Exhaust Valve and Cylinder Block Mounting

Next up, the exhaust valve housing and mounting the cylinder block.
I turned the housing from some brass, I was hoping for bronze but none to be had when I was ready for it. This piece threads into the support plate, it will need some thread locker on assembly to keep it in place. IMGW1374

The cylinder block, which I made on my Taig in fall of 2014, was marked up for holes on 3 sides. 2 are tapped for the spark plug and carburetor, the other is the exhaust port.

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Making the Crankshafts

With the shafts for the cranks ready, it is now time for the webs and crank pins.

The webs were machined to 25mm from 1” stock. The shaft hole was drilled to 5.5mm and then reamed out to 6mm to fit the shafts closely. They will be attached with Loctite 603 (or more likely the affordable alternative from Weicon). Cutting off went quite well, having a strong lathe makes this so much less traumatic. The webs gave me some challenges as they are only 6mm thick after cutting them off the raw stock. Holding these straight in the 3 jaw was not easy but I ended up using a piece of 6mm rod in the tailstock chuck to align the web. This let me face the second side and reach the 6mm target dimension.

Crank webs installed

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Main shaft

With more parts to make, there are more tools to make 🙂

In making the main shaft, which mounts the flywheel and the exhaust valve, I needed to cut 3 flats 120 apart. From my stash of metals I dug out some hex and bored, then reamed for 10mm. A set screw finished that tool off. While cutting the 2.5mm slot in the end I broke the cutter.

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Mounting the supports

After drilling the base plate, the next item was to drill the supports to the same pattern. This was a bit nerve wracking as there is not much wiggle room for ‘adjustments’.

To align the holes in middle of the supports I used a .375 rod in the mill arbor, and a parallel to make it align with the top surface of the support. The spindle was then in the middle, the vertical was then locked into place. The other position was aligned each time with a spotting drill and then drilled 4.2 for the m5 SHCS.

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Drilling the bottom plate

The bottom plate is up next. I need to mount the bearing/shaft supports so that I can measure dimension changes needed for the shafts. The material is Imperial, the drawings metric. Without redrawing everything I think this is my best approach to arriving at parts that fit together.
I bought a full set of ER32 collets so that I can use the horizontal mill for drilling as well as milling. I used a 5/16 end mill to counter-bore the holes, I really wanted to make some metric counter-bores, but need to use the tool grinder to finish those. The end mill worked out ok but not great. Thankfully I am the only one who will see the 2 bores that are out of center 🙂

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