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

[RReid]

You are making great progress, Achim. It's all looking really good!

[fumopuc]

Thanks Ron.


Tappet brackets, the next challenge.
Doug Kelley has a drawn and recommended a fabricated part from 4 single components, soft soldered and finally machined.
At the end a fixture had to be made too.
My idea was to make it with my CNC mill from a solid block of brass.
It was clear, that a kind of flipping over was necessary to get it complete machined.
The first attempt to get the split line at the lower end of the part failed, because of the cutting length of my 5 mm VHM cutter.
At the end a split line is visible now, but with some additional polishing I hope to get ride of the optical marks.
tbc...

[fumopuc]

... more brass swarf.
After flipping over an additional 0,1 mm in Z could have avoided the massive burr.
I will try to make it with the next mirrored part that way.
tbc...

[fumopuc]

... and additional necessary machining is a 1 mm slot for the guidance of the tappet.
Also made by a CAM program.
I have had a lot of sweat at my hands and forehead when I have press the start button first time.
It was my one and only 1 mm cutter at this point.
But the very conservative chosen cutting parameters seems to be the reason for a successfully machining of all 4 slots by not loosing the one and only cutter.

[Roger B]

Some excellent carving    and a lot of swarf  How much did the original block of brass weigh?

[Dave Otto]

Nicely done!

Dave

[crueby]

Excellent, as usual!     

[fumopuc]

Hi Roger, thanks.
148 Gramm was the weight of the stock part, as shown in in the CAD picture.
So a bit less than 10 % survived.
If you compare the whole fabrication work with a fixture to my milling out of the stock, I do not know who will win.

[fumopuc]

Dave, Chris thanks for watching.

[Admiral_dk]

They looks really good Achim - I'm guessing that you need to make one more of those 

Per

[fumopuc]

Hi Per, thanks.
Why do you think another one is necessary ?

[fumopuc]

Hi everybody, next to do the newly designed roller tappets.
A set up at several machines was done for each operation of one tappet in line.
Starting at the lathe from  bar stock.
A gauge was made to check the slip fit at each part before the next machining step was started.
Than the part with the stock and the collet moved to the conventional mill into the square collet block.
The slot for the roller was machined here.
Next, the collet block with the part moved to the CNC mill.
The bearing pin hole was drilled in this set up.
The collet block has been flipped over by 90° to be ready to get the 1 mm hole, for the guidance pin of the tappet.
The CNC mill was manually and very carefully operated by the hand wheel for the drilling of these holes.
tbc...

[fumopuc]

...Also manually the reaming of the bearing pin hole to final dimension, all jobs so far still fixed in collet block.
Back to the lathe and a parting-off.
The push rod hole was made next.
The little belt grinder has been very useful for the final shape.
These tappets are not really big.
First set in situ.
tbc..

[fumopuc]

... some more pictures and finally some movement.




<a href="https://www.youtube.com/watch?v=41UEWpkMfBI" target="_blank">http://www.youtube.com/watch?v=41UEWpkMfBI</a>

[Kim]

Very nice work, Achim!   
Those are VERY tiny parts!

Kim