Bar-stock "Mary"

[cwelkie]

Lovely work and wonderful lessons in how it can be done without castings to good effect.
Thanks for sharing this build.
Charlie

[joe d]

Tug, Bear, Charlie:

Thanks guys!

Joe

[Don1966]

Just finish reading from start to finish Joe. Don’t know how I missed it but that is some great fabrication work. I will be following till the end....



 
Don

[joe d]

Thanks, Don.  Glad to have you looking in!

[joe d]

A short detour into some wood-working for the base.  Had some oak off-cuts from a little project I had done for one of the daughters-in-law
so put them to use.

Viewed from the underside:


But it does have some metal work: made up a a well for the flywheel from some brass sheet, little bits of tube as spacers, & soft soldered it all
together


The base from above


and with the flywheel well in place:


Also made up a well for the crank, it fastens to the underside of the aluminum base.  There is enough clearance between the metal base plate and the wooden base, so this is not essential,
I may well omit it eventually, if so, will just cover the hole in the wooden base with some flat stuff.  This has also been my test piece for paint, it's been green, red, and now brown, not crazy about any of them so far...




a bunch of studs to attach everything to the base


A quick turning job to make the trunnion for the beam (here it's chucked up for polishing)


in place


and with the bits fastened to the wood base, and the beam perched in it's spot:


Cheers, Joe

[Bear]

Impressive work, Joe.

[joe d]

 Thanks Bear!

Joe

[Admiral_dk]

Look really good now that one truly can see what it should end up as 

Still following 

Per

[joe d]

Thanks Per.  I agree, a mile-stone moment once it's all sitting on it's base, it's encouraging!

Joe

[joe d]

Flywheel part one... a lot o photos of this, so I'm breaking it up into 3 posts.

Pretty much made this up as I went along based on what material I had on hand.

Cut 6 pieces of the mystery brass, drilled hold-down holes in what would eventually be waste,
screwed down on a sacrificial bit of aluminum on the rotary table and cut the sides to the requisite angle


In the same set up, ran a light cut to define the inside radius, and then chain drilled the lot


Hacksawed off the waste and then back to the mill to clean up the arc


Then chain drilled the outer arc, and as above, sawed off the excess and cleaned it up on the mill


This took away the hold-down holes, so had to clamp the work to the table, but happily, nothing moved throughout the process


Then drilled the centre of each segment radially, with a short counterbore on the inner side, for fitting the spokes


More to come....

[joe d]

fly wheel part 2...

Chucked a length of brass, drilled and counterbored the size of the spoke material


Added a little decorative cut, and then parted off, repeat 5 more times


cut 6 pieces of stock for the spokes, turned down one end and threaded them on the lathe


Turned them about and turned a short length to the diameter of the counter bore in the rim segment, with a further length smaller
to the diameter of the through hole in the rim segment


Stuck together just to see how it was coming...


Cleaned up a bit of brass in my larger lathe to create a chucking piece for the small lathe


Once trued up on the Taig lathe, cleaned it up ready to move to the mill


The point to doing the set up on the Taig lathe is that the Taig chuck fits the indexing head built for the Taig mill
So, here drilled 6 equidistant holes, counterbored them to fit the decorative bits made earlier, and tapped to fit the threads
on the spokes.  (This threading is simply to hold things together for soldering)


more to come...

[joe d]

Flywheel part 3

Test fit:


Looked good, so went ahead and tapered the spokes


5 down, 1 to go...


Cleaned up all mating faces, fluxed and clamped down & silver soldered


set up as true as I could on a faceplate, ready to clean up the rim, hub, and drill & bore the hub


Flipped around, centred by putting a little stub in the shaft hole, cleaned up the reverse side and removed the excess
on the hub

( and could not find a speed or feed that this crap brass liked to get a clean cut radially,  glad I've almost run out of it!)

Broached the keyway in the arbor press, and here it is sitting where it belongs:


Big job done!  Cheers. Joe

[Bear]

Looking awesome!

[joe d]

Thanks, Bear!

[Kim]

Wow!  That was a lot of work, but the results look great!
Kim