Currin's Webster IC

[Hugh Currin]

It's time to attempt an engine build. It will be my first attempt at any engine and I've decided to attack a Webster IC . I wanted to build an IC engine, and the Webster seems to be one of the simplest. I know many of you have built this engine and will depend on your expertise from time to time.

Over the last month or so I took the plans and modelled them in CAD. It does look like all the parts will fit together.

I ordered most of the materials and parts around Dec. 20. Metal Stock from Speedy Metals, spring wire from McMaster Carr, gears and bearings from SDP, and a carburetor from Omni Models (Ebay). I like OnLine Metals but I couldn't find cast iron from them. With these and stock on hand I have most of the needed supplies. I forget how long the least expensive shipping method can take. The last order, from SDP arrived today. I still need to obtain a spark plug and points but can likely get these locally.

I ordered the ball bearings suggested in the plans and was surprised they are sealed on one side only. It'll run infrequently (the optimistic view) but dirt and grit may cause problems down the road, time will tell. The plans give a carburetor design but suggest an RC carburetor will work better. I decided to go this route, at least till it's running.

I have a manual lathe and a knee mill I've converted to CNC. I'll use these as the mood strikes. I do want feedback on the CNC set-up (and everything else). I'll likely describe in detail the way I approach a CNC part at least once, probably at the beginning for the base, side & cylinder supports. I know some here do CNC milling and others do it professionally. I'm mostly self taught so am looking for input.

I don't know if this will take months or years, but you're welcome to tag along. But be forewarned this will NOT be a “wow, that's the coolest trick I've ever seen” but more “it'd be so much easier if he'd...., boy that was stupid”. A true comedy of errors.

I should have chips, and maybe even parts, in a few days or a week. Thanks for looking in.

Hugh

[Kim]

Hey Hugh,
Looks like it's going to be a fun build!  Count me in! I'll be following along and learning with you.  Someday, I hope to build an IC engine too!

Good luck, and enjoy the journey! That what it's all about, right?!
Kim

[b.lindsey]

Somehow I missed your post on this Hugh. Looks like you've got plenty of materials to get going on it and I'll be along for the ride also!

Bill

[Don1966]

Hi Hugh, count me in on the journey. With the drawing and material it looks like you will be making short work of this engine. Pulling up a chair here friend.

Don

[ogaryd]

Hi Hugh, I'll be anxious to watch your progress on the Webster. My friend Rebush just completed one and we will be glad to help with any questions you have. Gary

[Hugh Currin]

Thank you for the interest. I do hate to start a thread, then not have parts yet. I've been busy though, and parts should show up soon. Here are all my excuses. :-)

I bought a new CAM program, CamBam, and have been trying to come to terms with it. It's taken a while to get a post (small script that tells the CAM software how to generate G-code for a particular machine) which I think is now working. I have enough trouble getting stuff right, so spending the effort to verify the post eliminates one source of trouble. I don't like surprises running the machine.

I reviewed CamBam before purchase and it seemed very nice. Trying to use it I've found a few things of concern, mostly with manual tool changes. I think CamBam doesn't always recognize a new tool. It assumes the machine is at the same place as before the new tool. I caught this looking through the code before running a program. I believe I've worked around it in the post.

I tried to go back to SheetCAM, the CAM program I was using previously. It's a nice program but requires each cut to be on a different CAD layer. At least I haven't found a way around this. It's a pain if a part has many features. Spot drill=one layer, #24 drill holes=another layer, #9 drill hole=layer, outside cut=layer, chamfer=layer, you get the idea. It does recognize V-cutters and has a reasonable simulator. I'll try to use CamBam for awhile.

I tried a few trial pieces to verify drilling, counter sinks, etc. Also faced a small plate with a 3" facing mill for these trials. I found the mill slightly out of tram, several thousandths step between cuts. I checked the tram and adjusted to within 1/2-thou over 8", but still got a step. Fiddled with the tram a little and am now happy with the results.

So mainly a note to let you know I'm still here and working away. Parts and pics to come soon.

Thanks.

Hugh

[Dave Otto]

Keep after it Hugh you will get it figured out.

Like I told my daughter when she was struggling with Edge CAM at school last year; sometimes you need to go after them with a sledge hammer. most CAM programs (even the entry level ones) can have a pretty steep leaning curve.

Dave

[philjoe5]

Hi Hugh,
I'm just nearly completed making all the parts for my first IC engine.  Whether it will actually be an engine as opposed to a doorstop, well time will tell.  Good luck on your project.  I hope to look in from time to time.

For your info, check out Durabar (cast iron) locations near you.  I buy all my CI at a location near me for scrap prices.  If you're lucky, they'll let you go through the drops

http://www.dura-bar.com/distributors/

Cheers,
Phil

[steamer]

Have at it Hugh...I'm watching!

Dave

[Hugh Currin]

For your info, check out Durabar (cast iron) locations near you.  I buy all my CI at a location near me for scrap prices.  If you're lucky, they'll let you go through the drops

http://www.dura-bar.com/distributors/

Cheers,
Phil

Phil:

Thanks. If mine ends up a door stop, I hope it's a good looking door stop. :-)

I looked at the Dura-Bar web site. They have distributors in:
    Tigard, OR  (228 mi north)
    Portland, OR  (233 mi north)
    Stockton, CA  (297 mi south)
Not convenient for dropping by. These distributors, from their websites, didn't look like the type to cut and ship one foot of 1" round. I could be wrong though. Anyone know of suppliers for small quantities of cast iron on the west coast (USA)? Oh heck, why not ask. Any suppliers on the west coast of Australia (just for fun)?

But next time I end up in Portland, OR I'll go by and see if they have any drops though. Thanks.

Hugh

[Dave Otto]

MSC, McMaster Carr, possibly Enco

May not be labeled Durabar but it looks and machines just the same.

Dave

[GailinNM]

Just for reference. Some of the cast iron suppliers don't list it as cast iron in their index. They call it grey iron.
Gail in NM

[smfr]

SpeedyMetals has "Class 40 Grey Cast Iron" which I've been quite happy with; is that the same as Durabar?

Simon

[philjoe5]

Durabar comes in a variety of grades, "gray iron" and "ductile iron" being the two most common.  I never get further than that with the guy I get it from.  There are subdivisions of those listed:

http://www.dura-bar.com/products/index.cfm

but for model making, though I'm not sure I have a need to know.  I've had very good experiences with the gray irons and although I only get small drops of "ductile", it gives a finish like a mirror.

Cheers,
Phil

[Brian Rupnow]

Hugh--The Webster was my very first internal combustion engine. It is a great first engine and I wish you a world of success.---Brian