Author Topic: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version  (Read 27383 times)

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #180 on: November 13, 2022, 08:43:17 AM »
As in real life, there is always any kind of surprise around the next corner.
During the heating of the hole unit in the fixture first time, suddenly there was a strange noise.
Just measured a temperature of nearly 550° to 600 °C.
A bit frighten, I have stopped the heating and inspected the parts visual immediately.
A gap could be seen at a place, where no gap should be.
I have been able to disassemble everything without any problem.
By luck, I did not reach the melting heat of the foil so far.

My conclusion was, I have to increase the amount of bolts in the fixture, keeping everything in position during applying the parts with heat.
The design with one bolt was to weak for the heat deformation.
Now we do have 3 bolts each side and the second attempt was successful.
As learned by my test soldering the waste solder does flow forced by the gravity under the unit.
There it will not disturb the needed clean surface for the water outlet.
I have been very happy with this success, in my option it was a very easy and smart solution.
The easiest silver brazing I have ever done.
Kind Regards
Achim

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #181 on: November 13, 2022, 08:54:14 AM »
Encouraged by the result of the first operation with the solder foil, I have attacked the legs the same way.
By what I have learned before, the fixture was modified from one bolt per side, to two bolts per side, keeping the legs in position.
Also here I have been very, very happy with the result.
My conclusion, the usage of soldering foil in this specific application was a very go choice and I am sure, next time I will do it again.
Last picture does shown the final cleaning in citrus acid.
Kind Regards
Achim

Offline MJM460

  • Full Member
  • ****
  • Posts: 1647
  • Melbourne, Australia
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #182 on: November 13, 2022, 10:41:49 AM »
Excellent result Achim, a satisfying milestone before the next steps.

MJM460
The more I learn, the more I find that I still have to learn!

Online Dave Otto

  • Full Member
  • *****
  • Posts: 4693
  • Boise, Idaho USA
    • Photo Bucket
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #183 on: November 13, 2022, 04:34:11 PM »
Nice progress Achim.

Dave

Offline Kim

  • Global Moderator
  • Full Member
  • *****
  • Posts: 7860
  • Portland, Oregon, USA
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #184 on: November 13, 2022, 05:18:31 PM »
Beautiful fabrication, Achim! Lots of progress to catch us up on, I see :)  :popcorn: :popcorn:
Kim

Offline Admiral_dk

  • Full Member
  • *****
  • Posts: 3752
  • Søften - Denmark
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #185 on: November 13, 2022, 09:51:23 PM »
Very interesting Fabrication  :ThumbsUp:

Solder Foil - that is another new one to me  :cheers:

Per

Offline crueby

  • Full Member
  • *****
  • Posts: 18554
  • Rochester NY
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #186 on: November 13, 2022, 10:35:58 PM »
Interesting! I've been using the fine wire version of the solder, had not seen the foil type.   :ThumbsUp:

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #187 on: November 14, 2022, 06:41:33 AM »
Thanks everybody for watching and the friendly comments.


Here is a link to my German source of the foil.
https://www.sonderlote.de/epages/62173412.sf/de_DE/?ObjectPath=/Shops/62173412/Products/"A%20314%20F"/SubProducts/A314F022020

The manufacturer is FONTARGEN that belongs to VOISTALPINE and both are members of the BÖHLER WELDING group.
Kind Regards
Achim

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #188 on: November 20, 2022, 07:30:43 AM »
Hi everybody, Good Morning.
Now the soft solder operations had to be prepared.
The plate/frame has the hole pattern already for 3 pins, which was transferred to the cylinder unit first.
And a flat surface, hopefully at the right angle was needed.
I have marked the cylinder unit contour at the plate and with a soft solder paste at first solder layer was given to the plate.
The final soldering was made by the paste also.
Some areas could be better, but a reheating has solved this issue.
After soldering the water outlet in is final position, also with the paste, is was time to open the bore into the water jacket of the cylinder unit.
All surfaces around had to be machined to its final dimensions, similar to final machine a casting. (What I have never done so far.)
Also the hole pattern to connect to the base and crank case.
As a very last, but most important operation, the main bores for the liners had to be made.
The set up is shown in the last picture.
Kind Regards
Achim

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #189 on: November 20, 2022, 07:39:11 AM »
Doug Kelley has made and recommended the liner bore as a lathe operation.
I thought, this should be a perfect job for my small Wohlhaupter boring tool.
It worked well and now the real part does look very similar to the 3D printed dummy.
Still missing the hole pattern for the liners and cylinder heads.
« Last Edit: November 20, 2022, 10:07:42 AM by fumopuc »
Kind Regards
Achim

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #190 on: November 20, 2022, 08:14:26 AM »
Final operation at the cylinder unit, the hole pattern for liners and cylinder heads.
6 threaded holes each cylinder and 2 holes for coolant passage.
It took all my courage to do it with the small M2 cutting tool with the CNC mill.
The small long shaft of this tool is 0,9 mm in diameter.
The first time I have used the process in steel.
Until today I have to look out of the window when pressing the start button at the CNC mill to do it.
But here also, surprise, no cracking noise appeared.
The only issue, my saved cutting parameters has been learned by machining aluminium or brass so fare.
Here, making the thread in steel, the little fragile shaft oft the tool seems to bounce at bit more.
I had to increase the feed at bit and also to repeat the last turning around two times, to get a fine usable M2 tread.   

Kind Regards
Achim

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #191 on: November 20, 2022, 08:26:00 AM »
The pictures of making the liners are hopefully self explaining.
It is a more times proven process.

Kind Regards
Achim

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #192 on: November 20, 2022, 08:41:31 AM »

Finally the plotter has cut some paper seals.
The hole pattern in the liners was drilled by the Computer also and the conventional mill had supported the hole for the spark plug.
Now the most imported and in my eyes most difficult job will start, to the water jacket proper sealed.
During the adaption to metric sizes, the dimensions to Dougs original  plans has slightly modified.
Due to this, the O-Ring cord size and length, used for the lower sealing has to find out now.
I have purchased some rings and different cord size to find out the best solution for my build.
The gap between, "no chance" to press it in and "leaking" is very small.
A fixture was made to simulate the outer diameter of the slot, machined inside the liner.
But it is a guess more or less, because I can not measure it in a proper way.
With some try and error, some rubber scrap and my shown test equipment, at the end I have found the right cord dimension in diameter and length.     
« Last Edit: November 20, 2022, 08:55:11 AM by fumopuc »
Kind Regards
Achim

Offline Roger B

  • Global Moderator
  • Full Member
  • *****
  • Posts: 6133
  • Switzerland
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #193 on: November 20, 2022, 08:45:39 AM »
Some rapid progress  :ThumbsUp:  :ThumbsUp:  :wine1:

Internal O ring grooves are somewhat tricky  ::)
Best regards

Roger

Online fumopuc

  • Full Member
  • *****
  • Posts: 3231
  • Munich, Germany, EU
Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #194 on: November 20, 2022, 08:46:22 AM »
The sectional view shows the critical issue.
Last picture, the final  test, no bubbles anymore and the  basic to cut and glue some more rings of this specific size.
« Last Edit: November 20, 2022, 10:13:53 AM by fumopuc »
Kind Regards
Achim

 

SimplePortal 2.3.5 © 2008-2012, SimplePortal