Model Engine Maker

Engines => From Plans => Topic started by: toolznthings on March 01, 2019, 06:47:38 PM

Title: Travis Steam Engine 2 X Size
Post by: toolznthings on March 01, 2019, 06:47:38 PM
Starting a new build thanks to Thomas ( Ye-Ole Steam Dude ) for sharing his nice set of plans for the engine he designed. A couple of private messages back and forth with Thomas and he agreed a double size build
would work out. This will be posted as I progress through the build.

Going to start with the crankshaft which will be probably the most difficult part to make. Leaving the output ends long, the crank will be 16.5 inches long. In keeping with the style of the engine I decided on a metric
size ball bearing for the crank to run on. It's overall size is compact compared to a inch size bearing. I'm using a 6003-2Z bearing. McMaster Carr # 6661K16.

Fastener sizes will be chosen as I go forward.

The for throws for the crank are 1.000" thick x 1.500" wide and 2.000" in diameter on the rounded end. The main shafts are .750 diameter at the throws and .625 diameter at the output ends. The connecting rod journals are .500" diameter. A diameter is turned for a slip fit for 17 mm bearing I.D.


Extra attention to sizing the throws was done by surfacing grinding the thickness and width after rough milling from a finish turned 2.000 diameter making four blanks. The extra effort will be apparent as I begin addition machining.

The blanks with the CAD layout of the crankshaft.
Setup in the mill for drilling, spot drill first opp.

 
Title: Re: Travis Steam Engine 2 X Size
Post by: Johnmcc69 on March 01, 2019, 07:33:24 PM
Wow! That's going to be a big model! Great work so far!

 Sign me up for the ride....
 :popcorn:

 John
Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on March 01, 2019, 10:53:53 PM
Hello Brian,

I am so pleased to see the first parts being machined, it goes without saying that I will be following this build all the way. Sure hope that you document each step along the way and share plenty of photos with all of us. Let me know if I can help in any way, either PM or direct email.

I am excited to see this project underway :cartwheel:

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on March 01, 2019, 11:15:04 PM
Very cool Brian!
Iím looking forward to see the progress.  :popcorn: :popcorn: :popcorn:
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 02, 2019, 02:43:44 AM
Hello Brian,

I am so pleased to see the first parts being machined, it goes without saying that I will be following this build all the way. Sure hope that you document each step along the way and share plenty of photos with all of us. Let me know if I can help in any way, either PM or direct email.

I am excited to see this project underway :cartwheel:

Have a great day,
Thomas

Thanks Thomas !  And others !  :)
Title: Re: Travis Steam Engine 2 X Size
Post by: crueby on March 02, 2019, 02:57:46 AM
Those are impressive specs!  Do you have a pic or drawing of what it will look like?


 :popcorn: :popcorn: :popcorn:
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 02, 2019, 05:03:45 AM
Search for " Travis Steam Engine " Thomas has a build on his YouTube channel. Just think twice the size.  :)
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on March 02, 2019, 02:21:56 PM
This one will be quite a beast at 2x scale. Should be a great project though.

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 04, 2019, 05:48:41 PM
More work on the crankshaft ...........

A note on the initial setup for the crank throws. I used a dial indicator in the mill spindle and swept the width of the blanks to find dead center. All the blocks are exactly the same width, 1.500 "

After spot drilling all the blanks I rough drilled for the crank pin bores and the output ends. I like to chamfer the the bores after drilling to plus size of the finished bore before the boring operation. This prevents a burr from being rolled into the finished hole if chamfered last.

Setup the boring head and bored the .750" and .500" bores to close slip fit for the shafts. The rod journals will be ground 12L14 rod .500 in diameter and one piece .750" in diameter for the center link.

The crank ends will be turned from 7/8" diameter 12L14 stock. Three diameters in one setup, .750", 17mm for the bearing and .625" at the ends.

First attempt at the lathe starting with .750" ground stock in the collet did not produce a shaft true enough and I went with the 7/8" stock to turn all the diameters.

Last picture showing a dry fit assembly of the parts.
 
Title: Re: Travis Steam Engine 2 X Size
Post by: bent on March 04, 2019, 06:45:49 PM
Cool!  Will be following with interest  :popcorn:
Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on March 04, 2019, 08:03:19 PM
Hello Brian,

Beautiful work on the crank, are you going to make it 180 degree or a 90 degree?

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on March 04, 2019, 10:03:10 PM
Nice progress already Brian.  :ThumbsUp:

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 05, 2019, 02:22:19 AM
Hello Brian,

Beautiful work on the crank, are you going to make it 180 degree or a 90 degree?

Have a great day,
Thomas

Hi Thomas,
Keeping the crank like the drawing, 180 degrees. Trying to stay true to the design as possible.
Title: Re: Travis Steam Engine 2 X Size
Post by: Jim Abood on March 07, 2019, 12:19:55 AM
Hi Brian
You always do incredible work.   I am looking forward to seeing more  pics of the build.
Jim
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 07, 2019, 01:06:41 AM
Thanks Jim ! Welcome to the forum  :hi:
Title: Re: Travis Steam Engine 2 X Size
Post by: gbritnell on March 07, 2019, 01:10:33 PM
Hi Brian,
With the flat crank the engine won't be self starting? I went to Youtube to look up the engine but there's so many on the channel with the same name I didn't know which one to look at.
gbritnell
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 07, 2019, 03:26:26 PM
H i George !

Try this link to his YouTube channel :      https://www.youtube.com/channel/UCNWSrK1_cKLTO3gGfzbGvZw

I realize it won't self start, but the crank is a project in its self as designed.
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 07, 2019, 03:52:25 PM
More crankshaft build ..........

Assembling the crank parts using 609 Loctite with 427 primer. Output shafts assembled first with the center throws and .750 shaft as a separate assembly. ( no picture )

Set up each output assembly in Starrett V-blocks and established gauge block stack that supports the throws parallel to the surface plate. Two additional gauge block stacks will be used in the next
setup to support the remaining parts.

Aligning the V-blocks with a Starrett straight edge on a mill fixture plate. The rest of the parts are assembled and very lightly clamped. I will be using #2 and #3 taper pins to pin all parts after giving
a day or so for the Loctite to cure.

More to come ..........
Title: Re: Travis Steam Engine 2 X Size
Post by: dpaulson on March 07, 2019, 04:46:59 PM
Brian
I built the Travis# 4 steam engine you are building only to Thomas drawings , Looks great
Dave
Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on March 07, 2019, 05:08:47 PM
Hi Brian,
With the flat crank the engine won't be self starting? I went to Youtube to look up the engine but there's so many on the channel with the same name I didn't know which one to look at.
gbritnell


Hello George,

It is Steam Engine No. 4 (see attached drawing) and believe it or not it does self start most of the time even with low air pressure.

Brian, that crank looks great and I like your hold down technique.

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on March 07, 2019, 06:02:39 PM
Hi Brian, quite a bit of fixturing you got going on there...  :ThumbsUp: :ThumbsUp: :ThumbsUp:

 :popcorn: :popcorn: :popcorn:
 
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 11, 2019, 12:57:36 PM
More crankshaft work ..........

Setting up the crank to drill and ream for taper pins. Doing the connecting rod journals first with a #2 size pin. Edge find to center position and spot drill four places, drill and ream.
Using a left hand spiral-right hand cut reamer under power. Not a good idea for success to try this with a straight flute style reamer as they tend to grab and will often break.  :o

Same type of setup to do the larger .750" shafts with a # 3 reamer.

A note about installing the taper pins. Be sure the reamed holes are clean and oil free and the same for the taper pin, too. The pins will not seat firmly with oil left over from reaming, etc.

I had long pins on hand and used them for the assembly since I wanted pin stick out on both sides of the hole for the next operation.
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on March 11, 2019, 02:01:08 PM
Coming along well Brian and with those taper pins the crankshaft should be  good and solid as well.

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on March 12, 2019, 01:38:41 PM
That's one beefy crankshaft! Looking good.  :popcorn: :popcorn: :popcorn:

Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on March 12, 2019, 07:52:25 PM
Hello Brian,

Great looking crank and quite beefy. :ThumbsUp: :ThumbsUp:

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 13, 2019, 12:52:55 PM
Finish operations on the crankshaft .......

Sawed off the taper pins staying away from the throws as not to mark them. Won't take long to grind off the remaining part even though there looks to be a lot to remove.

Blocked up on the surface grinder for the first side with 1-2-3 blocks. will grind off the pins and take about .001" dust off on the throws to finish. Ran this side dry because I'm to lazy to cleanup
the coolant from the tooling.    ::)

The last side gets the same operation down on the magnet this time with coolant.   :cartwheel:



More parts to come .........



Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 13, 2019, 02:47:19 PM
The end results .........


The final check for run out with the crank running on its bearings. Happy !

Nm83VRDSe2M
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on March 13, 2019, 03:00:09 PM
 :ThumbsUp: :ThumbsUp:

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: Admiral_dk on March 13, 2019, 09:52:33 PM
That is a great result with the crank  :ThumbsUp:  :cheers:
Title: Re: Travis Steam Engine 2 X Size
Post by: jeff l on March 14, 2019, 12:56:11 AM
Great Job !
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 19, 2019, 09:03:54 PM
Machining the overall size of the base plate and bottom plate ......

Rough sawed from .750" plate. The base plate and bottom plate. I made the bottom plate thicker than 2X scale of the original that would have worked out to 1/2" thick. Overall finished size will be .750" x  9.750" x 6.000".
The bottom plate ( supports the cylinders ) will be .750" thick x 4.000" wide x 7.750" long.

Milled the width on both plates, first operation.

Using a angle plate in the mill vise I machined the ends and overall length to size. This setup will give a perfect 90 degree edge to the plate face, important since these two parts produce the engines main frame.
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on March 19, 2019, 09:59:32 PM
Looks good Brian. This is going to be a hefty engine when done.  Still watching along.

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on March 19, 2019, 10:03:46 PM
Looking good Brian!  :popcorn: :popcorn: :popcorn:
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 20, 2019, 01:24:04 AM
Thanks, guys.   :)
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 22, 2019, 05:12:01 PM
Machining the frame end plates and bearing bores .........

End plates for the engine frame are made from .375" thick plate and finished to overall size of 6.000" wide x 5.250" high. Overall size will be machined with the plates clamped in pairs.

(https://i.postimg.cc/NF7LVt4H/IMG-1033.jpg)

(https://i.postimg.cc/k504gGYS/IMG-1034.jpg)

I put a center mark on each side of the plates to scribe a layout circle for the bearing bores as a roughing guide.

Bored thru 13/16" clearance for the crank shaft and as a reference bore to locate when doing the opposite side.

(https://i.postimg.cc/W1fzxXMX/IMG-1035.jpg)
(https://i.postimg.cc/9fR02ZbV/IMG-1036.jpg)

Finish boring for slip fit to the ball bearing using a flat bottom ground boring bar. ( layout line visible ) The bore is half the thickness of the bearing in depth. Added a counter bore .010" deep to clear the inner race of the bearing.

(https://i.postimg.cc/Y214jNHC/IMG-1037.jpg)
(https://i.postimg.cc/g20rMf6x/IMG-1038.jpg)

Used a 45 degree chamfer bar to to break the bores edges. Flip to the opposite side and pick up bore and repeat the operations.

(https://i.postimg.cc/L62JPq9B/IMG-1039.jpg)
(https://i.postimg.cc/RVdNLMqr/IMG-1040.jpg)

Next operation will be to cut the angled features on the plates to a 4.000 width at the top to match the bottom plate width. Used a height gage to scribe accurate layout lines where the cut runs out.
Set up with sine bar for the correct angle and used mill stop to locate the position of the sine bar so opposite side cut would be the same.

(https://i.postimg.cc/SRqxc5hN/IMG-1041.jpg)
(https://i.postimg.cc/gJ30Xp1T/IMG-1042.jpg)
(https://i.postimg.cc/d3Bt6BsR/IMG-1043.jpg)

This finishes the plates for now.

If you like the posting of pictures this way, thank my friend Yogi for helping me out.  :ThumbsUp:


Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on March 22, 2019, 07:22:34 PM
Hello Brian,

Yes the photo layout is great with wording in between just works better. I have tried that a couple of times and for whatever reason I wind up deleting something.

Your work is beautiful. Like all involved projects I get anxious to see the completed engine, but hate to see it end because I enjoy following along.

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: Johnmcc69 on March 22, 2019, 08:56:26 PM
Very nice work Brian (& Yogi, great pics...)
 & a shout out to Thomas for his design.

 John
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on March 23, 2019, 01:37:15 AM
Looking good Brian!  :ThumbsUp: :ThumbsUp: :ThumbsUp:
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 26, 2019, 08:04:27 PM
Machining the bearing retainer plates ...........

These parts retain the bearing in the end plates. Sawed two circular rough cut outs on the band saw from 3/8" plate.
Will do the same bores as the end plates, but this time at the lathe.

(https://i.postimg.cc/SKbQY3Sn/IMG-1045.jpg)

Next set up will be at the mill picking up the bores to drill clearance holes for 10-32 screws. Will also drill and tap a matching set of holes in a scrap fixture plate.

(https://i.postimg.cc/HWvp9VWD/IMG-1047.jpg)


Will be machining the profile at the Tormach mill.

Since I drill clearance holes in the blank a little masking tape around the screws will take up the space when bolting the blank to the fixture.

(https://i.postimg.cc/QxBj4hVB/IMG-1050.jpg)

Pick up bores for part center.

(https://i.postimg.cc/TwRRCbWG/IMG-1048.jpg)

Finish machine the contour and chamfer all around.

(https://i.postimg.cc/nrrnttkP/IMG-1051.jpg)

Added a couple of ball end milled grooves for looks. These parts are finished. Shown with the end plates.

(https://i.postimg.cc/mknBL6p2/IMG-1052.jpg)

Thanks for the comments and views !  :)
Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on March 27, 2019, 08:24:44 AM
Hello Brian,

Really nice touch with the Ball End Mill work :ThumbsUp:

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: gbritnell on March 27, 2019, 11:17:54 AM
HI Brian,
It's coming along nicely. I really like those end plates!
gbritnell
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on March 27, 2019, 01:12:21 PM
I will second Georges comment on the end plates. Those add a very nice touch!!

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on March 31, 2019, 05:41:24 PM
Finishing the base plate rectangle cut outs on the Tormach with corner chamfers around the edges.

(https://i.postimg.cc/brX59MmM/IMG-1054.jpg)

(https://i.postimg.cc/SQ83xSsp/IMG-1055.jpg)

Making a final finish pass.

(https://i.postimg.cc/C5jQPNtK/IMG-1057.jpg)

(https://i.postimg.cc/15rdDvwC/IMG-1058.jpg)
Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on April 01, 2019, 12:56:01 PM
Hello Brian,

More beautiful workmanship by adding the chamfers on the cutouts. :ThumbsUp:

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 02, 2019, 05:25:50 PM
Machining the bottom plate for the cylinders ...........

Working with the previously machined to size plate. Rough drilling for the 2" thru bores first.
Followed by finish boring to size to 2.000".
(https://i.postimg.cc/GmqhgJwz/IMG-1061.jpg)
(https://i.postimg.cc/cJC1pgdW/IMG-1062.jpg)

Rough milling to a layout line for the counter bores that finish to 3.250" to fit the cylinder base.
(https://i.postimg.cc/brxqx19x/IMG-1064.jpg)

Followed by boring to size. 
(https://i.postimg.cc/k4tJ50Vh/IMG-1065.jpg)

Chamfer the 2.000" bore with the boring head and the 3.250" and using a fly cutter and tool bit since the boring head would not reach.

(https://i.postimg.cc/28N61S7d/IMG-1067.jpg)
(https://i.postimg.cc/dt9qDm1v/IMG-1068.jpg)

Drilling and counter boring for socket head cap screws to finish up.
(https://i.postimg.cc/x1T9mJJm/IMG-1069.jpg)
(https://i.postimg.cc/zXNzJPq0/IMG-1070.jpg)
(https://i.postimg.cc/qByBHdHN/IMG-1071.jpg)
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on April 03, 2019, 01:00:11 AM
 Looking good!

:popcorn: :popcorn: :popcorn:

Title: Re: Travis Steam Engine 2 X Size
Post by: Dave Otto on April 03, 2019, 01:12:38 AM
Very nice work as usual Brian.  :ThumbsUp:


Dave
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 03, 2019, 02:08:02 AM
Thanks everyone :)
Title: Re: Travis Steam Engine 2 X Size
Post by: gary.a.ayres on April 03, 2019, 12:04:47 PM
Great-looking parts!
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 07, 2019, 07:07:32 PM
Machining the crankshaft spit center bearing support ..........

Machined to size the bearing support block from stock long enough to get the base and top cap.

Sawed and machined the overall lengths of the base and cap. Drilled and counter bored for 10-32 socket head cap screws.

(https://i.postimg.cc/V6r0jZcH/IMG-1079.jpg)

(https://i.postimg.cc/3RvWyygs/IMG-1081.jpg)

Assembled the two parts clamped in the mill vise for alignment.

(https://i.postimg.cc/JnfDK3r7/IMG-1086.jpg)

Set up the assembly and drilled and reamed for 1/16" dowel pins.

(https://i.postimg.cc/5yWy8xg6/IMG-1087.jpg)

(https://i.postimg.cc/3wWkTfWJ/IMG-1088.jpg)

Next operation was to rough machine and finish bore on the split line for the bronze bearing that will be made.

(https://i.postimg.cc/s28vDPZP/IMG-1089.jpg)

(https://i.postimg.cc/zXSbSR95/IMG-1090.jpg)

Ready to machine the bearing to fit the block bore and the crankshaft .750" diameter center.



Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on April 07, 2019, 07:49:57 PM
 :popcornsmall:
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on April 07, 2019, 09:02:14 PM
More nice progress and good looking parts as well Brian.

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 09, 2019, 03:38:54 PM
Machining the bearing insert for the crankshaft center support.

Turned the O.D. of the bushings for a tight fit to the housing with the I.D. rough drilled. I parted off the bushing longer than needed.

(https://i.postimg.cc/3RF5bY7y/IMG-1091.jpg)

At the mill I set up both bushings for milling to half the diameter. Checking with gauge block over the split.

(https://i.postimg.cc/286RTst6/IMG-1092.jpg)

(https://i.postimg.cc/brYX7WNm/IMG-1093.jpg)

With the inserts installed I finish bored for the crank pin diameter. The reason for this operation was to insure that I was exactly on the center line of the crank measured from the base plate. Everything will be doweled when in final location.

(https://i.postimg.cc/nzJfkC8b/IMG-1095.jpg)

The final length of the insert is mill in relation to the thickness of the bearing support block, equal amount and centered. I left .005" per side clearance to the crank throws.

(https://i.postimg.cc/J0TwMxsM/IMG-1096.jpg)

Finished results. Added dowels to each half to keep the inserts from moving.

(https://i.postimg.cc/d1vgCpdJ/IMG-1100.jpg)

Added note : Repeated this operation after I found a piece of 660 bronze stock I did not know I had. IMO 360 brass makes a poor bearing material and was not my first choice. Beside who doesn't like doing things over again ?   ::)



Title: Re: Travis Steam Engine 2 X Size
Post by: crueby on April 09, 2019, 04:54:47 PM
Nicely done. And good to practise on the 360 before the bronze... Been there!
 :popcorn: :popcorn: :popcorn:
Title: Re: Travis Steam Engine 2 X Size
Post by: bent on April 09, 2019, 06:40:33 PM
Phew, glad you found the bearing bronze.  Agree, the 360 brass would wear too quickly for you.  Good progress, keep it up! :popcorn:
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on April 10, 2019, 01:38:07 AM
Coming along nicely Brian!
I always enjoy seeing your method of making parts.  :ThumbsUp: :ThumbsUp: :ThumbsUp:
Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on April 10, 2019, 08:53:55 AM
Hello Brian,

Beautiful job on the bushing. However as straight as you made the crankshaft I don't think there will be much wear on that bushing.

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 12, 2019, 01:38:57 PM
Dowel pins and some test assembly .....

Set up for drilling and tapping the base for the side plates.

(https://i.postimg.cc/htPqd3H8/IMG-1077.jpg)

Assembled the side plates to the base and added dowels at each end. The dowels are spaced differently so each plate only fits the matching end.

(https://i.postimg.cc/s2bFbf1K/IMG-1078.jpg)

A couple of views with the crankshaft in place. Happy with the results ! Everything turns freely.  :)

(https://i.postimg.cc/527WqSVh/IMG-1101.jpg)

(https://i.postimg.cc/NMThthHt/IMG-1102.jpg)
Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on April 12, 2019, 04:12:08 PM
Hello Brian,

Oh boy, now you have my blood pressure going way up. That is just plain old fashion BEAUTIFUL :praise2:, now I cannot wait to see a final assembly photo.

Have a great day,
Thomas

Title: Re: Travis Steam Engine 2 X Size
Post by: bent on April 12, 2019, 09:20:31 PM
 :P
Glad you said it first, Thomas, but if anything that looks prettier than the original.  Very nice craftsmanship!
Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on April 13, 2019, 01:22:49 AM
Still following along and really enjoying the build. Keep the pictures coming please.  :ThumbsUp:

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 13, 2019, 03:11:18 AM
Hello Brian,

Oh boy, now you have my blood pressure going way up. That is just plain old fashion BEAUTIFUL :praise2:, now I cannot wait to see a final assembly photo.

Have a great day,
Thomas

Hang in there Thomas ! I won't disappoint, more to come.  :)  And Thanks !!
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 15, 2019, 02:07:31 PM
Machining the cylinder head.

Luckily I had a piece of 6061-T6 bar stock in my collection of materials. The only problem was it was a 1" to big one way and a 1/2" the opposite. Got started milling to square up to the cylinder head overall size.
The head is 7.750" long x 2.500" high and 4.000" wide.

Getting one side cleaned up.
(https://i.postimg.cc/TYgxyRXZ/IMG-1103.jpg)

Then got to some serious milling to remove a bunch of material.

(https://i.postimg.cc/BZ840T7Z/IMG-1104.jpg)

Left some stock on the 2.500" height and started the milling of the steps on the sides.

(https://i.postimg.cc/s2DC07Zr/IMG-1105.jpg)

With the steps finished I took the last cut on the 2.500" thickness.   Not shown. I left some stock on both faces in case of any movement in the material from cutting the steps. Already did the side against the vise.

(https://i.postimg.cc/Jh6Cw0bB/IMG-1107.jpg)

Forgot to take pictures of cutting the corner radius using a 1/2" shank carbide wood router bit.   :Doh:   That worked very well.   :ThumbsUp:

All the machining for this part of the head is complete. More operations to come.

(https://i.postimg.cc/x1Q2MWfq/IMG-1111.jpg)









Title: Re: Travis Steam Engine 2 X Size
Post by: Ye-Ole Steam Dude on April 15, 2019, 04:53:14 PM
Hello Brian,

Man that is a stack of swarf on your machine  :Lol:. Same thing happened to me, my raw stock was too big and had a lot of milling to get it down to size. Looking good and my blood pressure is still rising.

Have a great day,
Thomas
Title: Re: Travis Steam Engine 2 X Size
Post by: yogi on April 15, 2019, 11:35:20 PM
A high metal removal rate is sure fun! The clean up afterwards not so much...   :Lol:
Beautiful part. I still marvel at the size of if it.  :popcorn:
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 17, 2019, 04:05:11 PM
More work on the cylinder head ..........

Add a center location for the bores that accept the cylinders and scribe a layout line to rough to with a end mill. The bores finish at 3.250" x .250" deep.

(https://i.postimg.cc/Cxxc3NJm/IMG-1112.jpg)

Rough out the stock close to the layout. Finish bore to size after this operation on both locations.

(https://i.postimg.cc/Df1pLm8d/IMG-1113.jpg)

(https://i.postimg.cc/J4qTYg3s/IMG-1114.jpg)

After the bores are complete the 17/64" drilled holes for the head bolts are drilled.

(https://i.postimg.cc/2yNHgNXZ/IMG-1115.jpg)

With the head turned over the head bolt counter bores were completed for 1/4-20 SHCS.

(https://i.postimg.cc/RZpg4HD9/IMG-1116.jpg)

Next set up added the tapped holes for the valve blocks and drilling for the air passages on both ends.

(https://i.postimg.cc/sxPnrHt0/IMG-1117.jpg)

Last operation connects the air passages to the cylinder bores. This completes the head for now.

(https://i.postimg.cc/Yqkn3kFc/IMG-1118.jpg)



Title: Re: Travis Steam Engine 2 X Size
Post by: b.lindsey on April 17, 2019, 10:39:38 PM
Still following along Brian, and enjoying the build. Nice looking parts too.

Bill
Title: Re: Travis Steam Engine 2 X Size
Post by: toolznthings on April 18, 2019, 02:06:50 AM
Still following along Brian, and enjoying the build. Nice looking parts too.

Bill

Thanks much, Bill !