Model Engine Maker

Engines => From Kits/Castings => Topic started by: b.lindsey on April 07, 2018, 02:22:27 PM

Title: PMR #5 - as a fill in project
Post by: b.lindsey on April 07, 2018, 02:22:27 PM
These castings are now very well aged...probably close to 20 years  :o (my how time flies). I got these from the PMR folks back when they sold them as all bronze castings rather than aluminum or iron or a combination of those. Anyway I had started on the sub base long ago and then got diverted to some other project and there things sat. I have resurrected this project as a fill in while finding time to do some larger machine work on the Little Pearl (will post more on that later today though). These #5 castings will generate some work for the Cowells lathe too which will be nice as well.

For now, I have gotten a few things done on the engine coke bottle frame on the top end and the mounting holes on the bottom to attach it to the sub base so am attaching a few pictures of that. As noted, progress will be sporadic as the Pearl is still on the front burner but I did always like this little engine and hope to be bringing it along not too slowly.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Gas_mantle on April 07, 2018, 02:34:57 PM
Great to see someone having a go at one of these Bill  :)

I rather like the slightly unusual look of bottle engines.
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on April 07, 2018, 03:15:50 PM
Looks like a fun project. Enjoy!
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on April 07, 2018, 03:58:33 PM
Looks good Bill!

Dave
Title: Re: PMR #5 - as a fill in project
Post by: crueby on April 07, 2018, 04:43:38 PM
That was one of the first kits that I made many moons ago, fun project, runs pretty well considering the looser fits I got back then. As I recall, the hardest part was figuring out how to hold it to machine the top end of the bottle. How did you do it?
Title: Re: PMR #5 - as a fill in project
Post by: Kim on April 07, 2018, 05:36:13 PM
Hey Bill,
This looks like a fun little project!  Looks like you had already done some work on the castings too.
Will be following along.
Kim
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on April 07, 2018, 06:22:14 PM
Chris, I did it carefully in the 4jaw chuck. Very light cuts too so it wasn't fast at all but it worked ok.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: J.L. on April 07, 2018, 06:44:29 PM
Hi Bill,

 :popcorn:

John
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on April 07, 2018, 07:42:11 PM
Ok Jo, how many are you going to start building  :lolb: :lolb:. Seriously, they are a great build. This engine was my third build and the first one I show when I’m showing someone about my addiction, er hobby.  :DrinkPint: and  :popcorn: in hand; lead the way.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on April 08, 2018, 01:38:41 AM
I had forgotten you did that one Cletus. I will look back at your build thread. Thanks also for looking in guys.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Jo on April 08, 2018, 12:05:44 PM
Ok Jo, how many are you going to start building  :lolb: :lolb:

:thinking: I don't have one of those in the collection... It looks desirable  :embarassed: Now who is it that does those castings in the UK  :noidea:

But I do have a couple of fill in projects on the go in between other infill projects  :naughty:

Jo
Title: Re: PMR #5 - as a fill in project
Post by: bent on April 09, 2018, 08:56:15 PM
Nice!  I have that kit waiting in the wings for me Bill, so will be following your build with interest.  I did see Cletus's build log too, which left me a bit worried, as there were places he, er, struggled.  The machining and alignment of the bottle features has me scratching my head, so like I said, will follow with interest. :popcorn:
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on April 10, 2018, 07:57:33 PM
I think you’ll really enjoy this one Professor. I was just looking at mine yesterday and remembered, if the flywheel and drive pulley is still brass or bronze; if you will put them in a oven on about 250Frankenstein for the paint to cure, they come out with an almost aged golden patina. Bent, I do remember my trials and tribulations on this one :facepalm2:. It was my first engine from castings and was the one in which the main body fell off the bench and when it bounced, I stomped the h e double l out of it and broke it  :lolb:. Learned a lot since then, yet, still having trials and tribulations . Now I look at it as “fettling and fitting” the “prototype” parts  :lolb:. Tally Ho to the showcase Professor  :cheers:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: bent on April 11, 2018, 09:48:29 PM
No shame in that, Cletus!  In my last log I showed my mistakes to people too, if only in hopes they'll learn from them, or at least get a laugh.  You lead by example, sir. 
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 12:32:07 AM
I'll get back on the Pearl engine cylinder tomorrow but this weekend and today was spent making the crosshead and finishing the inside of the frame casting to mate with the crosshead. I actually started with the frame on Saturday and clocked it in with the 4 jaw till the top bore was running true and then carefully used a boring bad to turn the two crosshead slides on the inner part of the frame. I just got the close and sorry, forgot to take a pic of that. At work today I put the frame in one of the full size mills, again centered on the already machined top opening using the coax indicator, and then slowly used that .750" reamer I had bought for the Pearl engines bearings to ream down through the slides. This is shown in photos 1 & 2.

I also  got the crosshead casting machined over the weekend. After turning and then drilling and tapping the stem for the piston rod, it was flipped around, and the OD turned to .749" as required. The crosshole was located and drilled and the bottom milled out for the con rod. The finished crosshead is shown in the last picture.

When I got home tonight, I tried the fit and it is a very nice sliding fit, no binding at all but not sloppy either so I was happy with that.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on May 01, 2018, 12:50:59 AM
Methinks someone smells retirement.  ;D

Glad to see this Bill.  :popcorn: :popcorn:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 01:00:27 AM
Thanks Zee. I actually got a bit done on the pulley too but not enough to show yet. Got to get back to the Pearl and get it finished up now.  This week is too busy to think about much of anything!! My final two classes tomorrow, collection and restocking of the student tool boxes all day Wednesday, Senior Design Expo Thursday, a very dull and boring half day seminar Friday and our final exam on Saturday from 11:30-2:30, just the perfect time to screw up a whole day.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on May 01, 2018, 01:07:33 AM
Thanks Zee. I actually got a bit done on the pulley too but not enough to show yet. Got to get back to the Pearl and get it finished up now.  This week is too busy to think about much of anything!! My final two classes tomorrow, collection and restocking of the student tool boxes all day Wednesday, Senior Design Expo Thursday, a very dull and boring half day seminar Friday and our final exam on Saturday from 11:30-2:30, just the perfect time to screw up a whole day.

Well I didn't say 'thinking', I said 'smelling'.  ;D They may end up to the same goal but getting there is a little different.  ;D

Looks like you've got this week 'counted'.  :ROFL:

[EDIT] It was me doing the 'methinking'.
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on May 01, 2018, 01:12:41 AM
Hi Bill

I went to the senior design showcase last Friday at our local University (Boise State). I had helped one of the Mechanical Engineering teams with some sheet metal parts, and also one of the Materials Science teams that my company had sponsored. The Materials Science team was working on properties of 3d printed samples from the systems that we have at work.

It was fun to see all the interesting projects that all the teams had worked on. These were from all the different engineering fields. Mechanical, Civil, Electrical, Chemical, and Materials.


Dave
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 01:22:52 AM
Ours is very similar Dave, many of the teams are multi-disciplinary in fact, just depends on the nature of the project. I know I complain at times about the freshmen I see daily (some of them anyway), but those that make it to their senior year really do some outstanding work and some very technical and theoretical work as well. I have mentored teams up until this year for the entire time I have been at the university. The team I had last year was one of the most outstanding teams I ever had, they completed a working automated test rig for Dixon Valve company for coming up with pressure vs. flow rates for quick disconnects from 1/4" up to 2" pipe sizes. They did so well in fact, the company hired two of them at the end of the project.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on May 01, 2018, 01:28:30 AM
That's really cool Bill.
I sure have enjoyed what I have been involved with over the last couple of years.

Dave
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 01:32:13 AM
Dave, its amazing how smart some of them get between freshman and senior year  :lolb:.  It truly is one of the things I will miss most though.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: bent on May 01, 2018, 03:49:50 AM
Still watching Bill. :popcorn:

BTW, what college are you working for next?  I'd sign up as an undergrad, but you'd probably con me into TA-ing some of the valve flow stand labs. :lolb:

The 3/4" pipe I used for my last honeydo (see the chatterbox/gardening thread) came off of one of the old test stands after we upgraded to a fast-clamp system for valve testing.
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 12:11:09 PM
Bent, I am at the University of North Carolina at Charlotte.  Might be a bit of a long commute for you but there is still time to   sign up for summer sessions  :LittleDevil:

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Gas_mantle on May 01, 2018, 02:48:47 PM
It's coming along Bill  :ThumbsUp:

Keep it up, I want to see it running  :)
Title: Re: PMR #5 - as a fill in project
Post by: bent on May 01, 2018, 06:05:09 PM
An old chum of the wife's (student with her at Northwestern in Chicago years back) is out from Raleigh for a visit.  I'd probably bunk with him.  But summer in NC...dunno.  Is the shop air conditioned?  :)
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 06:20:48 PM
Currently no, but when I revamp my old shop building (from before I came here to the  university) that is #1 on the priority list!!

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on May 01, 2018, 07:04:16 PM
Currently no, but when I revamp my old shop building (from before I came here to the  university) that is #1 on the priority list!!

Hee hee hee. Someone's got plans.  ;D
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 07:26:18 PM
Indeed I do Zee, all to be revealed in due time :)

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on May 01, 2018, 07:37:34 PM
Zee, I bet he’s going to open a private school for “model machining “ . If he signs up a few of us (attendance not required) he could probably update the shop, cental HVAC, new machines, and get funding and tax credits for doing it. See I know the educational and tax system works  :lolb:  TBH: wonder how I came up with that  :shrug: :naughty:.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 01, 2018, 09:04:21 PM
Close but no cigar Cletus. My teaching days are done as of today, the last day of classes this semester :)

Prof.
Title: Re: PMR #5 - as a fill in project
Post by: crueby on May 01, 2018, 09:05:46 PM
Close but no cigar Cletus. My teaching days are done as of today, the last day of classes this semester :)

Prof.

 :whoohoo:
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on May 01, 2018, 11:55:00 PM
Hmmmm, must be going into “consulting” :Jester:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on May 01, 2018, 11:56:57 PM
Hmmmm, must be going into “consulting” :Jester:

I'm depending on it.  ;D

Sad though to think that area is going to lose a great teacher.
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on May 02, 2018, 12:01:43 AM
Zee, living legends are a dying breed and there ain’t too many of us left. Quote: Waylon Jennings  8)

Cletus

Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 02, 2018, 12:09:24 AM
Thanks guys, but if it makes you feel any better, my replacement has been named and will do an outstanding job.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on May 02, 2018, 12:10:20 AM
What’s her name  :lolb: :lolb: :lolb:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 02, 2018, 12:12:43 AM
Well she is a she in fact, hired away from the Engineering Technology department. Much younger and more energetic than me too!!

B
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on May 02, 2018, 12:14:19 AM
Dang, I must have ESPN2 :lolb:. I was just joking  :thinking: 8) :lolb:  Ain’t got no problem with it  8)

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 02, 2018, 12:18:31 AM
Nope me either, I have been reporting to a female as long as I have been in this current job. She is one of the best bosses I ever had !!

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on May 02, 2018, 12:20:05 AM
Southern boys: we know when not to argue with a lady  8)

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: bent on May 02, 2018, 06:08:50 PM
"My teaching days are done as of today"

Nope, you still have to finish the PMR #5, and in the process teach (at least me and Cletus) how it's done.  :Jester: :stickpoke:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 03, 2018, 12:24:19 AM
I think Cletus already made this one Bent. But yes I will press on with some interruptions as I finish the Pearl. I always liked this little engine though so it will be finished.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Craig DeShong on May 06, 2018, 03:15:00 AM
Woo-hoo  :pinkelephant: :pinkelephant: :pinkelephant:  Bill has retired.  You're gonna  :Love: it
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on May 06, 2018, 01:05:17 PM
Not so fast Craig...its getting closer but not till the end of the month. The  :Love: will have to wait a few more weeks  ;). I have managed to collect a few more things (tools) though for the revitalization of the old shop.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 04, 2018, 02:05:48 AM
Still doing this between other things, but managed to finish up the pulley and flywheel except for the grubscrew holes. Not a lot to show from a machining standpoint but a few interim and finished pictures of both are attached below.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 04, 2018, 02:08:37 AM
Nice work. I’m sensing the beginnings of “settling in” .  :popcorn:&  :DrinkPint:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 04, 2018, 04:51:44 AM
Still doing this between other things,

As in getting your new shop together?  ;D  :stickpoke:

Hey. You've poked me enough times. It's all about what goes around comes around.  ;D
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 04, 2018, 12:00:41 PM
Zee, first few days are more like getting dogs to the vet, finding a place to put all the crap I brought home from my office, and other non-shop renovation things. The renovation is going to take a while, new roof, heat pump, and a lot of junk to get rid of there too. I will start a new thread on that shortly including pics of the good, the bad, and the ugly  :lolb:

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Gas_mantle on June 04, 2018, 04:15:28 PM
I'm still following along Bill, it's nice to see you making progress. I've always rather liked these engines so I'll be interested to see it running  :)
Title: Re: PMR #5 - as a fill in project
Post by: bent on June 04, 2018, 06:29:25 PM
Looking good.
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 09, 2018, 05:02:19 PM
A couple more things done on this one yesterday and this morning. The frame casting needed some clean up for parting lines and flash around the cut out areas which was done using a small sanding drum in the Foredom and a small burr for the smaller areas. The results are shown in photos 1 and 2. 

Next was the lower head casting which is straightforward lathe work as shown in the next three pictures. The final picture shows the lower head in place on the too of the main frame. The mounting holes will still need to be drilled as well as the two tapped holes for attaching the packing gland.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 09, 2018, 07:42:15 PM
Man I thought you were defoliating and you’re making parts  :ThumbsUp:. and looking great I may add. Summer break, ur, I mean, retirement, seems to be suiting you  :pinkelephant:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 09, 2018, 08:07:56 PM
Yeah, took a break from defoliating today Cletus. More of that in the morning perhaps....whatever day tomorrow is  :lolb:

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 09, 2018, 08:12:03 PM
I’m beginning to think everyday should be “Friderday”  :lolb:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 09, 2018, 08:24:04 PM
Yeah, took a break from defoliating today Cletus. More of that in the morning perhaps....whatever day tomorrow is  :lolb:

 :ThumbsUp:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 09, 2018, 11:25:20 PM
I’m beginning to think everyday should be “Friderday”  :lolb:

Cletus

It sure seems like that is the case Cletus. Though we need tomorrow to be Sunday, since you have promised swarf  ;D

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 10, 2018, 12:18:07 AM
I’m cocked, locked, and ready to rock  :naughty:  Film at eleven  8)

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 10, 2018, 01:01:07 AM
Is that AM or PM. PM is past my bedtime, and yours too if Monday is a workday....lol.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 10, 2018, 01:50:02 AM
That was a quote. I should have something posted by beer thirty tomorrow

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: crueby on June 10, 2018, 02:09:01 AM
Swarf!

Swarf!

Swarf!
Title: Re: PMR #5 - as a fill in project
Post by: Jo on June 10, 2018, 07:48:46 AM
Quote
Swarf

We were beginning to worry Bill, either you had got lost in the underbrush or were planning to head back to work for a rest :Lol:

Which reminds me: a little more weeding and I should be allowed back into the workshop  :cartwheel:

Jo
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 10, 2018, 03:03:35 PM
More likely lost in the underbrush Jo. But will post more on that in the shop thread.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 12, 2018, 07:21:22 PM
One more part finished up today, the cylinder head. After facing off the back side to get a flat surface I went to the mill and drilled the four mounting holes (photo 1) The 1" bolt circle lined up well with the center of each boss so that was encouraging. In order to turn the OD however I needed to make a simple jig out of some scrap aluminum, drilling and tapping it on the same bolt circle for 2-56 hardware (photos 2 & 3). Then with the head screwed onto the jig, it was easy enough to turn the OD to the proper diameter (photo 4). Then turning the part around in the 4 jaw and centering it the underside recess was machined with a combination of a grooving tool, and left and right hand tools as shown in photo 5. The center boss was then reduced to a height of 1/32" (half the depth of the total recess. The final piece is shown in the last two photos...top side then the underside.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 12, 2018, 07:34:14 PM
Nice trepanning there Bill. I like the look of the cast bosses on it also.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 12, 2018, 08:22:45 PM
The bosses were cast in as you say. Not sure if they retained that feature in the later casting kits. This set came from the all bronze days, before they changed over to cast iron for many parts.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Gas_mantle on June 12, 2018, 08:33:42 PM
Looking good Bill  :)

Will you be able to run the completed engine on the hot stuff ?
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 12, 2018, 09:57:31 PM
It should be capable of it, but will need to build the PMR vertical boiler for it before that happens but it is on the list.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on June 13, 2018, 12:23:18 AM
Nice Progress Bill.

Dave
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 13, 2018, 12:38:23 AM
but will need to build the PMR vertical for it before that happens but it is on the list.

hee hee hee. That's three so far.

Not counting the one made not so long ago. (I can't find it and don't remember who did it but was hoping to use it as a reference aid.)
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 13, 2018, 04:55:59 PM
Zee, it was Stan “A riveting build log”. Couldn’t get it to link  :shrug:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 13, 2018, 05:17:08 PM
Here you go, but Stan built the horizontal boiler.
http://www.modelenginemaker.com/index.php/topic,2360.0.html


Bill

Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 13, 2018, 06:13:14 PM
Thanks. I found the vertical I was thinking of. It was Tony's (AOG).

Apologies for the digression on your thread Bill.
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 13, 2018, 06:22:48 PM
No problem Zee. Glad you found the thread you were looking for. What sub-forum was it in btw?

Bill
Title: Re: PMR #5 - as a fill in project
Post by: J.L. on June 13, 2018, 10:06:27 PM
Hi Bill,
A great project.
The end of the month is coming!
John
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 13, 2018, 11:22:11 PM
What sub-forum was it in btw?

I can't figure out how to link...here's what I got...

Model Engine Maker » Supporting » Vehicles & Models » AOG's Steam Powered iPhone Charger

The thread includes a dynamo and other stuff so you may need to go through it a bit.
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 14, 2018, 12:36:27 AM
Ah no wonder I couldn't find it. Thanks!!

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 19, 2018, 12:42:52 AM
More progress on the cylinder casting today between other necessary things and the stiffling heat.  I faced off one end and turned the diameter for the head to fit. Then boring to the needed .625" for the piston. Finally facing the opposite end to reach the required overall length. Still need to do the Steam chest, ports and intersecting holes, but gaining on it at least. The last picture shows the cylinder in it's current state sitting atop the frame.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 19, 2018, 12:56:17 AM
Looking good Bill. Did you use the boiring bar to face off the cylinder after boring?

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 19, 2018, 01:00:41 AM
Cletun, no I used the Warner left hand insert tool to do the facing off. See photo 1 above.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 19, 2018, 01:02:14 AM
Can’t beat them. Used them on my build

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 19, 2018, 01:13:08 AM
It's pretty much all I use these days Eric. I love them. I needed something thin to turn the OD of each end of the cylinders and used the grooving tool set at a slight angle to do that as well.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 19, 2018, 10:49:58 PM
A little more progress on the cylinder casting today. Flycut the face of the steam chest (photo 1), then milled out the valve chamber to the required width, height and depth ( photo 2), and finally drilled the exhaust port (photo 3) which will be tapped 3/16"-40.

Lastly for today I sanded the underside of the steam chest cover smooth and drill the 8 clearance holes for attaching it to the steam chest face (photo 4).

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 20, 2018, 12:31:23 AM
Kinda hot down there, isn't it? I can see why the renovation will be a little later in the year.
In the meantime...it's a good time to be in the shop.

Looking good Bill.  :ThumbsUp:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 20, 2018, 12:56:03 AM
Hopefully not too much later zee. If I can get the HVAC system then I can work inside. But several thing before that happens and item one is all outside. My little shop space in the garage isn't cooled either, but if I don't get too energetic, I can tolerate it for a couple of hours then come it to cool off. For now, just trying to get a little bit done each day. Today was the hottest day in two years they said and it's not even summer yet  :Mad:

Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on June 20, 2018, 01:08:17 AM
Just have to switch your hours and work outside from midnight till dawn!  Retired guys can do that, you know!
 :cheers:
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 20, 2018, 01:16:51 AM
Just have to switch your hours and work outside from midnight till dawn!  Retired guys can do that, you know!
 :cheers:

This, from a guy who has elves doing all his work.  :lolb:

I almost feel like saying..."pay no attention to the man behind the...the...elves."
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 20, 2018, 01:19:53 AM
Too bad I am a morning person. My last all nighter was in grad school  ;)

Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on June 20, 2018, 01:20:54 AM
Just have to switch your hours and work outside from midnight till dawn!  Retired guys can do that, you know!
 :cheers:

This, from a guy who has elves doing all his work.  :lolb:

I almost feel like saying..."pay no attention to the man behind the...the...elves."
I still have to bake all those cookies to keep them paid, fix all those @#$@~!ing pointy hats after the fights....
 :ROFL:
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 20, 2018, 01:47:57 AM
Too bad I am a morning person. My last all nighter was in grad school  ;)

'-' on the morning person. '+' on the last all nighter.

I used to be a night owl. And I've never been a morning person. What's the term for someone who is at their peak between 10:00 am and 10:00 pm?
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 20, 2018, 02:04:29 AM
How about " Normal" ??

Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on June 20, 2018, 02:10:06 AM
10 am to 10 pm on the same day? Too much sleeping!
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 21, 2018, 06:03:21 PM
A little more progress on the cylinder. Got the three port holes milled in the steam chest (photo1), then the holes from each end of the cylinder to intersect the ports (photo 2), and photo 3 shows that they do in fact intersect. More later today.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Craig DeShong on June 21, 2018, 11:52:39 PM
Haven't visited this thread for a while and you're making excellent progress. :cartwheel:

Nice to have all that shop time now that you're days are endless Saturdays, punctuated by the occasional Sunday.

You're better to just use lots of shop time, today I practally wilted walking from the house to the shop. :facepalm:

Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 22, 2018, 12:32:06 AM
Thanks Craig, and today was a bit cooler even. I had to come in after a while even so. The humidity is terrible.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Kim on June 22, 2018, 05:59:52 PM
Nice to see you getting some time to work on your engines here, Bill! Looking good! :popcorn:
Can't wait to see you all moved into your new place too :)
Kim
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 23, 2018, 04:09:32 PM
The cylinder is done now except for the holes for the upper and lower heads. After centering the bore, I stepped off to drill the inlet port on the top side and the coubterbored hole for the gland on the bottom (photos 1-3). The tapped holes for the steam chest had been done previously (photo 4). Finally the latest family shot. Now have to finish up several things on the frame before I can go much further.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 23, 2018, 08:01:30 PM
Looking great Bill. Are you going to paint or polish the frame since yours is a bronze or gunmetal casting? And, before Jo asks: are you gonna replace the socket head cap screws on the valve chest for some proper studs and nuts  :stickpoke: :stir:? Keep it coming; seems like you are getting into a rhythm  :cheers: :ThumbsUp:.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 23, 2018, 08:36:24 PM
seems like you are getting into a rhythm  :cheers: :ThumbsUp:.

He's in a rhythm alright. Just look at his "found a peanut' thread.  :lolb:

Looking good Bill.  :ThumbsUp:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 23, 2018, 11:31:50 PM
We will see once it's done Cletus. Leaning towards paint or powder coating. Been wanting to try that. Another area I need to plan for in the shop renovation. Crap, I may have to expand...lol.

Oh , and will likely do studa and nuts, but I am not as obsessed as Jo!!

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Jo on June 24, 2018, 09:25:19 AM
will likely do studs and nuts,  but I am not as obsessed as Jo!!

One has to have little pleasures in life... I know sometimes it seems they have become a big obsessions you just have to work at it  ::)

Jo
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 25, 2018, 09:31:45 PM
Here are some pics comparing studs and nuts with SHCSs.  The nuts are 3/16" across flats. I think 5/32" would be better but don't have any on hand. What say you?

Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on June 25, 2018, 09:37:42 PM
I would vote for the smaller of the two. Though either is better than the SHCSs. Make one up as a test? Could quickly file or mill down one of the ones you have.
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 25, 2018, 10:02:39 PM
Nuts are a wee bit large in my opinion. I’ll look at mine,but, I want to say they were 3-48. Really if you have a hex collet block, you can shape the nut to fit the stud

Cletus

Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 25, 2018, 10:18:22 PM
Well niether McMaster nor PMR has 5/32" brass, so looks like I will need to make some from round stock. Cletus, mine calls for 2-56 threads on the steam chest cover and the upper head.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 25, 2018, 10:25:36 PM
Guess that’s why I have a set of taps and die in that size. That’s one of my first builds and had to buy everything.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: Craig DeShong on June 26, 2018, 12:47:25 AM
I was going to suggest (since you're retired now and need things to fill your days  :lolb:) that you could make your own nuts; but now i see you plan on doing so.  I've been there, but it does get old, even when you're retired !

You're making great progress Bill,  You must agree it's a lot more fun that working outside with the current temperature and humidity.
 
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on June 26, 2018, 12:58:05 AM
Hey Bill

My vote would also be for the smaller nuts.

A couple pieces of tooling that I want to make for my Sherline lathe is a simple indexing attachment and a good filing rest. Then I can make nuts the old school way, by filing the hex on them. This seems much more efficient than milling the flats. I do have to admit doing them in the CNC, standing vertical in a collet fixture and driving around them is pretty easy too. With the filing rest you don't have to worry about removing the cutter marks for each flat. :Lol:

Your PMR #5 is coming along very nice!
Dave

Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 26, 2018, 01:33:47 AM
Fortunately I should only need about 12 of them. At something like .100" height each, it's only 2-3 inches of hex I will have to mill. But yes there is time for that now.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 26, 2018, 01:40:13 AM
I now question the title of this thread...'a fill in project?'.  :lolb:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 26, 2018, 02:17:51 AM
It still is zee. Will be getting back to the little pearl some tomorrow.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: bent on June 26, 2018, 06:44:01 PM
Would 1/4" hex work, you can get that from McM.  They also have 4mm, which at about .157 is only a thou or so more than the 5/32 you wanted, and would probably still fit a 5/32 wrench or socket.
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 26, 2018, 06:53:26 PM
I found some 5/32" hex at online metals. About $4.00 for 2 feet, but $13.00 shipping. I will just mill some down from round stock but thanks for the ideas bent.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: J.L. on June 26, 2018, 09:20:03 PM
Hi Bill,

Excellent work.

If I've got things correct, you are out of the classroom now - right?

Join the club. It's a different world - and a busier one!

John
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 26, 2018, 09:46:20 PM
Yes John, going on a month now and settling into it quite well but like you say staying as busy as ever. It has allowed a bit more shop time though except for the very warm weather we have had so far this summer. Thanks for looking in.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 26, 2018, 10:00:07 PM
Before changing the mill back to the larger vise for some tapping on the Pearl cylinder, I did a few more small bits on the #5. This morning I made the air in and exhaust out fittings though that was lathe work (photo 1). Then the piston rod gland and the valve stem glands, which were both lathe work and some mill work with the rotary table. This was especially true for the valve gland which is more diamond shaped, but this was easy enough with the RT and mill (photos 2 & 3). These are also shown where they will go in the last photo. Now I just have to match drill and tap the 1-72 holes in the cylinder and bottom head to secure them.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 27, 2018, 10:04:11 PM
Just a quick update for today. Got the holes drilled and tapped for both the piston rod gland and the valve stem gland. Picture attached.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 27, 2018, 10:22:40 PM
Coming right along and looking great. You do remember that story of the fuzzy tail and the hard shell don’t you  :lolb:  Just saying  :ThumbsUp:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 27, 2018, 10:38:29 PM
Plenty more to do Cletus, but it's still progress. How's the lil popcorn coming along. Oh yeah, you still have to work too  :lolb:

Prof. (Retired)
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on June 28, 2018, 12:46:22 AM
Plenty more to do Cletus, but it's still progress. How's the lil popcorn coming along. Oh yeah, you still have to work too  :lolb:

Prof. (Retired)

Ok rub it in!  :lolb:
I'm happy for Bill, and it's good to see you out in the shop making some nice progress on your projects.

Dave
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 28, 2018, 12:50:02 AM
Hi Dave, well I'm trying to get the boy to retire so we can think about starting up a model engine show with a southern ambiance ...lol.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on June 28, 2018, 01:12:37 AM
Sounds great, I would love to come and hang out with you guys.

Dave
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 28, 2018, 01:48:50 PM
Y’all just keep rubbing it in  :lolb:  Maybe someday: heck, even DOG retired. Dave we would love to have you. Uh, on the l’tl popper Bill; let’s just say Bozo showed up and I’ll get to that this weekend. 

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 28, 2018, 05:34:49 PM
Well darn Cletus! Maybe if you offer Bozo free meals at the diner, he will stay away.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 28, 2018, 05:40:59 PM
A few little bits this morning. The piston is made from a piece of brass. Fortunately, I had made a .050" grooving bit for previous PMR engines no doubt so that helped (photo1). Then threaded the two eccentric rods and the piston rod as well as you can see in photo 2. Will see what this afternoon has to offer.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 28, 2018, 07:08:08 PM
One more quick picture. I made four 3-48 hex nuts and  one 5-40 hex nut, all from 3/16" hex stock. The 5-40 one locks the bottom of the piston rod to the crosshead. One of the 3-48 ones secured the piston to the piston rod and the other three fit on the valve and eccentric rods as shown.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on June 28, 2018, 08:30:06 PM
 :popcorn: :popcorn: :popcorn:
Title: Re: PMR #5 - as a fill in project
Post by: J.L. on June 28, 2018, 10:14:27 PM
Hi Bill,

 :popcorn: as well...

Watching with interest as my crosshead is mounted to the piston rod in exactly the same way.

Great work.

John


Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on June 28, 2018, 11:38:45 PM
Y’all just keep rubbing it in  :lolb:

Thanks!  :ThumbsUp:
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 29, 2018, 12:02:32 AM
All is looking great Bill. Those are right up there with Otto’s nuts. Will you be polishing your nuts  :Jester: :lolb:  Zee; naw I ain’t gonna do that on Bill’s thread  :Argue:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on June 29, 2018, 12:36:23 AM
Nice nuts are very important.  :lolb: Most folks put too steep of a chamfer on them, for models I like 20 degrees cut until it just goes full circle.

Looking good Bill!



Dave
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 29, 2018, 12:44:29 AM
Thanks guys, sorry there isn't more to show yet but I'll get there. Cletus, how did you go about cutting that square for the valve mechanism? Two "v" grooves on the mating parts or other? Still head scratching on that one.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 29, 2018, 12:44:25 PM
Bill, I had a look back at my build ( Lord that was five years ago). I didn’t show that part, but, if my memory serves me well, I did do it with two V cuts. I think I might even have bought a small 45 degree cutter for it.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: Jasonb on June 29, 2018, 01:16:00 PM
You could just mount them at 45degrees and then use the corner of a regular milling cutter.
Title: Re: PMR #5 - as a fill in project
Post by: bent on June 29, 2018, 04:24:45 PM
Been scratching my head on that one too, Bill.  Have not yet cut chips on the #5, but have been fettling and painting castings, and slowly accumulating tools (like a long boring bar for the support frame) and thinking it through...

Debated buying/making a square broach for the holes, but that seems overkill.  The v-cutter will likely work simplest.
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on June 29, 2018, 05:15:57 PM
Now that I have been thinking about it, I think I used one of those 45 degree spotting, chamfering, milling cutters.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 29, 2018, 09:22:33 PM
Thanks guys, I think I will go the route of the chamfer/milling cutter.

Bent, when I did that through bore on the frame, I got close with a boring bar and finished it with a reamer which worked well for me, though not a sherline job at all. The fit with the crosshead is just what I was looking for, a nice slip ( though not sloppy at all) fit. I thought about broaching too but not sure the casting can take that much pressure and the broaches are pricey to say the least unless you make one.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Craig DeShong on June 30, 2018, 02:03:19 PM
Good progress on both fronts Bill.  Glad to see retirement is affording you a little more shop time.
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on June 30, 2018, 05:23:39 PM
Thanks Craig. Retirement is agreeing with me well I must say ;D

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 04, 2018, 03:01:34 PM
A bit more done on the cylinder and valve in particular. After killing off the valve casting while milling the underside "D" pocket, I just remade it from bar stock. Apparently Cletus sent Bozo over my way  :lolb:

Anyway with the new valve made and the valve nut, things seem to fit well and slide nicely.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Kim on July 04, 2018, 03:46:01 PM
Sorry to hear about the untimely demise of the valve casting, Bill.  But it looks like you've got it sorted here and have a nice looking D-valve! 
Kim
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 09, 2018, 01:06:27 AM
Thanks Kim. Today's progress was the three pieces that make up the middle of the valve train. The first photo in the 3/16" square rod that rides in the frame. This was attempt two, as I had previously made a perfect one out of 1/4" stock rather than 3/16"....duh!!...read the print before machining. The second photo is the beginnings of the swivel part that will connect to the eccentric eventually ( as well as a shamelessly photo of mini mic who has been feeling outcast lately). The third picture shows all three parts and the last photo how they fit together and are positioned on the frame one the v grooves are cut.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 10, 2018, 01:07:47 PM
Not much shop time yesterday but did manage to get the bearing caps and valve guide caps all separated from a single casting tree. Now to get them all cleaned up and machined down to size and mounting holes drilled, etc.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: J.L. on July 10, 2018, 02:10:39 PM
Hi Bill,
Following along closely. We are almost at the same spot in our builds.
You are making good progress.
John
Title: Re: PMR #5 - as a fill in project
Post by: propforward on July 10, 2018, 02:38:34 PM
Hi Bill,

Looking great. I love your build logs - very informative and detailed - lots of good advice on technique to be gleaned here, much appreciated.

Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 10, 2018, 04:01:58 PM
Thanks guys, hope to have more to show later today.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on July 10, 2018, 05:37:26 PM
Regarding that square part...is there a reason why it's square rather than round?
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on July 10, 2018, 06:30:54 PM
Looking great Bill. I was looking at my #5 yesterday and remembered those fiddly bits. You seem to be handling them with ease  :ThumbsUp:

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: crueby on July 10, 2018, 07:16:38 PM
Regarding that square part...is there a reason why it's square rather than round?
The square rod keeps the pivots at the top and bottom lined up, since it goes through a square bushing. If it rotated, it would bind up the pivots. That lets them offset the eccentric from the valve. On other designs, the connection is via a bent rod rather than this way.
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 14, 2018, 07:09:26 PM
After a brief pause to head down to the beach for a few days to be with family, I got back and have finished up these four little bits. First was the bearing caps. After getting both milled to the proper width, I put then in the mill vise to drill for the oil hole (photo 1), and then the two mounting holes (photo 2). With these done it was on to the smaller caps for the valve rod. After milling one side of each casting flat, I was able to use that as a reference surface against the fixed vise jaw to locate and drill the clearance holes for eventual mounting to the base frame ( photos 3&4). This left very little to hold the part in the vise with for me lling down the other side so I took a scrap piece of aluminum and drilled/tapped two holes with the same center distance and then attached these with screws to hold then for miling to the final width (photos 5&6). The last photo shows all four parts completed.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: J.L. on July 14, 2018, 07:15:26 PM
Hi Bill,
Nice seqquence of operations and photos here.
John
Title: Re: PMR #5 - as a fill in project
Post by: bent on July 16, 2018, 07:10:40 PM
Looking good, Bill!
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 16, 2018, 10:13:15 PM
Thanks John and Bent. I have odeed a 90 degree cutter to cut the "v" grooves n the underside of he valve guide straps, and later in the frame itself. Should have that tomorrow and he same fixture will be used to center the grooves. More on that tomorrow.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on July 16, 2018, 10:16:22 PM
Aren't you able to tilt your mill headstock 45 degrees? That would let you use a normal end mill.


 :popcorn:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 16, 2018, 10:22:55 PM
Yes Chris I could, but am trying to get perfect matching of the v grooves between the straps and frame and I think this way will be easier for that. Good excuse to get a chamfer mill too.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on July 16, 2018, 11:14:11 PM
Good excuse to get a chamfer mill too.

There ya go.  ;D
Title: Re: PMR #5 - as a fill in project
Post by: crueby on July 17, 2018, 12:09:46 AM
Good excuse to get a chamfer mill too.

There ya go.  ;D
More tools?   :thinking:


Heck yeah!   :D
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 17, 2018, 12:14:26 AM
My thinking exactly  :lolb:

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 18, 2018, 09:35:08 PM
Today the crankshaft got finished. I had turned the two shaft ends previously between centers ( photo 1). In order to turn the crank I had to make a little jig with the proper offset (photo 2) and with that done turning the crank pin wasn't too bad (photo 3). The final part is shown in photo 4.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on July 18, 2018, 09:43:02 PM
That's pretty cool. I don't think I've ever seen a jig like that.  :ThumbsUp:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 18, 2018, 10:24:31 PM
Zee, unlike Chuck's procedure using hot rolled steel, this was a CI casting with no "ears" protruding from the crank pin section. My 4jaw chuck is too small to offset the .437" required so this was the only option I could come up with. I'm sure I seen others do something similar. The slot in the jig allows for positive drive and you can see I used a short piece of rod with the center to keep it pressed into that slot. May not be the best way but it worked.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on July 18, 2018, 10:31:56 PM
One of the kits I did many years ago (either a Stuart or a PMR) had this method in the instructions, I still have the big bar I used, makes a good weight. It was just able to fit in the chuck on the Sherline, was a scary operation as I recall, with that heavy a bar out in midair.
 :popcorn: :popcorn: :popcorn:
Title: Re: PMR #5 - as a fill in project
Post by: Dave Otto on July 19, 2018, 01:24:03 AM
Hey Bill
The crank looks great!


Dave
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on July 19, 2018, 11:21:20 AM
Nice job Bill. I used a jig like that for the Red Wing. They do add an extra bit of rigidity. I just watched a David Richards video and he was working on a full size square valve rod setup like this engine uses. I really like his videos

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: steamer on July 19, 2018, 11:59:39 AM
I like it Bill!    Storing that one away in the file!..

Dave
Title: Re: PMR #5 - as a fill in project
Post by: Craig DeShong on July 21, 2018, 02:31:06 AM
Nice job Bill, and I like the way you did the one piece crank.  I'm going to file this away for future reference  :ThumbsUp:
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 21, 2018, 12:17:29 PM
Thanks guys. AS Chris said, it isn't an original idea and now that he mentions it I think something similar was included in the plans for the PMR #1, though that was a somewhat bigger crankshaft than on this one. Up till this one I have always used a built up crankshaft but decided to try to use the casting this time.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Ye-Ole Steam Dude on July 21, 2018, 01:46:17 PM
Great job Bill and thanks for sharing the helpful process.

Have a great day,
Thomas
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 27, 2018, 08:32:35 PM
Finished up the valve stem caps this morning using the same fixture I used to face the edges, only this time I recessed the part between the screw holes to allow the triangular part of the casting somewhere to fit ( photo1). With this done the caps were screwed to it upside down, centered, and the 90 degree chamfering bit used to cut the "V" ( photo2). The finished parts are shown in the third photo.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Tennessee Whiskey on July 29, 2018, 11:51:58 PM
They are a tad fiddly aren’t they Bill? I like the jig idea. I can’t for the life of me remember how I did mine  :facepalm:  Really looking good though.

Cletus
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 30, 2018, 12:39:17 AM
Thanks Cletus, it held them well and the cutter worked a treat too.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: steamer on July 30, 2018, 01:27:26 AM
Good thinking there Bill!   

Dave
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 30, 2018, 01:34:00 AM
Thanks Dave. Holding the main frame to do the mating "v"s will be the next challenge.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: steamer on July 30, 2018, 01:54:55 AM
Work Cube!.... and a jack under the cylinder end  hanging out the side of the vise

Dave
Title: Re: PMR #5 - as a fill in project
Post by: crueby on July 30, 2018, 01:56:54 AM
Huh.


The cube I worked in didn't have all the air holes...


 :Lol:

Title: Re: PMR #5 - as a fill in project
Post by: steamer on July 30, 2018, 02:04:05 AM
Actually, I'd use the 3 sided one in the front

Dave
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 30, 2018, 02:10:53 AM
Yeah, something along those lines is the plan, just scaled to fit the sherline.


Bill
Title: Re: PMR #5 - as a fill in project
Post by: crueby on July 30, 2018, 02:29:03 AM
Dave, is that cube a homemade item? Never seen one before.
Title: Re: PMR #5 - as a fill in project
Post by: steamer on July 30, 2018, 03:08:16 AM
Possibly...but not by me.   These were once pretty common....but you see less of them now   It's a 4 sided box with tapped holes, but flat square and parallel.

Dave
Title: Re: PMR #5 - as a fill in project
Post by: steamer on July 30, 2018, 03:31:33 AM
Yeah, something along those lines is the plan, just scaled to fit the sherline.


Bill


How big is your vise Bill?

Dave
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on July 30, 2018, 01:37:25 PM
3" wide Dave, will open up to about 5" I think.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on August 02, 2018, 11:08:19 PM
Got the con rod done today. Didn't take a lot of pics but the standard process...yada yada.  I used a sacrificial plate to drill the two holes once everything else was done ( photo 1). Photo two shows the linkage from the crankshaft to the crosshead and connecting to the piston. Photo 3 shows a family shot including the cylinder and valve train. Getting down to the final few parts and finishing the main frame.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: Ye-Ole Steam Dude on August 02, 2018, 11:16:49 PM
Hello Bill,

All those castings sure look clean and lack of any porosity. Project is looking good.

Have a great day,
Thomas
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on August 03, 2018, 12:10:30 AM
Thanks Thomas. These are a nice set of bronze castings. I have had this set for a long time and just getting around to it.  As I have said before I wish PMR still offered all bronze casting sets but perhaps the cost is prohibitive these days. I much prefer them to some of the more recent sets with cast iron castings.

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on August 03, 2018, 01:35:01 AM
Nice family shot.  :ThumbsUp:

Looks like some parts got cropped out.  ;D
Title: Re: PMR #5 - as a fill in project
Post by: b.lindsey on August 03, 2018, 01:45:05 AM
Nothing pertinent to those subassemblies Zee. Just some misc. other parts waiting for a home ;)

Bill
Title: Re: PMR #5 - as a fill in project
Post by: zeeprogrammer on August 03, 2018, 04:25:16 AM
Nothing pertinent to those subassemblies Zee. Just some misc. other parts waiting for a home ;)

 :thinking: