The Webster Chicago

[maury]

After about a year and a half working on the Fairbanks-Morse R
3 cylinder, I needed a break. Nearly done, I need to set up for powder coating
and finish a few minor details before final assembly.
 I have a freind who has access to  a partially disassembled Chicage Webester,
 and he feels the strong urge to have a model of it. I've gotten the bug too, so
we decided to get started measuring it. A month or two back. Information
trickled in and there were a lot of questions and more measuring and pictures.
So, I've spent the past few weeks with Solidworks cranking out a design.
Currently the modeling of most of the parts is complete, and everything  seem
 to fit properly in the elevation, though I'm sure there will be engineering
changes  during the building phase.
This will be my first hot tube design, so a few new challenges.
I will be making the patterns for castings and casting some of the parts for the
prototype in aluminum. My friend has assess to an iron foundry, so he will
supply the iron castings. I just got a new Bambu Labs A1 printer, and can't wait
to start making patterns.

Maury

[Jasonb]

I'll look forward to this one coming together, what sort of size have you gone for?

[Alyn Foundry]

I have a ‘ bit of a thing ‘ for inverted vertical engines…. 😉

I too will be following the progress. Regarding hot tube ignition, yes it does scale but within certain limits.

We also use a Bamboo labs 3D printer, very pleased with its performance. Here’s a sample of recently produced patterns.

   Graham.

[maury]

Well, Im back after my Computer gave me a big scare. It would not boot, gave a CPU fan error. After checking it out (???) I ended up taking it in to a repair hack shop to get it repaired. Fortunately, it was only the fan that was broken. It's my CAD computer, and everything I've done since 2013 is on there.

So, I've been printing some patterns which were exported before the fan issue. These are the parts I need in iron for building the prototype, and have been sent to my friend for casting in iron.

Most are strait forward except the Exhaust valve cage. That part has really unusual geometry, and I have no ldea how it was initially manufactured. After studying it some, I decides to pattern the bottom of the part split in cope and drag. The top of the part has its geometry in an external core. Thus is the first part I've made like this, We'll see how it goes.

[crueby]

Hopefully all backed up onto other drives too? Still a pain to restore on a new machine if needed, but it least it isnt lost that way.

[maury]

Thanks to all who have tuned in.
I won't loose my data, its the applications I'm worried about. My Solidworks License is 2013 and my Bob Cam 4 axis software is also no longer "supported". I won't be buying new versions if I loose my computer. I'll still have my lathe and bridgeport though.

[maury]

Still too cold to work in the shop here so I'm printing more patterns and working on shop drawings. As soon as we get a reasonably warm clear day Ill be pouring castings of these patterns. With any luck, the ones I sent to the iron foundry will be back next month. Still working on the water jacket pattern, and core box. It has some really interesting geometry. Can't wait to start cutting metal.

[maury]

Well the weather has cooperated, so a good opportunity for foundry work.
I always have a bit of anxiety about trying out a new core box, but this one worked well.
I cored out the exhaust passage and combustion chamber in the head. The rest of the parts are
for the intake, bearing caps and the latchout. I was concerned about the yoke, as it is only 3/16 thick
and wide in sections. The part filled well, can't wait to get it on the Bridgeport.
There will be another batch of castings before I can get into cutting metal though, and more pattern
making.

[Admiral_dk]

I'm absolutely no expert on castings - but they look good 

Enjoy your time machining them 

Per           

[maury]

Thanks for the compliment on the castings

I still have more patterns to make, but I wanted to start cutting metal. not having all the castings, I decided to start with the valve train. I only need 1 casting for that.