together so quickly and started so easily. The amazing part about this is that the one week delay in getting my 3/32" broach didn't hold me up at all. I just kept forging ahead doing all of the things I wouldn't ordinarily do until after the flywheels were broached. Once the broach arrived here, it was only a couple of hours until I had the engine running.---Brian
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 28, 2019, 12:12:40 AM
When I built the gas tank for this engine, I incorporated my anti backflow valve into it. Since this is a throttled engine and not a hit and miss, the only advantage that I could see is that on cold starts the fuel would be "right there" at the carburetor, so I wouldn't have to go thru prolonged choking of the engine to get the gas all the way from the tank up to the carburetor. I am very pleasantly surprised---The engine starts immediately on a cold start with no manual choking being necessary at all. Just thought I would pass that bit of information on to other home model engine builders.---Brian
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on April 29, 2019, 01:18:50 PM
After I finished this engine, I toyed with the idea of putting a governor on it. However, the engine runs so well that I have decided not to mess with it. I may build a governor as a "stand alone" unit which gets driven by this engine, but is not an actual part of it.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on May 19, 2019, 09:01:03 PM
I looked around my shop for flat belts, but I only found this short little guy to run my over-center clutch.
https://www.youtube.com/watch?v=z7yJJXCxH-E
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on May 24, 2019, 06:31:02 PM
I try to post a video of my engines working once they have been set up and tuned. All of my engines have to be capable of earning their keep around here by working at something. They work on a number of nifty things, but this is one of my favorites, the sawmill. The sideshaft engine seems quite capable of running the sawmill with no hesitation, so here we are, sawing some lumber today.---Brian
https://www.youtube.com/watch?v=3Q3MbtXumEY
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Johnmcc69 on May 24, 2019, 07:37:52 PM
 :ThumbsUp:
 :NotWorthy:
 What a sweet display Brian! Clutch, sawmill, & sideshaft engine with the governor!

 Just fantastic!

 John
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on May 24, 2019, 07:49:02 PM
I had hoped that this would show the governor working, and it does, but you have to be quick to see it. At 0.26 seconds into the video, just as I engage the clutch, you will see the governor move the throttle linkage to give the engine a little more throttle to prevent the engine rpm from dropping when the load of the clutch is introduced.
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Johnmcc69 on May 24, 2019, 08:03:31 PM
Yep, you can hear the engine load & recover.

 Mission accomplished!

 Great stuff Brian!

 John
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on May 24, 2019, 08:30:49 PM
Thanks John. There are a lot of hours represented on that table top. :Lol: :Lol:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: crueby on May 24, 2019, 09:08:13 PM
Very well done!  I'll have to send you the logs next time I need some lumber!
All working great!   :ThumbsUp:
Title: Re: Sideshaft i.c. Horizontal engine
Post by: Brian Rupnow on May 24, 2019, 11:06:56 PM
Thanks Chris. It is a nice layout and fun to watch. Your project is looking very nice with all the cabin framing going up.---Brian
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