Model Engine Maker
Engines => From Plans => Topic started by: joe d on December 15, 2020, 03:42:17 AM
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Well, it's been quite a while since I've posted a project. With a fair amount of shop time available these days I decided to get going on Tubal Cain's MARY,
with the additional challenge of doing it all from bar stock. The only things I've bought in for the project are some scale nuts, so far everything else has come from stock in hand.
I have changed all the fasteners & threads to UNC or UNF, much simpler than sourcing a bunch of BA stuff here in Canada.
Started at the beginning of July, so will post retrospective stuff until I catch up to present... so don't go thinking that I work at the speed of a Lombard & Man Wagon builder :ROFL:
Will be back with some photos as soon as I figure out how to insert them from coppermine...
Cheers, Joe
(https://listerengine.com/coppermine/albums/userpics/10047/M0001.JPG)
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Hmmm... picture attached after all, not at all sure how I did that. It was the first bit I started with, turned an off-centre chucking spigot for the cylinder.
Joe
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Hello Joe
It's good to see someone tackling this rather attractive beam engine. I've long had thoughts to do similar but at a third bigger - Mary's big sister! - but though the drawings (in TC's book) are now annotated as such I've never actually got round to it.
I have another project to begin shortly so shall enjoy watching yours progress instead.
I'm not sure if memory serves correct but many (and I do mean many!) years ago I recall buying an American(?) publication somewhere on my travels. Not sure of the exact name (it was something like 'Popular Mechanics') but I do remember it was of horizontal format and quite thick with many varying and interesting hobby projects inside.
There was a beam engine project included and I'm pretty sure it was 'Mary' - this would be long long before I became aware of it over here in the UK.
Just a memory but wish I still had the magazine
Good luck with your engine :ThumbsUp:
Tug
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Tug: Thanks for looking in. I've much enjoyed following various of your projects here.
Going along: Used the chucking spigot to hold the work and bore the cylinder,
(https://listerengine.com/coppermine/albums/userpics/10047/M0002.JPG)
then turned a mandrel and mounted it on the mill with the dividing head and commenced to mill away everything that didn't look like a cylinder.
(https://listerengine.com/coppermine/albums/userpics/10047/M0003.JPG)
The rough stock had just enough meat to allow for the platform that the valve chest mounts on.
(https://listerengine.com/coppermine/albums/userpics/10047/M0005.JPG)
Lots of round-n-round & back & forth but came out OK.
(https://listerengine.com/coppermine/albums/userpics/10047/M0006.JPG)
(https://listerengine.com/coppermine/albums/userpics/10047/M0007.JPG)
Joe
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Subscribed. I am also interested in the identity of your lathe, and is that a Taig mill?
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Hi Bear
The large lathe is a B2227L Craftex from Busy Bee, 10 x 18 screw cutting, another variant of Chinese manufacture, it has served me well to date.
Also have a Taig lathe, my first, and it still gets a fair amount of use, and yes, it's a Taig mill. Would love to upgrade to some big hunking "real" mill, but have no room for one!
Joe
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Joe, I also have a Taig lathe and mill. I like the mill, and it is a good size for model making. The same goes for the lathe. In any event, I wish I had the room for a Bridgeport ;D.
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Anyone else not able to get the last set of images up to a decent size, they seem to be thumbnails not "normal" size as the first
Will also be looking in to see this one progress.
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Same here Jason. However the file name suggests that it is the thumbnail that was posted rather than just a smaller file size.
I am sure that Joe will soon work it out.
MJM460
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Yes, Joe appears to have posted thumbnails.
This will be an interesting build.
Following...
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Try again... same images at a reasonable size (I Hope)
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I personally love to see them even bigger - but it is a true improvement - when I click on them now I get the 400x300 size :ThumbsUp:
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Hi all.
Jason, MJM, Gary & Admiral ... I seem to have sorted the photo issue, thanks for looking in.
Used my rather low-end tilting vise to hold the cylinder for drilling the steam passages.
(https://listerengine.com/coppermine/albums/userpics/10047/M0008.JPG)
Turned the cylinder covers, then used the indexing head
to drill the bolt circles at tapping size
(https://listerengine.com/coppermine/albums/userpics/10047/M0012.JPG)
used the covers as drill guides on the cylinder, then opened them out to clearance size holes.
(https://listerengine.com/coppermine/albums/userpics/10047/M0009.JPG)
Put the cylinder in a small vice and used the UPT for tapping the holes.
(https://listerengine.com/coppermine/albums/userpics/10047/M0010.JPG)
Cheers, Joe
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I've always thought this was a very nicely proportioned engine. I look forward to seeing you build it.
Steve
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Nice set-ups.
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Steve, Bear: Thanks!
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Moving on, turned the piston, threaded it for the piston rod, and grooved for an O ring.
(https://listerengine.com/coppermine/albums/userpics/10047/M0015.JPG)
Milled 2 slots for the steam passages, and drilled the exhaust passage.
(https://listerengine.com/coppermine/albums/userpics/10047/M0013A.JPG)
The valve ports are in a separate piece,
(https://listerengine.com/coppermine/albums/userpics/10047/M0014~0.JPG)
then the valve chest & valve,
(https://listerengine.com/coppermine/albums/userpics/10047/M0015~0.JPG)
the valve cover had some work on the rotary table.
(https://listerengine.com/coppermine/albums/userpics/10047/M0015A.JPG)
A picture of the the valve port plate in place,
(https://listerengine.com/coppermine/albums/userpics/10047/M0016~0.JPG)
and finally, the cylinder assembly. (after a stud-making festival).
(https://listerengine.com/coppermine/albums/userpics/10047/M0017.JPG)
Cheers, Joe
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Coming along great. In reference to your rotary table, what are you using on your Taig mill? I am looking to get one.
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Thanks, Bear.
The rotary table is a 4" one I got from Victor Tools in NYC several years ago. Not much point in getting anything larger given the size of the Taig mill.
By no means a top-end tool, but it's OK.
Made up a bracket from a bit of spare angle to fit a t-nut for the mill table, there was only 1 factory hold-down point on the base casting.
Joe
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Thanks, Joe.
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Next up was the pedestal for the cylinder: Drilled, tapped, and screwed together some brass stock,
(https://listerengine.com/coppermine/albums/userpics/10047/M0018.JPG)
hit it with some silver solder.
(https://listerengine.com/coppermine/albums/userpics/10047/M0019.JPG)
Once out of the pickle,
milled off all the screw heads and brought it to size. Drilled and filed the various openings required, then soft-soldered a piece on the bottom, and milled out the centre and edges to dimension.
(https://listerengine.com/coppermine/albums/userpics/10047/M0020.JPG)
I trapped a length of some 1/16" round on a sacrificial plate on the mill, and very gently milled half of it off
to make some 1/2 round beading, annealing it several times while shaping it into an oval,
(https://listerengine.com/coppermine/albums/userpics/10047/M0022.JPG)
which then was soft soldered in place. Here's the part in place under the cylinder
(https://listerengine.com/coppermine/albums/userpics/10047/M0023.JPG)
Cheers, Joe
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Back with some more of the bits:
Turned some ali for the columns, then off-set the tailstock to taper the top 2/3rds.
(https://listerengine.com/coppermine/albums/userpics/10047/M0024.JPG)
Moved them over to the indexing head on the mill, ran once around with a ball-end cutter to create the fluting, then shimmed the tailstock the same 1/32" I had previously offset them on the lathe, and chased the flutes around again on the tapered portion.
(https://listerengine.com/coppermine/albums/userpics/10047/M0026.JPG)
Some straightforward turning cutting and drilling to make up the rest of the bits that make up the base/tops of the columns.
(https://listerengine.com/coppermine/albums/userpics/10047/M0027.JPG)
Joe
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Very nice Joe. I really like your Taig set-ups that I assume you made for your mill.
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That's some really nice work you are carrying out there Joe - a good result on that pedestal and those fluted columns 'look just the ticket' :ThumbsUp:
You are certainly making inroads into it for sure - keep it coming :)
Tug
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Great results on the columns! :popcorn: :popcorn: :popcorn:
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Bear: made that dividing head some years ago so I could cut gears for a traction engine, plans were found on line, it was purpose-designed for taig equipment. Tug, Chris, thanks!
A brief diversion into real life: Friday afternoon my youngest son & daughter-in-law presented us with a shiny new grandson! Some good news in an otherwise long and weary year.
Some bits for the eccentric assembly: turned the rod, tapered by eye with files in the lathe, threaded the ends.
(https://listerengine.com/coppermine/albums/userpics/10047/M0028.JPG)
The rod end presented one challenge, the slot for the cotter is .047", I own exactly ONE file small enough to get in there to clean it up. Maybe time for some shopping...
(https://listerengine.com/coppermine/albums/userpics/10047/M0029.JPG)
Silver-soldered a bit of round onto a piece of flat stock as the hub for the lever, shaped it in the mill
(https://listerengine.com/coppermine/albums/userpics/10047/M0030.JPG)
Straightforward turning for the bolt, and there we are
(https://listerengine.com/coppermine/albums/userpics/10047/M0033~0.JPG)
Cheers, Joe
Joe
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Great progress this far Joe and the parts are looking first rate!!
Bill
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Thanks, Bill. Good to see you back!
Joe
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Thanks, Joe. Great job on the dividing head and all your machining.
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Those columns are excellent Joe :ThumbsUp: :ThumbsUp: Terry
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Yes - the columns are excellent.
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Terry & Gary: thanks for looking in!
Joe
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Moving on:
Started the crank assembly by drilling a blank with the necessary holes, then reaming, and then hacksawing off most of the waste
(https://listerengine.com/coppermine/albums/userpics/10047/M0034.JPG)
turned a mandrel, mounted the crank on it, moved it to the dividing head on the mill and nibbled all around, then turned the spigot on the mandrel smaller to fit the other hole and repeated the exercise
(https://listerengine.com/coppermine/albums/userpics/10047/M0036.JPG)
a little clean up with some files, turned the crank pin and pressed it in
(https://listerengine.com/coppermine/albums/userpics/10047/M0038.JPG)
then turned the shaft & pressed it into place, secured with a pin
(https://listerengine.com/coppermine/albums/userpics/10047/M0039.JPG)
Cheers, Joe
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Coming along very nicely.
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Thanks Bear.
Main bearings were next. Bolted together 2 bits of brass, centred them in the 4 jaw & turned a boss on both sides, did somehow get one the wrong diameter, but decided to live with it (can't see both sides at the same time, can we?)drilled & reamed to fit the crank shaft
(https://listerengine.com/coppermine/albums/userpics/10047/M0040.JPG)
Into the mill to cut away most of the excess metal
(https://listerengine.com/coppermine/albums/userpics/10047/M0041.JPG)
went around 4 sides of each to shape the recessed portions, no CNC so was "etch-a-sketch" time
(https://listerengine.com/coppermine/albums/userpics/10047/M0043.JPG)
Countersunk the pads and soft-soldered in some plugs tor the bolt pads, milled them to height & clearance drilled
(https://listerengine.com/coppermine/albums/userpics/10047/M0044.JPG)
Turned the eccentric sheave from some cast iron, didn't get a photo of that, and here's the assembly. Not to worry, the cap screws will be replaced with studs & nuts...
(https://listerengine.com/coppermine/albums/userpics/10047/M0045.JPG)
Cheers, Joe
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That was quick. Really like your work.
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Thanks Bear. Can't make any claims to speed, this is still in the "catching-up" phase of posting, am actually currently at the parallel motion portion of the build (But, we're getting closer to real-time!)
Next up was the eccentric strap, tried once with cast iron, no good, so tried with a bit of bronze, scrapped it, third time was the charm
(https://listerengine.com/coppermine/albums/userpics/10047/M0046.JPG)
Didn't have a piece of bronze large enough to make the bit for the eccentric rod integral to the part, so turned a scrap of the bronze cone-shaped, with a little locating nub on the bottom, milled a flat on the strap with a hole for the nub, soldered it together, and milled away the excess, leaving the boss for threading in the rod. Bored out the centre in the 4-jaw, Managed to not take photos of most of this one.
(https://listerengine.com/coppermine/albums/userpics/10047/M0047.JPG)
Felt like this thing was never going to work out, but it finally did. Still needs final lapping on the sheave, but that will happen eventually!
Cheers Joe
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You are welcome, Joe. :ThumbsUp:
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Moved onto fabricating the base plate, this was a fun bit to do. Having a chunk of ali in the stock-pile large enough to do this is what got me going on this whole build.
Milled the upper piece to size with a fly cutter, shaped the smaller chunks for the pedestal with a router bit, relieved the underside of the top to bring it out to final dimension upon assembly. Milled slots for some .25 square stock for the hold-down bolt pads. Drilled, tapped, clearance drilled & counter sunk a bunch of holes, and screwed it all together.
(https://listerengine.com/coppermine/albums/userpics/10047/M0051.JPG)
If you look closely at the photo above, you can see where I had to tap 2 holes, screw in a plug of ali, mill flat, and re-drill in the right spots..happily, only out by a little, covered by the base of the columns once assembled!
From below: starting to assemble
(https://listerengine.com/coppermine/albums/userpics/10047/M0052.JPG)
Everything fastened
(https://listerengine.com/coppermine/albums/userpics/10047/M0053.JPG)
The beauty shot:
(https://listerengine.com/coppermine/albums/userpics/10047/M0054.JPG)
And the family shot:
(https://listerengine.com/coppermine/albums/userpics/10047/M0055.JPG)
All the joints will get a fillet of JB Weld when doing the paint prep.
The outboard crank support was much the same, here I'm shaping the bottom portion with the same router bir
(https://listerengine.com/coppermine/albums/userpics/10047/M0056.JPG)
cut slots for the hold-down bolt pads, installed them as per the main base plate, fastened a chunk of ali on top, & mounted the outer bearing
(https://listerengine.com/coppermine/albums/userpics/10047/M0057.JPG)
Quite satisfied with how these parts turned out.
Cheers, Joe
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:ThumbsUp:
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Ha Ha Joe - great minds think alike eh ;) That's exactly how I had planned to do the base if I ever get round to it. Great result and once those JB Fillets go on and a coat of primer who could ever tell :ThumbsUp:
Keep up this great approach - Tug
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Thanks Bear, Tug: appreciate that!
Another fabrication, the entablature: Some more milling with a router bit
(https://listerengine.com/coppermine/albums/userpics/10047/M0058.JPG)
drilled through the centre, & cut them off
(https://listerengine.com/coppermine/albums/userpics/10047/M0059.JPG)
Used the same cutter on some flat bar, then milled away the squares to fit the bars in place
(https://listerengine.com/coppermine/albums/userpics/10047/M0061.JPG)
Milled some squares, and trimmed some flat bar, drilled and tapped all around for some No 2 capscrews to hold it all together for soldering
(https://listerengine.com/coppermine/albums/userpics/10047/M0063.JPG)
all cleaned up & fastened in place
(https://listerengine.com/coppermine/albums/userpics/10047/M0062.JPG)
After soldering
(https://listerengine.com/coppermine/albums/userpics/10047/M0064.JPG)
Out of the pickle, sweated on a plate of brass
(https://listerengine.com/coppermine/albums/userpics/10047/M0065.JPG)
Brought the edges to dimension in the mill
(https://listerengine.com/coppermine/albums/userpics/10047/M0067.JPG)
Drilled the holes for the studs from the columns that hold it in place
(https://listerengine.com/coppermine/albums/userpics/10047/M0066.JPG)
Milled out the centre, counter-bored the corner holes for the locating spigots on the columns
(https://listerengine.com/coppermine/albums/userpics/10047/M0068.JPG)
And here it is in place
(https://listerengine.com/coppermine/albums/userpics/10047/M0070.JPG)
Another satisfying bit!
Cheers, Joe
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Love it :ThumbsUp: :popcorn: Terry
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Beautiful job on the entablature! :popcorn: :popcorn: :popcorn:
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Beautiful work!
I wish the photos were larger to make it easier to see all the nice detail.
Dave
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Terry, Chris, Thanks! Dave: currently putting the photos in AdeV's Coppermine at the 800x600 recommended size.
It took me a few goes to remember how to insert them in the text instead as thumbnail attachments.
If anyone has a non-complex method of putting larger ones, within the site's size rules, please let me know!
Cheers, Joe
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You need to remove the "normal_" from the the tag for the picture to display full size.
Coppermine uses three different picture sizes depending on where you copy the link from. Below are links for the same picture, you can see that there is a thumb nail, normal and full size.
https://lister-engine.com/coppermine/albums/userpics/10012/thumb_Vise_092.jpg
https://lister-engine.com/coppermine/albums/userpics/10012/normal_Vise_092.jpg
https://lister-engine.com/coppermine/albums/userpics/10012/Vise_092.jpg
Hope this helps,
Dave
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Well crap, that's easy.... Thanks Dave!
Joe
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Well, with thanks again to Dave Otto, I've gone back to the start and put in the full-size photos.
Currently as far as post #20, and am cross-eyed. I'll go at it again in the morning!
Cheers, Joe
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Hi Joe - Super job on that entablature. I've puzzled that part quite a bit as to how best to machine it from solid. Shan't be doing that any more - copying and flattery etc ;)
I use Google Photos for storage - take the pics with a Nikon Coolpix set on 3 MPx. Transfer the selected ones into 'My Pictures - upload to Google album - select pic and click into the post box. I don't need to resize at any time.
Looking forwards to how you tackle the beam and cylinder
Regards - Tug
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Thanks Tug! I've now caught up replacing the photos with a more user-friendly size for anyone who wants to go back and see what I was on about....
Cheers, Joe
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Hi all
Next was the dummy pump (as this will run on air, don't need feed water)
Turned the gland on the end of a brass bar, put it in the dividing head to drill tapping size holes through into the main body, then opened up the ones in the flange to clearance size
(https://listerengine.com/coppermine/albums/userpics/10047/M0072.JPG)
Put the chuck back on the spindle of the lathe, parted off, drilled the pump body to accept it, installed it with some temporary cap screws, drilled the hole for the pump ram. Moved the dividing head to the mill and shaped the flanges while still attached to each other
(https://listerengine.com/coppermine/albums/userpics/10047/M0073.JPG)
Nearly done: need to make the studs to complete it.
(https://listerengine.com/coppermine/albums/userpics/10047/M0074.JPG)
Then made the rocker bearings for the valve, rounded the edges of some flat bar, soldered on a flat bit at the bottom, drilled tapping size from the top, split them , cleaned up the mating faces, clearance drilled the top, assembled, drilled, then reamed. Manged to not take any "in progress" photos
so here's the end result in place. As always, the cap screws are temporary, awaiting studs
(https://listerengine.com/coppermine/albums/userpics/10047/M0071.JPG)
Cheers, Joe
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Excellent.
Your Taig mods and additions are very clever as well.
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Bear: three weeks later, thanks for that... (apologies for not responding sooner!)
Next up was the beam: A lot of time spent for three pictures
Got nearly 2 sq feet of 1/2" brass from a friend's garden shed many years ago, have been whittling away at it ever since.
No idea what alloy it is, but it's miserable stuff to machine, but given the price of brass these days, worth the trouble I guess...
Cut a piece out, and chain drilled the outline of the beam, laid out and drilled the holes required for later that also conveniently act as hold-down spots for milling
(https://listerengine.com/coppermine/albums/userpics/10047/M0075.JPG)
Good old Mk1 hacksaw to cut off the excess, and then a lot of work with the belt sander to clean it up and bring it to size
(https://listerengine.com/coppermine/albums/userpics/10047/M0076.JPG)
Bolted directly to the mill, and etch-a-sketch time
(https://listerengine.com/coppermine/albums/userpics/10047/M0077.JPG)
Then flipped it over and repeated... spent quite a bit of time with some rifflers smoothing out the machining marks left on the inner curved faces
A lot of work, but as one of the most "visible" features of a beam engine worth the trouble I think!
Cheers, Joe
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No apologies needed. Looking great.
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Great work on the beam. Boy I don't hear the word rifflers thown around much. I use them all the time for my projects.
gbritnell
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I'm enjoying the build in the background :) :) :wine1:
I don't know how you can do model engines without rifflers ::) IC engine ports certainly need them :ThumbsUp:
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Bear, George, & Roger: Thanks for looking in and the kind comments.
Finished the beam, reduced the width of the flanges, and lowered the ribs, and shaped the transition to the eyes on each end
(https://listerengine.com/coppermine/albums/userpics/10047/M0077A.JPG)
And moved on to the trunnion bearings. Raw material with a piece for the cap in place, and various lay-out & hold down holes drilled:
(https://listerengine.com/coppermine/albums/userpics/10047/M0079.JPG)
Set up on the rotary table and milled the bosses with a ball-end mill
(https://listerengine.com/coppermine/albums/userpics/10047/M0080.JPG)
Switched to an end mill to reduce the thickness all over, and a final pass with a ball end cutter to form a fillet at the base
(https://listerengine.com/coppermine/albums/userpics/10047/M0082.JPG)
The cross slide on the Taig lathe was the exact height needed for drilling & reaming the holes for trunnion without any packing, so stacked the two pieces and did them at once, so they match up
(https://listerengine.com/coppermine/albums/userpics/10047/M0083.JPG)
Back to the rotary table on the mill to connect the dots of the various lay-out holes, and finished by sawing off the excess that had the hold-down
holes
(https://listerengine.com/coppermine/albums/userpics/10047/M0084.JPG)
Milled a pair of curved segments on the rotary table for the outriggers, relieving the centre of both sides, added a bit of round bar to form a boss,
held them all together with some sacrificial brass cap screws, and silver soldered the lot together
(https://listerengine.com/coppermine/albums/userpics/10047/M0085.JPG)
cleaned up on the belt sander, and here in place on the entablature:
(https://listerengine.com/coppermine/albums/userpics/10047/M0087.JPG)
Cheers, Joe
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Hi Joe
Haven't been on for a while so just caught up with your latest progress. Great work on that beam - that internal milling must have been quite time consuming. Very nice thinking and a great result on those trunnion bearings too.
Ha who needs castings eh? Lovely :ThumbsUp: :ThumbsUp: work
Tug
PS Plus 10 for rifflers too ;)
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Always a pleasure to see how nicely it is coming along.
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Lovely work and wonderful lessons in how it can be done without castings to good effect.
Thanks for sharing this build.
Charlie
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Tug, Bear, Charlie:
Thanks guys!
Joe
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Just finish reading from start to finish Joe. Don’t know how I missed it but that is some great fabrication work. I will be following till the end.... :Love:
:drinking-41:
Don
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Thanks, Don. Glad to have you looking in!
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A short detour into some wood-working for the base. Had some oak off-cuts from a little project I had done for one of the daughters-in-law
so put them to use.
Viewed from the underside:
(https://listerengine.com/coppermine/albums/userpics/10047/M0088A.JPG)
But it does have some metal work: made up a a well for the flywheel from some brass sheet, little bits of tube as spacers, & soft soldered it all
together
(https://listerengine.com/coppermine/albums/userpics/10047/M0088C.JPG)
The base from above
(https://listerengine.com/coppermine/albums/userpics/10047/M0088B.JPG)
and with the flywheel well in place:
(https://listerengine.com/coppermine/albums/userpics/10047/M0088D.JPG)
Also made up a well for the crank, it fastens to the underside of the aluminum base. There is enough clearance between the metal base plate and the wooden base, so this is not essential,
I may well omit it eventually, if so, will just cover the hole in the wooden base with some flat stuff. This has also been my test piece for paint, it's been green, red, and now brown, not crazy about any of them so far...
(https://listerengine.com/coppermine/albums/userpics/10047/M0088E.JPG)
(https://listerengine.com/coppermine/albums/userpics/10047/M0088F.JPG)
a bunch of studs to attach everything to the base
(https://listerengine.com/coppermine/albums/userpics/10047/M0092.JPG)
A quick turning job to make the trunnion for the beam (here it's chucked up for polishing)
(https://listerengine.com/coppermine/albums/userpics/10047/M0089.JPG)
in place
(https://listerengine.com/coppermine/albums/userpics/10047/M0090.JPG)
and with the bits fastened to the wood base, and the beam perched in it's spot:
(https://listerengine.com/coppermine/albums/userpics/10047/M0093.JPG)
Cheers, Joe
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Impressive work, Joe.
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Thanks Bear!
Joe
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Look really good now that one truly can see what it should end up as :cheers:
Still following :popcorn:
Per
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Thanks Per. I agree, a mile-stone moment once it's all sitting on it's base, it's encouraging!
Joe
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Flywheel part one... a lot o photos of this, so I'm breaking it up into 3 posts.
Pretty much made this up as I went along based on what material I had on hand.
Cut 6 pieces of the mystery brass, drilled hold-down holes in what would eventually be waste,
screwed down on a sacrificial bit of aluminum on the rotary table and cut the sides to the requisite angle
(https://listerengine.com/coppermine/albums/userpics/10047/M0101.JPG)
In the same set up, ran a light cut to define the inside radius, and then chain drilled the lot
(https://listerengine.com/coppermine/albums/userpics/10047/M0103.JPG)
Hacksawed off the waste and then back to the mill to clean up the arc
(https://listerengine.com/coppermine/albums/userpics/10047/M0104.JPG)
Then chain drilled the outer arc, and as above, sawed off the excess and cleaned it up on the mill
(https://listerengine.com/coppermine/albums/userpics/10047/M0106.JPG)
This took away the hold-down holes, so had to clamp the work to the table, but happily, nothing moved throughout the process
(https://listerengine.com/coppermine/albums/userpics/10047/M0108.JPG)
Then drilled the centre of each segment radially, with a short counterbore on the inner side, for fitting the spokes
(https://listerengine.com/coppermine/albums/userpics/10047/M0107.JPG)
More to come....
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fly wheel part 2...
Chucked a length of brass, drilled and counterbored the size of the spoke material
(https://listerengine.com/coppermine/albums/userpics/10047/M0109.JPG)
Added a little decorative cut, and then parted off, repeat 5 more times
(https://listerengine.com/coppermine/albums/userpics/10047/M0110.JPG)
cut 6 pieces of stock for the spokes, turned down one end and threaded them on the lathe
(https://listerengine.com/coppermine/albums/userpics/10047/M0113_28229.JPG)
Turned them about and turned a short length to the diameter of the counter bore in the rim segment, with a further length smaller
to the diameter of the through hole in the rim segment
(https://listerengine.com/coppermine/albums/userpics/10047/M0112.JPG)
Stuck together just to see how it was coming...
(https://listerengine.com/coppermine/albums/userpics/10047/M0113.JPG)
Cleaned up a bit of brass in my larger lathe to create a chucking piece for the small lathe
(https://listerengine.com/coppermine/albums/userpics/10047/M0114.JPG)
Once trued up on the Taig lathe, cleaned it up ready to move to the mill
(https://listerengine.com/coppermine/albums/userpics/10047/M0115.JPG)
The point to doing the set up on the Taig lathe is that the Taig chuck fits the indexing head built for the Taig mill
So, here drilled 6 equidistant holes, counterbored them to fit the decorative bits made earlier, and tapped to fit the threads
on the spokes. (This threading is simply to hold things together for soldering)
(https://listerengine.com/coppermine/albums/userpics/10047/M0116.JPG)
more to come...
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Flywheel part 3
Test fit:
(https://listerengine.com/coppermine/albums/userpics/10047/M0117.JPG)
Looked good, so went ahead and tapered the spokes
(https://listerengine.com/coppermine/albums/userpics/10047/M0118.JPG)
5 down, 1 to go...
(https://listerengine.com/coppermine/albums/userpics/10047/M0119.JPG)
Cleaned up all mating faces, fluxed and clamped down & silver soldered
(https://listerengine.com/coppermine/albums/userpics/10047/M0120.JPG)
set up as true as I could on a faceplate, ready to clean up the rim, hub, and drill & bore the hub
(https://listerengine.com/coppermine/albums/userpics/10047/M0121.JPG)
Flipped around, centred by putting a little stub in the shaft hole, cleaned up the reverse side and removed the excess
on the hub
(https://listerengine.com/coppermine/albums/userpics/10047/normal_M0122.JPG)
( and could not find a speed or feed that this crap brass liked to get a clean cut radially, glad I've almost run out of it!)
Broached the keyway in the arbor press, and here it is sitting where it belongs:
(https://listerengine.com/coppermine/albums/userpics/10047/M0123.JPG)
Big job done! Cheers. Joe
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Looking awesome!
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Thanks, Bear!
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Wow! That was a lot of work, but the results look great!
Kim
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Thanks Kim!
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Great job on the flywheel! Very impressive.
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Thanks Chris. I need some of your shop elves to get up to your speed. Looking at the base plates you've been doing just now
for your latest project... don't envy you the tapping you have coming!
Joe
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Thanks Chris. I need some of your shop elves to get up to your speed. Looking at the base plates you've been doing just now
for your latest project... don't envy you the tapping you have coming!
Joe
Yeah, the tapping will be spread out over a bunch of sessions, probably will alternate next parts with it.
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Great job this fabricated fly wheel. Very impressive.
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Thanks Achim. Good to have you looking in!
Joe
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A truly outstanding job on the flywheel! You're a very patient man!
gbritnell
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Damn Joe very impressive fabrication work. I noticed after you finished the wheel, that you cut spline joints to butt the wheel rim together. I only build one flywheel in pieces but lapped the joints on the rim and had a jig to hold them together for silver soldering. The other two were made by rolling the rim around a former then cutting a cross lap to joint them, (like cutting a 45 degree on a straight piece.) then pulled them together in the vise to solder.
Great work and plenty of photos to show how things are done. love to see new ideas on fabrication.
:cheers:
Don
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George, thanks! Coming from you, I'd better go and get a bigger hat!
Don: Thanks to you too. The spline joints are revealing my wood-working past.... (and present...)
Joe
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Educational and inspiring! I'm on my second bar stock engine and have bought in flywheel castings for both. I may think differently in future. Excellent work. Terry :ThumbsUp: :popcorn: :popcorn: :popcorn:
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Thanks Terry. Good to have you looking in!
Joe
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Great work all round.
Like everyone else I'm particularly admiring the flywheel.
Really nice machines, too - the universal pillar tool, and the lathe with your shop-built dividing head. Nice setup!
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Thanks Gary (unless you are currently in France, then <merci> )
Must admit, derive as much enjoyment from making tools & gadgets as from building engines....
Cheers, Joe
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Yes - machine tools have a beauty all their own, for sure.
I'm not in France - still can't over there due to covid restrictions. Malheureusement...
:cheers:
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Got going on the linkages for the parallel motion:
1st parts were some flat bar stacked together for drilling the requisite holes, then added some filing buttons and brought to shape
(https://listerengine.com/coppermine/albums/userpics/10047/M0127.JPG)
sitting in place: the various shafts were all straight-forward turning jobs
(https://listerengine.com/coppermine/albums/userpics/10047/M0128.JPG)
needs 3 pairs of links of different lengths, made the jig described in the book which permits keeping the holes in the same plane, and at
right distance apart. TC suggests a bit of steel for this, I went with a spare piece of aluminum, it only needs to hang together for 24 holes...
and it did.
(https://listerengine.com/coppermine/albums/userpics/10047/M0129.JPG)
Once the holes were done, back in the lathe to turn to dimension, and a bit of a polish
(https://listerengine.com/coppermine/albums/userpics/10047/M0131.JPG)
next clamped back on the jig in the mill to flatten the ends
(https://listerengine.com/coppermine/albums/userpics/10047/M0132.JPG)
Finished by rounding over the ends with some filing buttons
(https://listerengine.com/coppermine/albums/userpics/10047/M0133.JPG)
Next was the thrust links... made a lovely set before re-checking the bill of materials... brass called out, not the steel ones I had just made..
so, did them again! Went faster the second time around. Re-started by turning some hex brass (as it was the right size to get the parts out)
(https://listerengine.com/coppermine/albums/userpics/10047/M0134.JPG)
Milled to their final rectangular dimension, and then relieved on two sides to trap the strap
(https://listerengine.com/coppermine/albums/userpics/10047/M0135.JPG)
drilled under size, cut off the ends and brought them down to dimension, then cleaned up the holes carefully with an end mill
(https://listerengine.com/coppermine/albums/userpics/10047/M0136.JPG)
Simple turning job to make the top half of the upper bearing, made 2 and milled half of them away
(https://listerengine.com/coppermine/albums/userpics/10047/M0137.JPG)
simple job to bend a bit of flat steel for the straps, drill & file the slots for the cotters which were filed out of some of the same stock
(https://listerengine.com/coppermine/albums/userpics/10047/M0138.JPG)
And here they are assembled on to the beam. The retaining collars are currently held in place with cotter pins, they will be permanently pinned upon final assembly after painting
(https://listerengine.com/coppermine/albums/userpics/10047/M0140.JPG)
The last pair of links (with the fancy bead detail) are for the valve linkage... which will be next. Made them all together as they used all the same set-ups.
Cheers, Joe
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Very pleased to see your excellent progress.
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Thanks Bear. Good to have you following along!
Joe
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Nice work on all those links, Joe. They look great mounted on your engine!
Kim
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It's my pleasure, Joe. I am learning from it.
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I do like gib and cotter split bearings :) and yours are NICE. :cheers: Terry
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Very nice work!
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Terry, Gary, thanks!
Moved on to the valve linkage: turned a shaft, match-drilled 2 bits of flat bar, and then filed them down to make the arms. The short length of round
is a spacer to hold the arms the right distance apart for soldering, and the quick & dirty clamp is to keep them in the same plane & not move during soldering
(https://listerengine.com/coppermine/albums/userpics/10047/M0141.JPG)
After soldering & clean-up
(https://listerengine.com/coppermine/albums/userpics/10047/M0142.JPG)
A straight-forward turning job for the valve crosshead & collars, I will permanently pin these as they do not need to be disassembled later for paint
(https://listerengine.com/coppermine/albums/userpics/10047/M0145.JPG)
Turned & threaded a pair of shoulder bolts
(https://listerengine.com/coppermine/albums/userpics/10047/M0146.JPG)
some fussing around to get the lever assembly into the base of the cylinder, reassemble the cylinder assembly, and here the arms are bolted to the levers
(https://listerengine.com/coppermine/albums/userpics/10047/M0147.JPG)
And then got to fit the eccentric rod that was made ages ago...
(https://listerengine.com/coppermine/albums/userpics/10047/M0148.JPG)
a different view:
(https://listerengine.com/coppermine/albums/userpics/10047/M0149.JPG)
Next up will be the connecting rod, and then things can go round-n-round!
Cheers, Joe
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:ThumbsUp:
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That's a great looking engine and really nice work! As a fellow Taig user I have an additional interest to follow your work. Is that dividing head I see based on the Tony Jeffree design?
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Thanks Bear. Ron: Thanks for looking in, yes it is more or less Jeffries' second version. It has been a very useful addition to the tool chest, gets a fair amount of use. Excellent in that it matches up with all the Taig bits.
Joe
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Just checked in Joe - more fine progress and good to see it all coming together :ThumbsUp:
That paint on the flywheel - is that the finished colour or a primer - whatever I really like the shade.
Regards - Tug
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Nice work on all the linkages there! Very nice looking engine. :popcorn: :popcorn:
Kim
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Thanks Kim. Tug: thanks, the paint is supposed to be a self-etching primer. Unfortunately, on this particular brass it is not adhering
well at all, I can scrape it off with my fingernail. I do like the colour as well, if I can find a primer that sticks, I may well use this one as the top coat.
Joe
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I like all the fiddly little bits. It's all coming along nicely.
Please share what you settle on with a primer for brass that provides better adhesion if you find any.
Charlie
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Thanks Charlie. It's those fiddly bits that keep us coming back! A good primer for brass is like that winning lottery ticket... it's out there, but odds are long.
On to one of the parts I've been looking forward to, the connecting rod.
A length of round of great enough dia to get all the parts out, and some flat bar for the big end. the random looking hole in the flat is to ensure
full penetration of the silver solder, it's location was not spot on centre, but as it will be milled away no big deal
(https://listerengine.com/coppermine/albums/userpics/10047/M0150.JPG)
Once soldered, in the mill and brought down to near dimension, and in the same plane as the shaft
(https://listerengine.com/coppermine/albums/userpics/10047/M0151.JPG)
dialed it in the big lathe & centre-drilled the end of the big end (not shown) then extended further out to turn the centre part of the shaft down to it's maximum diameter
(https://listerengine.com/coppermine/albums/userpics/10047/M0152.JPG)
Back to the mill to start to shape the small end, using a taig vise to index the cuts plane to the big end
(https://listerengine.com/coppermine/albums/userpics/10047/M0153.JPG)
1st oops on this part, turned a dial the wrong way & put a nice rabbet on one side of the smaller square section...
(https://listerengine.com/coppermine/albums/userpics/10047/M0154.JPG)
Happily, this was shallow enough that I just made the square section octagonal... and actually like it better!
(https://listerengine.com/coppermine/albums/userpics/10047/M0155.JPG)
on the taig lathe to make the fish belly curve on the centre part, this was done with a succession of files, strictly to eye
(https://listerengine.com/coppermine/albums/userpics/10047/M0156.JPG)
transferred to the mill with the indexing head, off-set half the desired thickness of the rib, and angled faintly to simulate draft angle, and 4 times around with a ball-end cutter, then off set the same distance from centre on the other side, reverse of the angle, and 4 more passes
(https://listerengine.com/coppermine/albums/userpics/10047/M0157.JPG)
back on the lathe to turn the decorative bands that join the fish-belly centre to the bearing ends..
(https://listerengine.com/coppermine/albums/userpics/10047/M0158.JPG)
All the turning completed, all mill & hand work to go
(https://listerengine.com/coppermine/albums/userpics/10047/M0159.JPG)
Cheers, Joe
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That's a really interesting sequence Joe; very instructive and a beautiful result. It looks like you had fun!
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Very clever, Joe. You are truly a machinist. I may have asked in the past; but, what is the other lathe you are using, the green one?
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RReid: Thanks, yes this was a fun bit to make! Bear, thanks, that lathe is a far east product, badged as "Craftex" by Busy Bee here in Canada,
no doubt available under many names around the globe! It has served me well, lots of grunt compared to a Taig. Dropped enough $ to get the model that screw cuts.
(https://listerengine.com/coppermine/albums/userpics/10047/DSCN0221.JPG)
Joe
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Thanks, Joe.
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Nice work on the connecting rod, Joe! Love how you did the flutes along the length.
Thanks Charlie. It's those fiddly bits that keep us coming back! A good primer for brass is like that winning lottery ticket... it's out there, but odds are long.
Why don't you ask Chris (Crueby) what he uses? He paints plenty of brass - he must have some method he uses!
Kim
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Nice work on the connecting rod, Joe! Love how you did the flutes along the length.
Thanks Charlie. It's those fiddly bits that keep us coming back! A good primer for brass is like that winning lottery ticket... it's out there, but odds are long.
Why don't you ask Chris (Crueby) what he uses? He paints plenty of brass - he must have some method he uses!
Kim
I have had good luck with Duplicolor engine enamel with ceramic spray paint, meant for car engines. Holds up great to heat, no baking, dries quick, goes on thin. Cleaning off any oils first is important, just very hot water and dish soap will do. A good etching primer would likely help, I have not found one these days. The engine paint holds up well, still nothing like a baked on paint or powder coat for durability. The bake on ones I tried required mixing and spraying which was not great for small batches. A lot of great paints went away with reduced VOC rules.
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Thanks Chris, I'll give that a try. Local autoparts dealer stocks duplicolor.
Joe
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More connecting rod:
Trimmed the small end, milled the relief for the bearing, drilled & filed the slot for the cotter & gib
(https://listerengine.com/coppermine/albums/userpics/10047/M0160.JPG)
Milled out the centre of the big end, then on the rotary table to shape the outside curves
(https://listerengine.com/coppermine/albums/userpics/10047/M0161.JPG)
Cut off the excess material, milled the bearing locations, drilled & filed the key & cotter slots
(https://listerengine.com/coppermine/albums/userpics/10047/M0162.JPG)
soldered together two pieces of brass that had been cut in half lengthwise, centred the part line in the lathe,
turned & drilled the bearings. Wrapped some wire around them for the drilling & parting off to prevent them separating
(https://listerengine.com/coppermine/albums/userpics/10047/M0164.JPG)
Where it goes:
(https://listerengine.com/coppermine/albums/userpics/10047/M0165.JPG)
As before, some simple cutting, filing, & bending for the strap & cotter & gib
(https://listerengine.com/coppermine/albums/userpics/10047/M0166.JPG)
Assembled on the crank pin
(https://listerengine.com/coppermine/albums/userpics/10047/M0168.JPG)
More of the same for the big end
(https://listerengine.com/coppermine/albums/userpics/10047/M0169.JPG)
Won't be long now!
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Connecting rod in place:
(https://listerengine.com/coppermine/albums/userpics/10047/M0170.JPG)
And a short run on air! IT'S ALIVE!
https://www.youtube.com/watch?v=V6d1eU0psQI
Running on about 20 PSI from the compressor reservoir, hadn't fitted a valve to reduce the flow. Should run nice and slow once it's all run in.
Joe
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Congratulations - you got a runner :cheers:
It is a bit tight, but I expect that this will disappear after more running time or are you doing more work on it first ?
Per
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Thanks Per. Still have the inlet & throttle valves, and the governor left to do. May well jury rig some sort of belt drive to run it in while
I'm playing around with those parts. Then, of course, take it all apart for finishing!
Joe
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That looks great now, will look fantastic all prettied up and just ticking over. :ThumbsUp:
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Great job, Joe. It has been a treat to watch this build and the ultimate accomplishment of it running well.
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Terrific! Always a big grin when it first takes off!
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Ron, Bear, Chris: Thanks guys! Definitely big grin time here.
Joe
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Excellent :praise2: The first run is always good :ThumbsUp: :wine1:
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Great to see your beautiful workmanship burst into life.
It has been great following along, and I look forward to the remaining details take shape.
MJM460
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Excellent a runner makes you proud every time. Nice work Joe…. :Love:
:cheers:
Don
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What a super engine - I really like the intricate parts, it's a beauty.
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Lovely result Joe and a good runner too - bet you're happy with that :)
Once that valve goes in it'll be nice to slow it down some so you can watch all that motion.
I'm surprised how quickly that came together - super work indeed :ThumbsUp: :ThumbsUp:
Regards - Tug
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Lordy, Lordy!! that is pretty!! Well done!.... :DrinkPint: :smokin2:
BC1
Jim
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Roger, MJM, Don, Propforward, Tug, & Jim: Thanks guys!
I've been fussing with the valves, seems like I've almost got there, hopefully another video soon!
Joe