Author Topic: Mills 1.3 (Read 4037 times)

Ghosty · « **on:** January 05, 2023, 07:33:16 AM »

Hi All,
I looked into making a Mills 1.3 engine as they are getting very hard to get.
Found a web site with plans https://outerzone.co.uk/plan_details.asp?ID=13735
Printed the plans out and studied for a few hours. Have found many mistakes in downloaded plans in the past.
Found a mistake, width of the starter block for the crankcase was marked at 1-9/16" wide. on plans the width of the crankcase is total of 1.654" a difference of 0.0915".
After double checking dimensions, I checked on what I had at hand. I had enough to get started with.
First got the material cut, then squared up and sized the block for crankcase.
Then marked out and drilled 4 holes for the mounting lugs, then drilled and tapped the 4 holes for the cylinder mounting.
Will move on to crankcase machining tomorrow.
Cheers
Andrew

Kim · « **Reply #1 on:** January 05, 2023, 05:33:01 PM »

Looks like a fun little engine to make. Hopefully, the errors in the drawings won't be too much of a distraction.

Kim

Ghosty · « **Reply #2 on:** January 06, 2023, 03:57:57 AM »

Hi All,
Started the machining of the crankcase, setup, trued and centered, machined crankshaft pocket and bore, and threaded for backplate, thread is listed at 26TPI, as I can't cut imperial threads on my lathe, I used a 1mm pitch and the dia listed on the plans.
Then rotated the case, trued and centered then machined the cylinder bore.
Then moved to the mill, machined conrod relief, exhaust ports, and transfer port.
Will now move on to machining the outside or the case.
Cheers
Andrew

Admiral_dk · « **Reply #3 on:** January 06, 2023, 11:59:36 AM »

Looks like a good start to a fine little Classic Engine

Will follow with interest

Per

Roger B · « **Reply #4 on:** January 06, 2023, 02:36:57 PM »

That's off to a good start

I will be following along

Ghosty · « **Reply #5 on:** January 07, 2023, 02:19:23 AM »

Hi All,
Got on with the outside of the crankcase/body.
Started with the base/engine mount lugs, then the top sides, then cut the sides to the angle.
Then machined up two jigs to hold the case to machine on the lathe.
Machined the nose of the case and then on to the mill again to machine the base of the case.
Then glass bead blasting to get the finish on the case, then back on the lathe to do the final machining(sorry no pics of machining) of case.
Great care is needed when you do this step so you don'y drive the tool into the case.
Cheers
Andrew

Ghosty · « **Reply #6 on:** January 07, 2023, 02:20:15 AM »

Some more

Ghosty · « **Reply #7 on:** January 07, 2023, 02:24:58 AM »

Hi All,
P.S. Remounted crankcase to show final cutting of case. tool post compound set at 7deg for cutting.
Access for grub screw is through the crankshaft pocket.

Cheers
Andrew

crueby · « **Reply #8 on:** January 07, 2023, 02:25:44 AM »

Excellent job on those parts! The bead finish looks great!

Ghosty · « **Reply #9 on:** January 07, 2023, 03:02:48 AM »

Thanks, crueby, the finish that I get from doing this also hi-lights the machined section
Cheers
Andrew

Admiral_dk · « **Reply #10 on:** January 07, 2023, 11:17:18 AM »

Two great looking Crank-/Engine- Cases/Blocks

Very good progress in my book

Per

Don1966 · « **Reply #11 on:** January 07, 2023, 04:31:10 PM »

Nice work…..

Don

Ghosty · « **Reply #12 on:** January 08, 2023, 03:02:19 AM »

Hi All,
Worked on the cylinder today.
Machined the first end out of square bar, thread should have been 0.540" x 26TPI, I used M14x1(0.551") as I cant cut imperial threads on my lathe.
Then, with a bit of 19mm hex bar, I drilled and tapped M14x1 to use as a jig to hold the cylinder , so I can machine the other end.
I machined down the other end to fit the case body, then drilled and reamed to 0.406".
Then I started on the cooling cap. Drilled and tapped M14x1, and checked fit of cylinder.
Machined the cooling fins, parted off, tapped for compression screw, then machined compression screw and assembled.
Cheers
Andrew

Ghosty · « **Reply #13 on:** January 08, 2023, 03:03:07 AM »

And some more

Roger B · « **Reply #14 on:** January 08, 2023, 01:25:22 PM »

Excellent

RReid · « **Reply #15 on:** January 08, 2023, 03:56:44 PM »

Outstanding work! I really like the satin look of the cases contrasted with the shiny fins.

Ghosty · « **Reply #16 on:** January 09, 2023, 03:58:15 AM »

Hi All,
Started on the crankshaft today, machined the crankshaft bearings from bronze and installed in cases, then reamed to size.
Machined and tapped the nut from 7/16" hex bar.
Centre drilled the crank blank, and then machined the end down for the threaded end as per plans.
Then machined crank down to suite the bearings, then machined taper on shaft.
Machined the prop drive hub, cut slots to drive hub instead of using drive pins as plans.
Cut groves with tool on side, 15thou deep.
Cheers
Andrew

Ghosty · « **Reply #17 on:** January 09, 2023, 03:59:13 AM »

And a couple more.

Kim · « **Reply #18 on:** January 09, 2023, 05:08:16 AM »

Wow! Your engines are looking fantastic! And they're really coming along quicly. You work at Chris's speed

You didn't happen to pick up any of Chris's shop elves did you?

Kim

Ghosty · « **Reply #19 on:** January 09, 2023, 08:34:58 AM »

Quote from: Kim on January 09, 2023, 05:08:16 AM

You didn't happen to pick up any of Chris's shop elves did you?

Kim

Kim,
No elves, it has just been basic machining so far, the major time will be when I get to the piston and contra piston, fitting to cylinder.
Cheers
Andrew

Ghosty · « **Reply #20 on:** January 10, 2023, 04:17:37 AM »

Hi All,
Started on the fuel tank/venturi today.
Machined the tank body from Perspex and alloy.
Machined needle valve from 1214, machined venturi/needle/jet in two pieces. Machined nut(5/16) from 10mm round bar.
Assembled needle/jet/ fuel tank top/venturi with loctite, when set drilled through and then cleaned out jet and needle threads.
Cut fuel tube piece and assembled fuel tank.
Cheers
Andrew

Admiral_dk · « **Reply #21 on:** January 10, 2023, 11:23:57 AM »

That was a very quick build and the result looks Great

They appear to be ready for first Pop

Do you have Props, fuel and experience running and breaking in CI (Compression Ignition) Engines ?
If not - you should do a bit of reading on Adrians Great page :https://adriansmodelaeroengines.com/
See about Fuel, Break in :https://adriansmodelaeroengines.com/catalog/main.php?cat_id=3

Hope to see a Video of them running

Per

Ghosty · « **Reply #22 on:** January 10, 2023, 07:47:33 PM »

Quote from: Admiral_dk on January 10, 2023, 11:23:57 AM

That was a very quick build and the result looks Great

They appear to be ready for first Pop

Do you have Props, fuel and experience running and breaking in CI (Compression Ignition) Engines ?
If not - you should do a bit of reading on Adrians Great page :https://adriansmodelaeroengines.com/
See about Fuel, Break in :https://adriansmodelaeroengines.com/catalog/main.php?cat_id=3

Hope to see a Video of them running

Per

No piston, and the crank is not finished yet. So far it is only basic machining, nothing to hard. I hope to get the conrods done today. I have been involved with model aircraft for over 45 years, yes I have all the stuff. Building these because the originals are very hard to get and I have a couple of aircraft I would like to build.
Cheers
Andrew

Admiral_dk · « **Reply #23 on:** January 10, 2023, 09:06:58 PM »

Ups - I forgot that I haven't seen you do those

45 years of experience should defenitely do it - so no reason for me to think about show and tell

Per

Ghosty · « **Reply #24 on:** January 11, 2023, 02:50:14 AM »

Hi All,
Started with conrod machining today.
Used a piece of 7075 10mm alloy plate, cut a 10mm slice off and squared up.
Marked out and drilled and reamed big and little ends to size.
Then machined to thickness, then machined centre section to thickness.
With the use of a 1mm(big end) and a 1.5mm(little end) drill bits I machined the outer sides to size.
Then machined the outer big, and little ends.
Still have the final finishing to do.
Cheers
Andrew

Ghosty · « **Reply #25 on:** January 11, 2023, 02:50:59 AM »

And some more

bent · « **Reply #26 on:** January 11, 2023, 05:30:26 PM »

Wow, miss a few days and Andrew bangs out a nearly complete engine!

Agree with others, the grit blast finish makes a lovely contrast with the machinined areas.

Ghosty · « **Reply #27 on:** January 11, 2023, 07:56:48 PM »

Quote from: bent on January 11, 2023, 05:30:26 PM

Wow, miss a few days and Andrew bangs out a nearly complete engine!

Agree with others, the grit blast finish makes a lovely contrast with the machinined areas.

Thanks for the vote of quality of finish.
So far it is only straight up machining, just following the plans, things may slow down when it comes to the piston/contra piston, as the fit have to be exceptional, I have the tooling to check cylinder bore/taper. So I hope every thing goes well, I will just be taking my time.
Cheers
Andrew

vtsteam · « **Reply #28 on:** January 12, 2023, 02:12:40 AM »

I very much like your method for shaping the connecting rods, and the crankcases look wonderful!

Why do the connecting rods look gray in the middle. Is that tape?

jcge · « **Reply #29 on:** January 12, 2023, 02:59:09 AM »

Andrew - lovely engines and some clever workholding well illustrated !!
Regards
John

Ghosty · « **Reply #30 on:** January 12, 2023, 05:27:12 AM »

Quote from: vtsteam on January 12, 2023, 02:12:40 AM

Why do the connecting rods look gray in the middle. Is that tape?

vtsteam,
No its just the way the light reflected of the milled surface.
Cheers
Andrew

Ghosty · « **Reply #31 on:** January 12, 2023, 05:28:18 AM »

Hi All,
Finished of machining of the crankshaft today.
First machined up a jig to hold the crankshaft with correct offset for big end.
Fitted crank in jig and then machined the big end to suite the conrod.
Then moved assembly to the mill to machine the crank webs.
Cheers
Andrew

Roger B · « **Reply #32 on:** January 12, 2023, 08:22:02 AM »

Excellent work on some tiny pieces

The ruler next to the conrod bought home to me how small these engines are

Admiral_dk · « **Reply #33 on:** January 12, 2023, 10:46:38 AM »

Fine looking Cranks and Rods

So contrapiston, piston and pin left to do or ...?

Per

Ghosty · « **Reply #34 on:** January 12, 2023, 09:14:24 PM »

Hi All,
Thanks for the kind words from you all.
Yes Admiral_dk, only the squeezy bits to do, hope to get them done on one engine today.

Cheers
Andrew

Ghosty · « **Reply #35 on:** January 13, 2023, 12:09:35 AM »

Hi All,
PROBLEM:- Getting small diameter cast iron round bar.
FIX:- Make your own.

I have some 40mm(1.575") round bar, cut length off of it, I have a 1mm(0.040") slitting saw, cut the round bar into quarters.
Pieces almost triangular, fit into 3 jaw and machine round.
Now have a piece almost 14.5mm(0.565") in dia, A lot less waste that machining the 40mm bar down to size, and I also have 4 pieces.
Now to make the pistons.
Cheers
Andrew

Kim · « **Reply #36 on:** January 13, 2023, 01:19:27 AM »

A pretty ingenious way to get smaller round CI!

Kim

crueby · « **Reply #37 on:** January 13, 2023, 01:36:10 AM »

Now that's thinking!

Ghosty · « **Reply #38 on:** January 13, 2023, 02:40:59 AM »

Kim, creuby,
I just thought there had to be a way to get smaller dia cast iron, my supplier can only supply 30mm as smallest, I had the 40mm on hand as I used it for liners on another engine I built. Done a couple of quick measurements and away I went.
Had to do the same with some bronze bar to get material for some conrods.
Cheers
Andrew

Ghosty · « **Reply #39 on:** January 13, 2023, 05:18:04 AM »

Hi All,
Up until now I have been making the parts for two engines. Now I will be working on just one engine at a time.
Started the most exacting part of the build. Started with lapping the cylinder, very messy part of the build.
Then machined and fitted the contra piston to the cylinder.
Then from the same blank, I machined the piston and then lapped for fit in cylinder, more mess.
Then cleaned in ultrasonic cleaner and then assembled complete engine.
We are almost there, now on to the starting bit before finishing the other engine.

Cheers
Andrew

vtsteam · « **Reply #40 on:** January 13, 2023, 03:25:02 PM »

I've learned a lot through your build.

What are the dowel pegs for in the last photo?

Ghosty · « **Reply #41 on:** January 13, 2023, 07:24:03 PM »

Quote from: vtsteam on January 13, 2023, 03:25:02 PM

I've learned a lot through your build.

What are the dowel pegs for in the last photo?

Glad that it helped, you will learn a lot through sites like this.
Had a couple of coach bolts come loose, they hold up the TV antenna, unscrewed the bolts, inserted a couple of the dowels refitted bolts, nice and tight.
Cheers
Andrew

Ghosty · « **Reply #42 on:** January 13, 2023, 08:49:22 PM »

Hi All,
Well after a little bit of playing around, "IT'S ALIVE", After about 20mins of runtime now it's swinging a 9x6wide blade with no problems.
Now on to the other engine.
Cheers
Andrew

<a href="https://www.youtube.com/watch?v=b878EoPAqq4" target="_blank">http://www.youtube.com/watch?v=b878EoPAqq4</a>

jcge · « **Reply #43 on:** January 13, 2023, 09:26:59 PM »

What a great little engine and build log - congratulations Andrew.
Would you mind sharing what fuel you are using ?
Regards
John

Ghosty · « **Reply #44 on:** January 13, 2023, 10:14:01 PM »

John, just 1/3 castor, kero, ether.

Hi All,
What is better than one engine running, how about in stereo. Sorry no sound until 1:40min
Cheers
Andrew

<a href="https://www.youtube.com/watch?v=u8g5T1yJdps" target="_blank">http://www.youtube.com/watch?v=u8g5T1yJdps</a>

Kim · « **Reply #45 on:** January 13, 2023, 11:46:02 PM »

Wow! That's quick work to go from nothing to a two great runners like you have here!

Well done Andrew!

Kim

Ghosty · « **Reply #46 on:** January 13, 2023, 11:52:31 PM »

Kim,
I was building two to start with, only piston had to be done for the second, not hard just had to be careful with the size of the piston.
Cheers
Andrew

RReid · « **Reply #47 on:** January 14, 2023, 01:05:44 AM »

Two great runners, congratulations! Did you build two to power a model aircraft twin?

vtsteam · « **Reply #48 on:** January 14, 2023, 01:06:44 AM »

Amazing speed and workmanship! And two runners right off the bat. Must feel great!

The sound of those engines brought me back to flying U-control 1/2As in the sixties. Of course your engines are a lot more powerful. But hadn't heard that sound in a very long time. I can still smell the fuel, and feel the knicked knuckles, and because they were glow engines, remember the big dry cell starting batteries we brought. The excitement of flying a new plane. I remember it.

Ghosty · « **Reply #49 on:** January 14, 2023, 02:02:28 AM »

Hi All,
Thanks for the kind words everybody.

vtsteam, the bulk of the build was just straight up machining, the piston fit is the only problematic part of the build, but when you have everything ready to go, it goes smoothly.

And thus endith the build of these engines.
Now to build the planes for them.
Cheers
Andrew

Admiral_dk · « **Reply #50 on:** January 14, 2023, 11:43:23 AM »

Like the rest - I think that was a very fast build and the result is two great Runners (and starters)

What kind of plane(s) do you have in mind ?

Per

Ghosty · « **Reply #51 on:** January 14, 2023, 07:38:26 PM »

Quote from: Admiral_dk on January 14, 2023, 11:43:23 AM

What kind of plane(s) do you have in mind ?

Per

Type of plane is already started, will take longer than build of engines
Cheers
Andrew

vtsteam · « **Reply #52 on:** January 14, 2023, 09:36:15 PM »

Classic high wing cabin job.

jcge · « **Reply #53 on:** January 14, 2023, 10:49:33 PM »

Two running engines - superb Andrew !!
When you say 1/3 castor, kero and ether......where in OZ do you get the ether? I have only ever run methanol glow engines....
Regards
John

Ghosty · « **Reply #54 on:** January 15, 2023, 12:23:21 AM »

Quote from: jcge on January 14, 2023, 10:49:33 PM

Two running engines - superb Andrew !!
When you say 1/3 castor, kero and ether......where in OZ do you get the ether? I have only ever run methanol glow engines....
Regards
John

John,
You would have to go to West Wyalong Free Flight site, or to an Oily hand event to get ether.
Cheers
Andrew

Admiral_dk · « **Reply #55 on:** January 15, 2023, 10:12:28 AM »

Classic Engine for a Classic Model Aeroplane - that makes sense

RC or Line Controlled ?

Please a picture or two of the finished plane (and maybe without fabrick)

Per

jcge · « **Reply #56 on:** January 15, 2023, 10:03:32 PM »

Thanks for the ether sources Andrew - much appreciated.
Regards
John

Roger B · « **Reply #57 on:** January 16, 2023, 02:09:40 PM »

Splendid work

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Author Topic: Mills 1.3 (Read 4037 times)