Author Topic: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version  (Read 13998 times)

Online Admiral_dk

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #210 on: November 23, 2022, 12:11:50 PM »
Another fine bunch of parts  :ThumbsUp:

Happy to see that it was a simple solution with the Interferance  :cheers:

Per

Offline RReid

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #211 on: November 23, 2022, 03:02:15 PM »
Hi Achim. I'm glad that the interference problem was relatively easy to rectify. I'm sure we've all had that experience- "I hear something strange, but where the ##$@# could it be coming from?".

Great to see everything working so well in the video. For me at least, that's always a very satisfying milestone to reach, and a nice interim reward for all the work up to that point. :cheers:
Regards,
Ron

Offline crueby

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #212 on: November 23, 2022, 04:22:24 PM »
Nice investigative work, glad it wasn't too hard of a fix.
 :popcorn: :popcorn: :popcorn:

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #213 on: November 25, 2022, 08:16:44 AM »
Per, Ron and Chris thanks for watching.


Up to this point a drip pan, strongly recommended by Doug and also Rustkolector (Jeff) who has build this engine too, was missing.
And as Ron mentioned, I wanted to get the feeling, up to this special point it is done.
The only worst thing here, a complete disassemble is necessary.
There have been two options.
A fabricated pan made from a brass sheet or a job for the 3D printer.
So I have had a look to the CAD model first.
The out coming result, a simple two part design will combine my wishes and the way a 3D printer can make it easily.
I have had a new roll of PETG filament under the bench, purchased at a new supplier, so a good opportunity to test it and to find a good adjustment for it and my printer.
At test part was made first.
During the disassembling I have tries to get some records for the later reassembly.
I will fix the pan with 4 small M1,6 studs, glued into the pan and some nuts.
The pictures below does show a sample fixation with bolts sticking loose into it.
I had to order a threaded rod first  to make these studs.
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #214 on: November 25, 2022, 08:29:27 AM »
Now it was time to think about a final assembly up to this point.
Still missing some coating /color.
For me a job that does need some time and patient.
Still a fan of powder coating, because it gives always this kind of irregular surface I do like very much, which remind me a bit as the surface of a casting.
I will show some, not further commented,  pictures here of the way I have done it. 
The masking is the most time consuming job here.
Some place has got some cold black burnish only.
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #215 on: November 25, 2022, 08:31:53 AM »
next lot of pictures
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #216 on: November 25, 2022, 08:33:46 AM »
and some more.
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #217 on: November 25, 2022, 08:42:10 AM »
For the final assembly I had to spend some many at my favorite model fastener supplier again.
Some very unusual long, black bolts has been found in China and could be easily modified into the required long studs.
My cutting equipment also shown below.
Today I have still no source for the very small model washers, so a black burnish has to be needed for each washer.
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #218 on: November 25, 2022, 08:52:33 AM »
Here some detail pictures of the fasteners at the engine.
I am very happy with it, how it does looks like now.
Again the link to the engine video how it looks like today.
EPrUoUV3QYYIt is the same video, which I have linked some weeks earlier, when I have started my catch up marathon of this build report.
Also missing here and next to show, the coolant gear pump.
It will follow soon.
Kind Regards
Achim

Online Kim

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #219 on: November 25, 2022, 05:55:48 PM »
Very nice paint job, Achim!   :popcorn:

I'm with you, I like the look of the powder coat.  And I also enjoy the powder coating process  MUCH more than standard paint.  Somehow I find it more satisfying and less distressing.  Yours came out beautifully!

Kim

Online Dave Otto

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #220 on: November 26, 2022, 01:03:14 AM »
Beautiful work Achim!
All the new hardware also looks very nice!

Dave

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #221 on: November 26, 2022, 01:56:05 PM »
Kim, Dave thanks for stopping by and the friendly words.


After my shop summer break for nearly 2 month, I was looking first for the best way to get familiar with it gain.
Before I will continue with the cylinder heads, I thought the coolant pump may be a good subject to start with first.
At all the available videos of other IHC Titan 50 HP model engines, I have seen, that the builders have made a gear pump, instead of the well known centrifugal pump, also designed by Doug Kelley earlier.
I have build several of these centrifugal coolant pumps so far, there is also one finished in the box, but my intention was to try now a gear pump too.
Looking at the plans of Art Burns, published in MEB in 2007, I thought it will not be that rocket science.
I have found at company Mädler here in Germany some suitable Modul 0,7 gears with 12 teeth, which are similar in the other dimensions to what Art has used in his plan.
So I have copied the rest of his design around my gears.
Another modification, instead of the O ring shaft seal he used, I have found a suitable small lip seal.
Don´t be irritated, the section view below does show it as a dummy, because there was no CAD model available.
These part was a very good object to combine my sunny summer mind again with the CAM challenge.
I have found a lump of brass which could parted in two pieces, so I have on trial for each part of the pump housing.
Here I have started with the part which do house the gears.
There have been 6 different set ups necessary with my system to clamp it.
I have started by milling a flat surface and immediately with the pocket for the gears.
Than the bores for the gear shafts has been followed in the same set up with the holes for the housing connection also.
So all functional relevant machining was done in one set up only, my plan.
« Last Edit: November 26, 2022, 02:42:54 PM by fumopuc »
Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #222 on: November 26, 2022, 02:05:37 PM »
The last two set ups for coolant in and out at the beginning of the pictures below.


My challenge here was to use a reamer with the CNC mill too, first time.
The recommended speed for my industrial 3 mm NC reamer tool is close to 2.000 u/min.
The lowest revs of my spindle in CNC use is 3.000 u/min.
So before I will scrap my pump housing and the one and only available 3 mm NC reamer, the decision was made to do a test.
Result in the pictures below, it worked without any issues, so I have felt confident to try in my pump housing the same way.
 





Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #223 on: November 26, 2022, 02:08:11 PM »
Here the remaining pictures of the CNC machining so far.

Kind Regards
Achim

Offline fumopuc

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Re: IHC Titan 50 HP, 2 cylinder Doug Kelley, European version
« Reply #224 on: November 26, 2022, 02:21:11 PM »
First part of the pump housing finished machined.
Now some tubes connected by soft soldering.


Now I am ready for the second part of the coolant pump housing.

It must be hidden in the brass block shown below.
Also different set ups necessary.


The M2 tread was a job fore my special CNC thread milling tool.
If you see it at the tool length measurement, may be you can understand, why I can´t still look at it, diving into the hole for machining.
But, if my heat is back in normal mode, I did a thread test and it is fine, as always.
Also here the 3 mm bore was finished by the 3 mm NC reamer.
Then other hole is for a 4 mm shaft.
The recommended speed for the 4 mm NC reamer is 1.400 u/min.
I have withdrawn the  idea to ream it with the CNC mill here, it will be done later at the conventional mill.
Kind Regards
Achim