Model Engine Maker

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

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

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

Engine Block:

The block is 6061 Aluminum and was first squared.

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

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

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

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

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

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

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

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

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

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

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

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

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

CS




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

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

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


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

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

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

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

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

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

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

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

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

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

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

yYKUlcy-g1w
-Bob
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: zeeprogrammer on September 04, 2018, 12:56:54 AM
Fantastic!
And thanks. That's going to be a fun engine!  :ThumbsUp:
Title: Re: GDB Inline 4 Cylinder OHV I.C.
Post by: 90LX_Notch on September 04, 2018, 08:50:33 PM
Block continued-

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

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

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

Bill



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

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

Eric

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

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

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

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

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

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

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

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

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

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

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

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

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

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



Crankcase breather-

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

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








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

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

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

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

Block continued-

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

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

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

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

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

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

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

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

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

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

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

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

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

Thanks for looking in Dave.


Block continued-

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

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

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

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

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

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

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

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

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

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

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


Block continued-

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

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

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

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

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


Block continued-

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

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

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

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


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

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

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


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

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

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

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

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

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

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

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

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

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

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

-Bob


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

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

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

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

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

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

Some really nice work and the build is looking good.

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

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

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


 Thanks Bob.

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

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

I'll post pictures once I calm down.

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

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

Best wishes for the repair

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

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


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

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

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

-Bob

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Bill