Farm Boy

[Dalboy]

I acquired a small amount of metal from a deceased model engineer most of it was ali as can be seen the large disks were all over 2 1/2" thick(the piece on the left is 4"diameter to give an idea of size) There was also brass and bronze rods all over 1" thick and the shortest 12" up to 24" long. So I looked around for a small project I could use some of it on. Finally decided on the Farm Boy engine.

Cut and squared up some of the ali into blocks so I had a datum to work from.

I also ordered a couple of flywheels.

Because of the Christmas break I needed something simple to get back into the workshop as I had been doing some woodwork and making Christmas present(which were well received) So I turned the pulley as it was not going to be put to work I make that out of a slice of the 4" bar.

Finally down to making a start on the front base so now the serious work begins. A small note in that I will be machining this along side a Rob Roy 0-6-0 locomotive

[RReid]

That's a nice haul of "parts-in-waiting". I'll follow your progress with interest.

[vtsteam]

Yup, definitely going to follow along! 

[Dalboy]

Managed some time in the workshop as I have been busy with other things.

Started with a small tidy up before setting up and machining one part of the main frame, thing hopefully will get done now that I have started back again even if it is not this but the Rob Roy.

[Dalboy]

A little more done to the front body of the farm boy need to round over the top and hollow the centre out next. It is slow but then it is not a race I am just enjoying time in the workshop.

[Phil1965]

This engine is on my to do list starting to gather materials. I’ll will be watching with interest.

[Dalboy]

This engine is on my to do list starting to gather materials. I’ll will be watching with interest.

I kept looking at it after seeing someone build one on u tube and I had all of the material in my stock.

Anyway today set up and machined where the front and rear frames will join hopefully get some of the material out of the centre which means that I do not need to set up again as most of it can be done in this position.

[Dalboy]

Started to rough out the bulk of the material, need to take it deeper then I will change the cutter for a smaller diameter and machine to the correct size before setting up on the rotatory table to do around the hole.

 

[Dalboy]

Nothing done yesterday except make a mess turning down a lump of metal for a ER collet holder to fit the lathe.

I have managed to deepen the pocket and take it to depth width and to the position of the bottom. Still need to do the inside around the hole to the same depth and to bring the diameter to match the width. it will become clear when I do that.

[Dalboy]

Finished hollowing out even though I made a small error in machining but that does not effect the finished engine

Next onto making an aid to help the next machining just a simple turned item

in place on the rotary table along with the part in position. Both the rotary table and the part need to be secured before any machining is done

[Jasonb]

it's starting to take shape

[Dalboy]

it's starting to take shape

Thank you Jason. Very slow but I am learning a lot from this and the Rob Roy I am building. Yes there has been the odd mistake.

[Dalboy]

Spent the morning setting up the rotary table with the part secured to it. The afternoon was spent with a little machining as that part did not take as long as the set up. This means that the majority of the main machining on this part is complete just some holes to do and then onto the rear part which attaches to this. Not so much setting up.

Some pictures of the machining and then the part as it stands now

[Kim]

That looks really nice!  You've got a lot of operations into that part! 
Kim

[Dalboy]

That looks really nice!  You've got a lot of operations into that part! 
Kim

Thank you, I certainly learnt a lot of how to hold and machine the various operations on this piece.

[Admiral_dk]

Good progress and great result so far 

Per

[Dalboy]

Thank you Admiral_dk

This bring me to todays work not had much time so managed to mark out for some of the machining to the rear base.
This is mainly to keep me on track as most of the work is carried out using the DRO.



Starting on the end that will eventually join the front still need to remove more from the two steps as can be seen as I have not reached the lines for these

[Dalboy]

Only had a little amount of time in the workshop but did manage to get the joint done.

With the cutter I used I needed to machine 1" from the centre line but when I offered up the front section as I was machining it slipped on at 1.0021 which I am happy with.

Now to start machining the outsides down to size which have two protrusions on one side and one on the other.

[mikehinz]

I'm following along closely!  I'm just completing the posting of my build and it's always interesting to see how others approach a project!

Great work so far!  I'm enjoying it.

Mike

[Roger B]

Coming along nicely   

[Dalboy]

I'm following along closely!  I'm just completing the posting of my build and it's always interesting to see how others approach a project!

Great work so far!  I'm enjoying it.

Mike

That is what I do as a total novice at using these machines I am always learning. Mine is a bit slow as I am building the steam loco as well as trying to get the garden sorted after the winter which involves sowing hundreds of seeds which I also really enjoy doing

Thank you @Roger B

[Dalboy]

Work on the Farm boy has been slow due to other things need doing.

I have managed to taper the rear frame with the aid of some angle blocks. I did drill and ream to final size the radius before cutting away the bulk of the metal to save time as well as reduce the amount of swarf it would have produced.

Reset the frame in the vice and machine out the gear side of the part I did not put a radius on the bottom as I did not have a bull nose bit of the correct size.

Next the other side need doing that being simpler as there is only the boss for the main crank.

[Dalboy]

All of the outside machining done on the mill still need to do some drilling. Now to do the inside.

This is just a test fit and everything that should line up does. One more large piece to do and then it is all the small pieces that need making

I need to blue it up again to mark out the for the inside.

[Kim]

Very nice!  That's a lot of work to get to this point!  I'm still following along 

Kim

[Dalboy]

Back on the build today as I have been busy with the garden and making a replacement back plate for my collet chuck, pictured with the old thinner one.

I treated myself to a roughing end mill and used that to rough out the rear frame and I am very pleased at how quick it removed material.

[Dalboy]

Machined the rear internal section to final dimensions by milling with a straight cutter and leaving a step in the bottom this was then followed with a 1/4" bull nose mill to give the corner a radius, and then reset to an angle of 8deg to machine the rear wall to correct thickness again using the bull nose to complete the internal corners.

Need to drill some holes as well as a curved section in the rear wall to allow clearance for the con rod to swing

[Dalboy]

Only had a short time in the workshop today working on the Farm Boy. Rear frame main machining complete finished the rear cut out section for the con rod big end to revolve freely.

[Admiral_dk]

Very nice result so far     

Per

[Dalboy]

Very nice result so far     

Per

Thank you I am a little slow as I have other things that need doing one of which is going out last week and giving a demonstration on woodturning.

Very little done today found a lump of ali chopped off a piece, squared it all round and machined to final thickness. Cut a piece off the end and cut this in half before machining the other measurements to the final size for the crankshaft top bearing blocks. See the first two pictures

I also spent some time cleaning up the inside rear corner which had a little step in it all be it less than 0.005 but still visible and it would have annoyed me seeing it even if it is partially hidden when this is complete.

Still one main large piece to machine then it is onto all the little bits and pieces which should be fun

[Dalboy]

I am waiting for some BA fixings so that I can drill some of the holes in the rear section of the frame, so I thought I would start on the hopper assembly well the hopper top at least. The fitting I am using are the closest ones to what the plans state as BA are easier to obtain as well as I already have taps and dies in BA.

[Dalboy]

Machined out the water hopper. by doing this first it will reduce weight for when I machine out the through hole for the cylinder liner which will reduce any tendency to bounce the machine around(not that I think it will be much problem)

I did start on the mill but decided to transfer it to the lathe which is what I should have done to start with as I was getting a better finish to the bottom and also found it easier to get the right dimensions, I am still learning. A recess  was machined for the top to fit which I made the other day I did manage to get it just under 0.002" so a little heat to the hopper should allow it to slide in, that will only happen once all the machining and drilling is complete.

[Dalboy]

Over the last couple of days I managed to bore out for the cylinder liner as well as drill three holes to connect this part to the front base unit. The forth hole is for a oil passage with a recess for an O ring to seal it when they are bolted together

Marked out for the oil passage down to the cylinder liner

Set up and drilling of the oil passage using a couple of angle plates to set it at 18deg. Once set on the mill spot drilled and then drilled through to join the one on the joint

I needed to flip the part so I could countersink for some cap head bolts, after which reset the DRO to perform a 4 bolt pattern and lightly marked them ready for drilling and threading tomorrow. These are for the head fixing and as can be seen they are quite close to the other top bolt holes