Author Topic: Planis Farm Boy Engine  (Read 3091 times)

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #15 on: June 08, 2020, 09:33:59 PM »
Thank you gentlemen for the kind comments!

Terry, actually I'm doing both. To mill aluminum I'm using a little bit of coolant mixed into the airstream mainly to provide some lubrication. Milling steel with the carbide cutter is done dry. For carbide it's better to use either a lot of coolant (really flood it) or none, because if there's only little coolant the thermal stress on the cutting edge is increased and the cutter won't last as long.
The air helps to keep the swarf away from the surface. This is also vital to mill steel with high feedrates because otherwise the cutter tends to gall up and break. With the aluminum it helps the finish if there ar no chips mangled between the cutter and the finished surface.

Plani

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #16 on: April 29, 2022, 08:52:57 PM »
Oh dear, how time flies by..... :old:

Nevertheless, some Progress was made but I didn't get around to keep the buildlog up to date. I'll try to catch up, since some Pictures were taken along the way.

Next up the Flywheels needed some finishing work. Therefore the split collets used to clamp the flywheels to the crankshaft where prepared by turning them whit some stock left on the outer diameter and the bore reamed.

Drilling and tapping the holes for the bolts




The flywheels where then set up in the lathe in order to turn the conical bore for the collet and the rim in the same setup






To ensure a proper fit of the collets, a mandrel was devised and the conical outer diameter was turned with the compound slide of the lathe still set at the same angle as for the bore in the flywheels, running the lathe backwards




Collet finished turning




Cutting the slits in the collets




In order to align the keyway to the spokes, a custom guide for the broach was made




Broach in action




Flywheels finished  :D



Plani




Online propforward

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Re: Planis Farm Boy Engine
« Reply #17 on: April 29, 2022, 11:44:24 PM »
Excellent. Nice parts, and thanks for sharing your description of the process.
Stuart

Forging ahead regardless.

Offline crueby

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Re: Planis Farm Boy Engine
« Reply #18 on: April 30, 2022, 12:51:59 AM »
Those flywheels look terrific!

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #19 on: May 08, 2022, 07:39:10 PM »
Thank you gentlemen for the kind comments!

Next I wanted to start with the parts for the engine frame. I was able to purchase a decent chunk of aluminum to make these parts from.

Some work on the saw was needed




And some cutoffs were made on the mill




Raw parts for the water hopper, ant the two part engine frame prepared




Stay tuned, there's some machining ahead  ;) ;D ;D
Plani

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #20 on: May 11, 2022, 07:42:55 PM »
Hi everyone

Since there is quite some material on the bottom of the engine frame, I decided to place there an additional plate with four screws for each half of the frame in order to fix the parts of the frame.
This requires an additional pocket to be milled in the bottom of the frame, like so:




I started then with milling the front half of the frame.
Squaring up the stock.




Milling the front radius




Milling the pocket and reliefs for the fixing plate.




Pocket done and holes drilled and tapped.




Threads where the water hopper will be fixed and hole for the lubrication.




Then a pocket was milled where the cylinder will be fitted. The pocket is a bit deeper than the wall of the frame will be.




Next the radius on the upper side of the frame was milled.




Milling the top radius.




Holes for the bolts to connect the frame parts drilled and countersunk.




Milling the connecting part of the frame.




And then there is only a pretty deep pocket left to be done.




finishing cut with a ball nose endmill to create the radii in all corners.




Done  ;D  The thread for the oiler on top is missing, since I haven't decided on the size of the oiler yet.




Thank you for following along
Plani


Offline Roger B

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Re: Planis Farm Boy Engine
« Reply #21 on: May 11, 2022, 08:21:04 PM »
Looking good  :praise2:  :wine1:

What is the boring tool you are using to turn the taper in the flywheel? I am used to the boring bar being held in the tool post.
« Last Edit: May 12, 2022, 11:45:33 AM by Roger B »
Best regards

Roger

Offline Admiral_dk

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Re: Planis Farm Boy Engine
« Reply #22 on: May 12, 2022, 11:24:00 AM »
Very nice work converting stock to chips .... The parts looks fantastic  :praise2:

Per

Offline Plani

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Re: Planis Farm Boy Engine
« Reply #23 on: May 12, 2022, 08:47:32 PM »

Thank you Roger and Per  :cheers:

Roger, to turn the taper I used a normal HSS boring bar. The only thing is, since the boring bar is rather small compared to the tool holder I used a clamping device to hold it and this device was then fixed in the tool holder.



Plani

Online propforward

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Re: Planis Farm Boy Engine
« Reply #24 on: May 12, 2022, 09:07:25 PM »
This is great - lovely precision work that you are doing.
Stuart

Forging ahead regardless.

Offline Bearcar1

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Re: Planis Farm Boy Engine
« Reply #25 on: May 13, 2022, 10:35:31 PM »
Terrific piece of work! I appreciate your simple, no-nonsense approach in achieving the end results.  :cheers:


BC1
Jim

Offline Roger B

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Re: Planis Farm Boy Engine
« Reply #26 on: May 14, 2022, 07:32:28 AM »
Thank you  :) All is clear with a view from the other side.
Best regards

Roger