Flyboy Jim's PM Research #5

[Flyboy Jim]

My "Straight-Tooth Keyseat End Mill" showed up a while back.



I mounted my RT on the mill table and centered it under the spindle and then mounted my Fixture Plate on the RT. After turning a plug to fit the bore in the Eccentric Hub and mounted that on the Fixture Plate, I was able to use that to center the Eccentric Hub on the RT.



Not a great picture, but I was able to mill a groove in the Eccentric Hub to the dimensions as called out.



This part is still .040 thicker than the dimension that's called out, but will wait on that until I figure out if that's a problem or not.





Jim

[Kim]

Nice work on that internal groove.   You did this on your rotary table, right?  Not CNC or (heaven forbid) etch-a-sketch style?  That seems like it would be quite difficult!

Kim

[propforward]

Cunning approach to that internal groove. I like it.

[Flyboy Jim]

Nice work on that internal groove.   You did this on your rotary table, right?  Not CNC or (heaven forbid) etch-a-sketch style?  That seems like it would be quite difficult!

Kim

Thanks Kim and Stuart. Yes is was done manually on the rotary table. Like a lot of operations, the set up took a while and the actual cutting of the groove went pretty fast.

Jim

[propforward]

The universal truth. Success in machining is all about the set up.

He said, nodding wisely at the same time.

[Flyboy Jim]

Finally got to work on the Eccentric.



Drilled and reamed for the Crankshaft



Turned the part around in the 4 jaw, offset the proper amount and turned to the diameter to fit into the groove in the Eccentric Hub



Then the tricky part. I had to turn the hub down to the proper diameter on each side to fit the smaller diameter on each side of the Eccentric Hub



Drilled and tapped for the set screw for mounting on the Crankshaft



Parted off



Finished.



I assembled the Eccentric with the Eccentric Hub. After a little bit of wearing in, it's running nice and smooth............yes! 



Jim

[propforward]

Excellent! Great work Jim!

[crueby]

Excellent!   

[Kim]

Nice work on the eccentric, Jim! 
Kim

[Don1966]

Following you silently but great work.....



 
Don

[TerryWerm]

Lookin' good, Jim!   Looking forward to seeing it complete. Keep up the great work!

[Flyboy Jim]

Thanks guys. It's been moving along at a glacial pace, but it's getting there.

You all, as well as the other members of MEM, have a nice Christmas.

Jim

[propforward]

Just like eating an elephant, Jim. One bite at a time!

All the best.

[Flyboy Jim]

Time to drill and tap the mounting holes for the Cylinder.

Getting the first hole in the right place is critical since it positions the Cylinder so the Slide Valve will operate smoothly.



Once that is done the Inner Head can be used to locate, drill and tap the rest of the mounting holes.





Jim

[Flyboy Jim]

Well.......I've put it off as long as I can. Time to deal with the Crankshaft bearings. I superglued the caps to the Frame with a couple drops of superglue.



Drilled and threaded





These are a couple of pictures from earlier, but they show the same setup I used to drilling the bearings for the Crankshaft. It uses the Rotary Table on edge and the 4 jaw chuck.



Used my digital level to get everything set up.



Used a needle to figure out the center point to drill.



Drilled just under 1/4"



I then rotated 180 degrees and did the same thing. Except this time I ran the drill on through to pick up the hole already drilled. It pretty much lined up and went through the hole already drilled. YES!    I ran a 1/4" reamer through and tried some 1/4" drill rod and it worked great! That test went well, so I redrilled N size and reamed to 5/16" as needed for the Crankshaft.



Mounted the Crankshaft. It had a couple of tight-ish spots but a couple of minutes spinning with a drill motor and all was well.

Poor picture, but that's the Crankshaft mounted to the frame.



I just now realized that I've run out of parts to make on this project.    Now the task of bringing it all together.

Jim