1837 HMS Gorgon Engine

[RReid]

With the 2-Bits v-twin nearly completed, I started thinking about the next project and decided to make it a return to steam. The 1837 HMS Gorgon engine as built by Guenter Kallies caught my eye and my interest. His plans and write-up on the build may be found here:
https://modelengineeringwebsite.com/Gorgon_engine_build.html

Here's an image of the ship, and a shot of Mr. Kallies finished engine.




For my build I'm scaling the plans to 70%, which allows me to use a bar of 1” OD stainless I have on the shelf to get the cylinders out of. In Alibre I can model the parts using the metric dimensions on the Kallies plans, scale that, then can produce a working drawing with either metric or imperial dimensions (for me in the US, imperial is generally more convenient).

During some dead time while waiting for ignition parts for my v-twin engine build, I made a start on the SS cylinders, bronze pistons (without o-ring grooves yet), SS piston rods, and brass cylinder caps.

[crueby]

What an interesting looking engine!  Just took a quick look through the article link you posted, the condensors and pumps out the side really will look good when moving, all those links should be great.
Watching along!
 

[kvom]

Lots of ship engine builds nowadays.  This is very interesting, although the 100% brass is a bit monochrome for me.

[crueby]

Lots of ship engine builds nowadays.  This is very interesting, although the 100% brass is a bit monochrome for me.

Could always add a little paint or powdercoat for accent color.

[RReid]

This is very interesting, although the 100% brass is a bit monochrome for me.

For me as well. No reason for it to be 100% brass, and mine won't be.

[RReid]

OK, I'm starting to focus more on this project now. I don't think I'll do a detailed build log this time though, but will just update my progress periodically.

Both cylinders have been completed, with the exception of drilling/tapping for the studs that will fasten the steam chest. It looks like those may have to be 1-72, so care will be required tapping the stainless. I will wait to make the chest cover first, and use that as a drilling template for everything that goes under it.

The cylinder covers are fastened with 2-56 screws, and that went fine. I helped myself by drilling one size over the normal tap drill. Fear not, those SHCS will be replaced by studs eventually.

[Craig DeShong]

Wow, lots of moving parts.  I’ll admit that I’m struggling to envision all the movement.  This is going to be an interesting project.

 

[Michael S.]

Hello Ron,
you have chosen an interesting machine. The book on building the machine has been in my closet for a number of years. At exhibitions you could often see good and less well built models. I like that you don't make everything out of brass.

Michael

[RReid]

Hi Craig and Michael, and Thank you both. (I'll try to do better than "less well built" )

[RReid]

I've gotten the port plates, chests, and chest covers chunked out and attached to the cylinders.

I was nervous about tapping 16 1-72 holes into stainless until I realized I didn't really have to tap very deep. A few threads would be enough to hold the studs firmly vertical, then I would lock them in with red Loctite. This worked out well. The studs started as 1-72 hex head screws. I made some "tall" nuts from 1/8" hex stock. These were threaded on up to the screw heads. Then the screws got a tiny bit of Loctite on the end and were inserted through the valve chest parts and into the cylinders, using the heads to tighten down. The nuts were then run down to the chest cover. After allowing time for the Loctite to cure, the screw heads were cut off using a Dremel and an abrasive cut-off wheel.

The valve glands and steam ports are still to be added.

[steamer]

That is coming along swimmingly Ron!    Brass is such a nice material to play with, it just does what you want it to do and then it looks great too!

Dave

[crueby]

Looking great!   

[steam guy willy]

An interesting prototype to build and I will be following closely.....
Willy

[RReid]

Thanks Dave. I try to be an equal opportunity metal butcher, but you're right, brass is awfully nice!

Thanks Chris!
Glad to have you along, Willy.

[Kim]

Looks really nice Ron! 

So, did you Loctite the port plate onto the cylinder rather than silver soldering it?

Kim

[RReid]

Thanks Kim.

So, did you Loctite the port plate onto the cylinder rather than silver soldering it?

No, the only parts Loctited into the cylinder are the studs. The port plate in the photo seemed to be happy standing there in its place on the studs, so I left it, but it is a separate part like the chest and cover.

[Kim]

Thanks Kim.

So, did you Loctite the port plate onto the cylinder rather than silver soldering it?

No, the only parts Loctited into the cylinder are the studs. The port plate in the photo seemed to be happy standing there in its place on the studs, so I left it, but it is a separate part like the chest and cover.

Interesting!  So it's just another surface to seal, like the steam chest and the steam chest cover.  Cool.  I've not run into that before.  But why not?  Makes as much sense as the steam chest being a separate part I guess.   

Thanks for the additional explanation for me, Ron. I'll catch up to everybody else eventually! 
Kim

[RReid]

Been busy getting the valve chest attachments and innards made up and installed. Below is the valve rod, with (L - R) the gland (wrong way around on the rod in front), valve nut, and what the plans call a plug, but is also the guide for the tail end of the valve rod. The rod is stainless, and that tail end is only 0.055” diameter. Took a bit of tooth gnashing lathe, file and sandpaper work to get that down to size and smooth.




With those parts done it was time to turn to the valves themselves. First the topside features were cut.


Then the stock was flipped over to cut in the exhaust pockets and separate the two valves from the bar.


I thought the chest covers were a little too plain, so took a light cut around the edges to leave a raised central boss. The edges were polished a bit, while the bosses were left dull. Simple, but I think more interesting to the eye.

[crueby]

Beauty!

[Kim]

Looking good, Ron! 
Don't you love these two-cylinder engines?  Two of everything! 

Kim

[Admiral_dk]

Very nice looking Cylinder assemblies - you should be happy with them     

Following along with interest     

Per

[RReid]

Chris, Kim, and Per - Thanks a bunch!

Don't you love these two-cylinder engines?  Two of everything! 

Right! Doing things twice (or three times with mistakes) is within my comfort zone. Something like a Cosworth V8 with 4 valves/cylinder would probably drive me batty, though I greatly admire those who tackle projects like that. (Hint - there is a Twin Cam Twin beginning to take shape inside my computer).

[RReid]

It seems to be our turn around here to get a share of the stinking hot weather. As I write it is 2:30 in the PM, 107F (42C) outside in the shade, and ~116F (47C) in the garage, with the doors open. As a result, shop productivity is at a low ebb. Still I have been getting some things done.

In the photo is a collection of mostly unfinished parts. Across the top are the makings of the crankshaft and a pair of oil cups for the big ends. Below that are parts that will become the frame columns. One is loosely assembled as an example.

[Kim]

That's a nice set of beautiful parts there, Ron! 

And yeah, either 107 or 116 F is stinking hot!  TOO hot!  Anything over about 75 is really too hot if you ask me!

It only got up to 94F for us up here in the Portland area.  You guys are having it rough right now!

Kim

[RReid]

Thanks Kim! Yeah, 75 sounds good to me. Coastal fog is our friend, and I'll be glad when it comes back.

[RReid]

A lot less hot today, but still hot enough to drive me out of the shop by mid-afternoon.

I decided to go back to the beginning a make the Base Plate for this engine. I cut it out of 16 gauge sheet steel, and just gave it a coat of primer for now. I'm thinking of cutting some scribed basswood I have to make a “deck surface”, but first I have to find where I hid that sheet...

Holes for the stainless columns and cylinder assemblies were located and drilled, so those parts can now be mounted in position.




The Upper Plate was also roughed out, with the holes for the upper end of the columns drilled at the same time as the base plate. The columns still need to be drilled and tapped at the top, so the plate is just resting loose in the photo. The crankshaft lives up there on the upper level. The openings for the connecting rods and eccentric rods to pass through have not been cut in yet.

[RReid]

I decided not to use the steel top plate I showed previously, but opted instead to make one out of aluminum. This allowed me to match the thickness called out on the plans (but scaled to 70%) so I won't have to adjust the length of the conrods as I would with the thinner steel. It's also stiffer, and looks better.


I've also been working on the crankshaft bearing supports that mount to that top plate.




The “studs” are actually SHCS inserted into counterbored holes from underneath and threaded into the lower half of the bearing support.


I've also pieced together the crankshaft and turned up a flywheel. At this point though the crank is not yet fully drilled and pinned.

[crueby]

Really coming together, looking great!   

[Kim]

Wow!  I'll say!  That's really coming together nicely, Ron!   

Kim

[Dave Otto]

Great family shot!
Nice work Ron.

Dave

[RReid]

Chris, Kim, and Dave - Thank you!
Speaking of family shots, it's now time to spend some time with the oldest son and his family.

[Admiral_dk]

Lovely Family shot    and I agree - the Aluminium 'Plate' looks much better 

Per

[RReid]

Been away visiting the Oregon branch of the family, so no shop time. But I did have my laptop and had time while the kiddies were at work and school to work on drawings for a proposed next project. Actually two proposals, either a DOHC inline twin, or a full on DOHC 4, both meant to give a big nod to the Alfa Romeo Giulietta/Giulia engines. The twin I call the Halfa (ryhmes with Alfa) and the 4 cylinder the Bialbero (Italian for "twin shaft"). Still plenty of details to work out, but since we will be quickly heading off to TX to see that branch, I'll have that to work on.

[Kim]

Those look like some fun projects!  Hope Oregon treated you well while you were here!

Kim

[crueby]

Oh boy, more projects to look forward to! 

[RReid]

Thanks Kim, Chris!

Hope Oregon treated you well while you were here!

We always have a good time in Oregon, and often "treat" ourselves on the way home. This time we spent the night on the CA side in Dunsmuir at the Railroad Park Resort. Very nice place, you can stay in a caboose, a cabin, or in the campground. We opted for a cabin this time because I wasn't sure my wife would like the ladder up to the cupola of a caboose, but she thinks they're cool and wants to try one next time. Dinner in the dining car restaurant was excellent. At one time Dunsmuir was the base of a helper district with SP cab-forward Mallets added onto trains to battle the grade up toward Shasta.






When is a Shay not a Shay? When it's a Willamette. Made in Portland, OR after the Shay patents expired, but also with significant upgrades like superheat, Walshaerts valve gear, and piston valves. This is one of six said to survive.

[Kim]

Wow, Ron! That looks fun!  I've been through there a few times and never knew there was a railroad park there! And that Willamette is pretty neat!  I never knew about that either.  I've got so much to learn!   

Kim

[Admiral_dk]

Thank you for showing the pics - Like Kim - I never heard of a Willamette 

Per

[Roger B]

Still following and enjoying     

Those twin cam engines look fun, especially trying to fit water passages in the head. Long ago in the UK there was a man racing a Mini with a two cylinder Cosworth BDA which he had made from a blown up four cylinder version.

[RReid]

What a neat little engine! Thanks for that, Roger. I have an idea about designing a narrow angle Cosworth style head that could be interchangeable with the wider angle Alfa style head. But having the thought is all I've done so far.

My designs deviate from Alfa practice and will be more BDA'ish in the use of toothed belts to drive the cams instead of chain. I agree about fitting water passages in the heads; it remains to be seen if they'll get that feature or not. I'll go into more detail about the design options and final choices after I finish the Gorgon engine, finish the design phase, decide which of the two versions to build, and start a thread!

[RReid]

Looking back, I see that it's been two months since the last actual progress update on this engine. Most of that time involved visits to one or another set of kids/grandkids, including 3 weeks in TX bracketed by a week of travel going and a week and a half coming back. While away, I did get a lot of design time in on the two DOHC engines mentioned in a post above. So much time that I'm now excited to actually start building one. The Gorgon was always kind of a time filler while I completed those designs, but I didn't really expect to get so far with them so soon. Now I think I'm going to back-burner this project to get started on the Halfa build.

However, before leaving for TX I had made a start on the Gorgon connecting rods. The plans suggest a 3-piece construction, with separate big and little ends connected by a round tapering “web”. I thought I could turn them as one piece from rectangular bar and went down that road. To my dismay, twice I got toward the small end of the taper and the cutting forces broke the work off. The second time I used a finer radius on the cutting tool and less feed, but still broke it. Frustrating, since I've done smaller diameters in brass than that successfully. Just to cocky and careless I guess.

Now back in the shop, I thought I would finish those up before switching projects. I figured I would salvage them by making new small end pieces and silver soldering them together per the plans. That went fine on the first one. The second one though, just as the solder melted into the joint and I was about to pull the torch away, the web melted/broke. Fudge-nuts! Oh well, I think I'll pause here for now.

[Kim]

Ugh... That's frustrating! 

Gald you had some visits from the grand kids!  That's always fun!

Kim