Warrior Double acting twin cylinder steam engine from castings

[Zephyrin]

and what about leaving a straight edge on the steam ports "merely" with a little chisel as suggested by LBSC on several occasions?

[steam guy willy]

Back in the workshop  and yes "Z" I have now transferred the cylinders to the mill and cut the 1/8th slots to size ...I am waiting for a 3/32nd cutter for the other slots.  I have made more calculations for all the dimensions converting fractional inches to decimal inches ....and used the height gauge to mark them all out ... I have just purchased this  digital item and it is a lot easier to use than the analogue one. I have used my eyesight to position them on the mill using X 4 reading glasses....

Willy

[steam guy willy]

Have now started on the steam chests and there are threaded items at both top and bottom and  to drill the holes in alignment I insert a piece of perspex in the cavity, this then insures that the drill will not wander in the cavity. I now need to reverse the steam chest in the 4 jaw chuck and drill with a larger drill and tap for the top fitting. I am following the Bertinat upgraded model and this steam chest has the top fitting so the extended valve rod is held in position to prevent the valve lifting.

Willy

[RReid]

I like that idea of a simple perspex cavity filler for the drilling operation.

[Michael S.]

Hello Willy,
Nice to see how well you're progressing.
I'm looking at your pictures with great interest and trying to remember the individual construction steps.

Michael

[steam guy willy]

Hi all  thanks for the comments and I am now doing more work on the other cylinder block ...so quite repepative,,I have attached the steam chest and I am waiting to receive a 3/32 slot mill for the other ports...And wishing everybody a productive and happy new year

Willy

[steam guy willy]

I have made a couple of component holders for the valve rod tail guide and valve rod glands   these are 7/32nd X 40 and  1/4 X 40 TPI. they are made with silver steel ,hardened and are drilled and reamed to help with drilling these components .

Willy

[steam guy willy]

The valve rod glands have been made ..first the blank is drilled and tapped ..then the diameters turned and the blank sawn off. The blank is then screws onto the jig and turned to width and the six filing lines put on using the 3 jaw chuck jaws as a guide. the jig is then put in the vice and the slots filed with a narrow file. the part is then screwed on the steam chest and the part reamed through with no metal actually removed ..so everything lining up nicely

Willy

[crueby]

Great progress  Willy!   

[steam guy willy]

Thanks Chris and more work the other cylinder assy. the bottom cylinder cover is turned up and bolted to the standard to file to shape... the cylinder cover was bolted to the standard ready to drill using a tap stock, this was a quick and ready made item put to a different use !!

Willy

[steam guy willy]

I am now fitting the steam chest cover and although it is a casting it looks as though there are some letters and numbers cast in ??  one looks like warrior and the other two I couldn't decipher ?!!  Outside with the cast recess is turned first and I am using the steam chest as a mandrel to skim the other side by using brass bolts that will also be milled off.  I have been using the Bertinat rebuild drawings and he only uses 4 bolts/studs to affix the steam chest assy  whereas the original has 8 bolts ??
  The other side will need catching up 

Willy

[steam guy willy]

I have filed up the other steam chest and put in another piece of perspex to drill and ream through it  I have also got the 3/32nd Clarkson threaded slot mill and it has the dimensions on the box ...3/32 X 1/4 X 3/16 X2"...so 2" long o/a. 1/4"shank and 3/16 length of cut !!  Normally the label just gives you the cutting diameter.    so the ports will be milled out on Thursday ...

Willy...

[Michael S.]

Hello Willy,

good results on the engine. This really makes me want to follow you with my casting set. But I have so many other construction projects that I have started that I have to finish.
I will continue to follow.

Michael

[steam guy willy]

Hi Michael thanks for the interest and I will be continuing with a bit more detailed explanations ... The ports have been milled and a file used to square them up. the steam chest is drilled the tapping size for 7 BA and then used to locate the holes for the cylinder block and steam chest cover , I have used the steam chest as a mandrel to mill the cover inside dead flat and have to be careful to orientate the parts correctly so all the holes line up ..the cover is also tidied up once it is attached to the steam chest,

Willy

[steam guy willy]

A few more pics ..And now these parts are completed I will use them to calculate all the dimensions for the crankshaft piston rods and the eccentric rods ...

Willy