IHC Titan 50 HP, 2 cylinder Doug Kelley, European version

[RReid]

What have you done to make your shop elves mad?

[fumopuc]

What have you done to make your shop elves mad?

Easy, Bavarian Beer.
Special offer, could not be sold at the "Oktober Fest" last fall.

[RReid]

I've only been to Germany once. The company I retired from has a facility in Putzbrunn, near Munich. Unfortunately it was not Oktober Fest time, but I did enjoy the local Dunkel Weisse very much. 

[fumopuc]

Yes Ron, the Bavarian art of brewing is something very special.


After some mishaps but a good learning curve with vacuum part holding I have decided to make the part with two set ups now again.
The first set up with the vacuum table, cutting out, small holes and one big hole.
It was supported a bit by the protection sheet, the brass suppliers has used to cover one side of the plate.
The second set up in the vice for the second big hole only.
At the end after several attempts with this clamping technology, I do have a good part now.
For the fabricated cylinder assy a similar part will be necessary, but with less small holes in it.
This was very helpful for the vacuum table part holding.
Exactly were the grid of the table is, we do have enough surface there for another clamping attempt.
So I could make this part in one go.
At the very end of the cutting process, the spindle motor was shut of already and on its way into the home position, I could here suddenly a sizzling noise.
The vacuum escaped just at the right moment, so this part was made by luck only in this way and I got the confirmation, that here will be worked at the limit of the vacuum clamping technological with my equipment.

[fumopuc]

Ready now to attack the crank case.
A fabricated solution again.
Some brass bar stock was prepared.
Also an end plate was necessary.
All bolted together as a sample first time.
All of these brass bars needs some machining to get its final shape.

[Craig DeShong]

I've only been to Germany once. The company I retired from has a facility in Putzbrunn, near Munich. Unfortunately it was not Oktober Fest time, but I did enjoy the local Dunkel Weisse very much. 

I was in Germany several years ago.  I made it my mission to try to find a bad German beer.   I Was unsuccessful.

[fumopuc]

I've only been to Germany once. The company I retired from has a facility in Putzbrunn, near Munich. Unfortunately it was not Oktober Fest time, but I did enjoy the local Dunkel Weisse very much. 

I was in Germany several years ago.  I made it my mission to try to find a bad German beer.   I Was unsuccessful.

Craig, good to hear that you failed.


Some finishing and silver brazing was not a hard job.
Followed by the first set up for machining and surfacing.

[fumopuc]

Next steps of the crank case surfacing.
And the finishing of the part.
At the end we are ready to machine the crank shaft bearing places now.

[RReid]

That's coming together very nicely indeed, Achim! 

[fumopuc]

Thanks Ron.


Machining the crank shaft bearing cut out.
A very long cutter was necessary, what means some chatter will occur.
Important is the bottom surface only.
Front and rear a small gap could be an advantage for later alignment of the bearing blocks.
The hole pattern was marked first by an NC spot drill bit.
There is everything from M1,6, M2 and M2.5 needed.[size=78%] [/size]
Most of the threading could be made by CNC, except the thread cutting for the bearing block fixation.
The CNC thread cutter would cause a collision with the crank case.
So is was done the conventional way manually.

[Roger B]

Excellent fabrication as ever   

What is the operation in Picture 34, thread milling?

[fumopuc]

Excellent fabrication as ever 

What is the operation in Picture 34, thread milling?

Hi Roger thanks.

Yes, most of my M1,6, M2, M2,5, M3, M3,5 and M4 threads can be made by thread milling at the CNC mill now.

[fumopuc]

To give the engine a home feeling already, I made the pedestal next.
A 12 mm aluminium plate which should host the engine and the water pump.
The dimension for the a wooden base plate are defined in the meantime also.
Now I do have a good idea about the overall dimensions from this build.

[fumopuc]

Hi everybody, next part to be made, the crankshaft bearing blocks.
First a special CAD set up was made to prepare a common CNC machining.
Now I could start from a piece of 7075 round bar stock.
After the first operation with 3D adaptive cleaning, the general shape is visible already.
Than the complete hole pattern for fixation and lubrication was made.

[Admiral_dk]

You are really making fast progres now Achim - have you borrowed some Elves from Chris 

Per