Author Topic: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version  (Read 37777 times)

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #360 on: March 19, 2024, 04:37:46 PM »
Hi everybody,
after a break and thinking about a possible salvage of the crankshaft I have made an attack to it today.
So first the cooling was drained and than I have disassembled the crank drive.
And now the naked truth is laying on the table.
There is still a kind of slip fit if you try to split both parts.
The pictures saying more than my words could do.
The crankshaft flange has been made by ST37 (S235JR) the cheapest  construction steel at the German market and with very low quality.
Looking into the hole, it could seen all surface is black.
That means due to the long heating during the brazing of the whole part, the surface has get a lot of oxide scale, which does not allow the flux and silver solder to flow.
Very interesting, some very small drops of silver solder have found the way into the gap and can be seen as kind of small isles in the black see.
I will try to make a salvage with Loctite 648 and a taper pin.
The special reamer is ordered, the pins also.
A kinds of jig/fixture is in my head, I will make the design tomorrow.
And yes, some thoughts about the other 7 soldered connections between rod and cheap construction steel are  in my mind also.
« Last Edit: March 19, 2024, 07:46:34 PM by fumopuc »
Kind Regards
Achim

Offline Admiral_dk

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #361 on: March 19, 2024, 07:45:18 PM »
Good to hear that you found out why it failed  :ThumbsUp:

I hope that you find a satifying solution  :LittleAngel:

Per       :cheers:

Offline sid pileski

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #362 on: March 19, 2024, 11:12:27 PM »
This failure really stinks with an otherwise outstanding build.
I'm confident that you will come to a workable solution soon.

Good luck soon.

Thanks, Sid

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #363 on: March 20, 2024, 02:32:28 PM »
Per, Sid thanks for watching.


Here my idea for a fixture so far.
I will start to make it now.
Kind Regards
Achim

Offline crueby

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #364 on: March 20, 2024, 02:35:19 PM »
That fixture should work great to keep it all aligned and supported.  :popcorn: :popcorn:

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #365 on: March 20, 2024, 05:49:05 PM »
A start is done.
Good to remember how to move a mill table manually.
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #366 on: March 21, 2024, 12:23:40 PM »
Hi everybody, now the first step is done.
The fixture is finished.
Pin and hole are cleaned.
First by polishing and second chemical wise with acetone.
Both parts jointed and finally adjusted in the fixture.
I have used Loctite 648 to glue it.
Now I will wait 24h until tomorrow at noon.
If it still will run properly in the main bearings of the engine, than I can start with step 2.
2,5 mm hole should be drilled and prepared for 2,5 mm taper pin.
The reamers arrived today, pins should come tomorrow.
Plan is to drill a hole through the glued connection and to ad a pin there with Loctite too.
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #367 on: March 23, 2024, 09:38:43 AM »
Some patience was necessary, but I have been steadfast until this morning.
Now the first test in the main bearings of the engine again.
I have been positive surprised, it is running nearly true again.
If I fix the nuts on the bearing, at the side where it happened, than I can feel a spot with some more resistance in the turning movement.
But in my feeling, nothing to worry about really.
The attempt to measure it has shown a run out of about 0,01 to 0,015 mm.
The other side, were it is absolutely free turning, I can measure a run out of about 0,04 mm.
So it will be time now get the tapered 2,5 mm hole into the crankshaft creek and to get the taper pin inside there.
I will take the old mishap crankshaft from spring 2022 as a sample the test the process with the tapered reamer.
« Last Edit: March 23, 2024, 09:59:05 AM by fumopuc »
Kind Regards
Achim

Offline Admiral_dk

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #368 on: March 23, 2024, 09:50:25 AM »
Fingers crossed for a satisfactory outcome and a well Running Engine afterwards  :cheers:

Per

Offline Roger B

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #369 on: March 23, 2024, 01:16:17 PM »
Hopefully your repair works  :ThumbsUp:  :ThumbsUp: It's looking good so far  :)

Are you going to pin the other joints as a back up as well?
Best regards

Roger

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #370 on: March 23, 2024, 01:38:26 PM »
Hi Roger,
I have thinking about that a long time, but currently rejected.


Finished the experiments in the old crankshaft  half an hour ago.
First attempt was a bit to optimistic with the depth.
But second attempt was better.
Using the quill of the mill with its fine feed was very helpfully and save also.
But anyway, it shows me that an additional hole in the fixture was necessary.
The real crankshaft was done in a couple of minutes than.
Now I will let it cure until tomorrow morning.
The pin was also dipped in some Loctite 648 and than fixed by some blows of a small hammer.
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #371 on: March 24, 2024, 05:39:09 PM »

Are you going to pin the other joints as a back up as well?


Hi Roger,
45 Minutes more runtime later with the so far repaired crankshaft I do know exactly now, that my decision was wrong.
<a href="https://www.youtube.com/watch?v=HJ4LVXKj63c" target="_blank">http://www.youtube.com/watch?v=HJ4LVXKj63c</a>


But it doesn`t matter.
I have had so much fun in this 45 Minutes, with a slightly modified timing.
I my eyes it runs with around 600 rev/min and lower nearly like a hit & miss engine.


The fixture is available, and the way to it do it is known.
And yes, all the other remaining connections will get a pin too.



Kind Regards
Achim

Offline crueby

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #372 on: March 24, 2024, 05:45:37 PM »
Ouch!  Well, at least the fixture is already built!   :popcorn:

Online Kim

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #373 on: March 24, 2024, 06:45:51 PM »
Bummer!  Well, as Chris said, at least you know the fix and have the jig made already.

You'll have it back up and running in no time, I'm sure!

Very nice run, too!  :popcorn: :popcorn:

Kim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #374 on: March 25, 2024, 05:03:58 PM »
Per, Chris, Kim thanks for watching and the friendly words.





This morning I have started the disassembly again.
Second time is always faster.
With the blue tape as a stop marking at the taper reamer it was a kind of easy going for all holes.
So we do have 8 taper pins at all possible critical connections now.
The holes has been cleaned with some acetone before setting the pins with Loctite 648.
Afterward immediately  some oil for corrosion protection.
Over the lunchtime I have give it some time to cure.
Now, a couple of minutes ago, I have made the first test if it is still running true.
It does.
So I will leave now everything as it is and go ahead with the assembly tomorrow.
« Last Edit: March 26, 2024, 04:55:39 AM by fumopuc »
Kind Regards
Achim

 

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