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The manual is copyrighted and it contains drawings for the myriad non-cast parts. - Terry

While wrapping up a number of 'minor' details related to the design of crankshaft so work can begin on it, the Mabuchi RS-775WC-8514 motors arrived. Other than a larger shaft diameter, their form factor is identical to the John Deere motor, and so its adapter was reused. The larger shaft...

In truth, my files wouldn't do you any good because the engine was built from a set of castings and my files related to piecemeal areas of those castings. In any event Richard Maheu, the original designer of the quarter scale has been adamant about sharing any drawings related to his original...

A pulley turned from wood was bolted to the crankshaft flange on the tester. What I was about to do next deserved a little more thought, but I was anxious to see the starter in action. With the tester clamped in my workbench vise and the Nichibo motor installed, a five pound barbell weight was...

Yes, see post #111.

Thanks, Charles. I'd never heard the term before (my copy of Ivan Law's book doesn't mention it), but after reading up on it I think you're right. My 12 tooth gear's addendum seems to have been increased to a DP of 42. - Terry

First up for the finished ring gear was a sanity check of its center-to-center spacing when meshed with a commercial gear of the same DP. An advantage of using 32 DP is that it's a popular gear pitch used in some Traxxas RC stuff, and a handful of pinion gears can be purchased for $10 from a...

A 3/4" disk of 4-1/2" diameter Stressproof arrived from Speedy Metals in time to start work on the flywheel/ring gear. Its sawed ends were faced flat, and a 1.3125" hole was bored through its center for a one-way clutch. This hole's exact diameter was important for a couple reasons. A too-small...

I really have no CAD/CAM experience except with 2007 and 2010 SolidWorks and 2007 Sprutcam which is what I started with 20 some years ago, and it seems I'm still learning about. So, I can't speak to any other software. I do know that George also uses SolidWorks, but I don't know about its...

The bell housing was designed around models of the already completed block and 775 motor adapter. The hope is that the adapter will absorb minor changes to the starter as its design is finalized. If it turns out that a 550 size motor will work after all, only a new adapter will be required. An...

Charles, Yes, that's the reason the flywheel was turned down just under the ring gear. I can press a flange onto the the crankshaft sleeve and then bolt a secondary flywheel to it if necessary. - Terry

An electric starter with ring gear engagement has been a nice-to-have feature of this engine since the beginning of its build. The starter will be an integral part of the bell housing, and so a candidate was needed before getting too deep into the design of the bell housing. My quarter scale...

A few small parts later, and I had a functional water pump. The impeller was machined from Delrin and pressed onto a 3/16" shaft. Its one thou interference fit wasn't tight enough to keep it from slipping under load and so it had to be pinned. The shaft runs in a pair of 3/8" sealed ball...

Peter, I just came upon this thread and must say its a marvelous piece of work. If you have any construction photos I'm sure we'd all be interested in seeing more of your process you'd be willing to share. This would have made a wonderful build thread being one of those projects that many talk...

Few More Photos ....

Several water pump variations were used on the small block Ford: forward vs. reverse flow, driver or passenger side inlet tube, and with or without a back plate. Although less common, I chose the driver-side inlet to avoid crowding the area around the alternator on the passenger side. I also...

I once tried a corncob mill and I seem to remember having good success with it. I have one variable pitch cutter but its only 3/8". I may revisit a corncob cutter when its time to machine the bell housing. - Terry

I tap the holes manually using a shop-made tap block - nothing complicated, just a block of Delrin with a hole drilled in it for the tap shank. I use WD-40 for tap fluid and the chart recommended 75% engagement tap drills. Gun taps for through-holes, and tapered followed by bottoming taps for...

You're right. I'll likely add one to the plug keeping an eye on poles.

I use ten teeth/inch as a compromise blade for aluminum and steel since I regularly cut both and don't want to keep swapping blades. Except for this stuff I've never (and still don't) have trouble cutting 6061. I'm using 7075 because I had a huge piece of it purchased many years ago for next to...