Osmo's first engine

[Osmo_]

Hi everybody from Finland. I have been planning to make some engine for years and now i decided to do one. From scrap pile stuff.
So first of all, i am not going to make piston or rotating assembly. For that, i use old chainsaw parts and magneto. Plan is to make vertical hit and miss engine.
Where i start, is making cylinder. For that i use 100mm rod and cast iron pipe as sleeve. Then i have possibility to design cranckcase. It will be cast aluminium and sides are going to be separated steel discs. After casting, my workmate will machine all mating surfaces, as i don't have milling machine. Just old Flather lathe and gear driven horizontal drill. Timing system comes to the side where clutch was before.
Opinions?

[uuu]

I like the sound of it.  Quite an adventure.  You'll have to post pictures so we can applaud - or laugh.

Wilf

[Casting Iron]

Welcome Osmo, glad to have you here.
Sounds like an interesting build.
Looking forward to watching your design/build as it progresses.

Pat J.
.

[Kim]

Hi Osmo!
Welcome to the forum!
Kim

[Osmo_]

Thanks for the firat of you I might bit introduce myself. Mid 30's, farmer and doing all kinds of metal work. Perfectionist and quite a Gyro Gearloose. Done lots of hobby metal work since early teens, portfolio might tell that two go-karts, couple farm implements, lots of engine work from 35cc to 4500cc, restored Datsun E10 and lots of more. Always been quite oddball and done jobs differet ways than others, adding some signature touches. My workshop consists quite much every basic tools. Welders, torches, 100y old lathe with Whitworth threads, melting furnace, cheap 3d printer, Enerpac, painting equipment and possibility of making tools by myself.

For Wilf, i will provide pics, as it is easier to get help when people will know what is situation.

And Pat, i don't quite do drawings. If i need some detailed parts, i might do it with millimeter paper. Other drawings are sketces made on what surface i find to be written, like parts, cardboard or even cigarette packs. Like in picture. For those drawings i just tend to wing everything.

And small apologies, as my dictionary isn't quite good always. I speak "rally english" and write quite well, but i don't always know all the words. Most importantly, as i am European, i use metric system, so bear with me

Pic shows some planning on cranckcase. With my drawing skills

[Roger B]

Welcome to the Forum   

Looks to be a fun project using whatever you have to build an engine 

[Osmo_]

Day 1 of making. Beginning of cylinder. I have got this piece of S235 steel in my workshop for years. First step was to make it flush on outer surface. It went very well and i started to make hole for sleeve. 10, 22 and 30mm holes and then boring with internal turning bit. Got somewhere about 40mm, when tip of bit cracked. Well, it was not a very good bit eventually, as it was made from round HSS. So not a big loss. I have to grind new one from small jackhammer tip, as it is hexagonal steel. Tomorrow is new day in office, if wife won't give any household stuff

[Grateful Ted]

This project looks very interesting,thanks.

[RReid]

Welcome to the forum! I like the way you approach things, and will be watching your progress with interest.

[Osmo_]

Welcome to the forum! I like the way you approach things, and will be watching your progress with interest.

Umm, could you clarify what you mean by approaching things? Winging everything, plan comes together when making or what?

[RReid]

Hello Osmo. I simply meant that I like the way you proceed with the tools and materials on hand, and an open mind, to pursue your projects.

[Osmo_]

I've done lots of stuff that looks good on paper but in real life, there is oversights and execution is not best. So doing something what you have, do couple of sketches and winging the rest makes best result. When you have certain mindset and vision, plans come together when making. If there is some parts you need to do multiple ones, rest is just reverse engineering. Also best way to learn is to hit head to stone, get back up and hit head again That is my philosophy when doing new stuff.

[Osmo_]

Mate made did yesterday that cylinder block boring to 49,80mm. Next step is to take cast iron pipe, heat block couple hundred celsius's and press sleeve in. Then turning bolt perimeter and drilling head bolt pattern with jig.
Cylinder sleeve is 50mm and block is about 100mm on diameter. What do people consider to be good diameter for bolt perimeter? Cylinder will have air cooling fins, so perimeter can't be too large, as block and head will tighten to cranckcase with M6 stud bolts. Is 4x70 perimeter enough? Cooling fins cannot be too low, but it cannot weaken structural integrity

[Osmo_]

Allright. Sleeve is in block. I heated block to about 500c° in furnace and lubricated sleeve with copper paste. Then popping in press i managed to crimp sleeve to bottom. It required couple heatings, as heat transferred and sleeve bit on.


Next step is to machine block to shape and bore cylinder to final dimension. Then it's time to start making crackcase.
That furace insulates heat quite well. After 1 hour cooling from 500c°, block was still 300c°, because i left it to cool slowly