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Ray, It is funny how one little change can snow ball into a succession of "adjustments." But that is where your experience comes into play. I have always believed that what separates the men from the boys is being able to solve such problems gracefully, and you are doing that. I am not too...

I agree with you. Those 2 plates are 5mm 6061-T6 aluminum, but I think they will flex during operation. To fix that, there will be a cover plate with a flange machined into it such that screws will come thru the existing angled plates, into the cover plate, and lock the structure securely...

I am at my laptop trying to post a few picture that I just took, with my hands still dirty and oily. Didn't stop to wash them. Getting too greedy. Need to slow down, clean the shop, and re-group before I mess something up. Anyone else ever have this dilemma? OK, I count almost 100% of you...

A grooved or ridged copper gasket has gotten me out of some bad situations. The grooves or ridges can be on the gasket or the mating surface(s). Have you tried tightening up the lash on the exhaust valve a little to keep the pressure from getting high enough in the cylinder to push the fuel...

Gents, @The Ignoble Troll and @Nerd1000 The silver steel sound like W1 high speed steel/drill rod in the US. Good to know! Thanks for that info, and it is readily available in the US.

My shop is getting messier and messier as I can almost sense the finish line in the distance. But I still can't see it! The cylinder liner was a real test of my patience, but it finally worked out. I started out with some 4340 cond N, chrome moly steel, 2" O.D. x.25" wall. It was expensive...

Agreed, the 316 swarf could be used for prison razor wire. I have had reasonable success drilling 316 with a sharp drill and as soon as I feel it get under the skin and start to cut, keep the pressure on so that the chip load stays sufficient. And it takes a healthy push to break thru the skin...

Nerd, A couple of reasons. The wrist pin hole passes over the pressurized intake ports so the ends of the pin need to be sealed to keep pressurized air from being blown around the pin and into the crankcase. In the Detroit Diesel the pins float and there is a cupped disk (like a Bellville...

ROTATING and RECIPROCATING ASSEMBLIES Even though everything looked more or less complete in the previous posts, there was still a lot of detail work that had to be done. Most of the material choices were based on general experience and not from any engine building. Considering the light duty...

@Rdean33422 , Very nice. That timing belt fitting just right is an indication of how that extra 6 cyl crank will be "just right" some day. I like the needle bearings. Compact and you use the shaft that you made as the inner race, correct? Is the outer race a pressed cup or a machined hard...

Ray, I have to say that this project is turning out incredibly well. The thought and detail are very nice, but what makes me chuckle a little is the casual way that you describe the work you are doing. The only stressful part I noticed was tapping all the holes in the top of the block. I think...

Do different vendors use different materials, machines, methods, etc? I guess they do(?) But still all of the castings printed parts pictured in the thread look extremely nice, as good as investment castings but at a much, much, lower cost. I will be interested to see if all the printed parts...

Final Boring for the Bearings Really getting into the fun stuff now. This is the outboard support for the one-piece crankshaft being bored for the insert bearing. The bearing O.D. is 27mm. I really love boring on the mill. When the results are good, it is extremely satisfying. I have no way of...

With the rag on the outside of the air intake cleaner? I have never witnessed a problem when this is done, although I guess something wrong could happen. Using gasoline and solvents always requires caution, and if you aren't sure, please don't do it.

Well! It looks like I got a couple of boot prints in the butt...... and some age shaming for saying I was too old to force myself to learn Alibre 3d. And @Gordon , I see you just posted to make me sink even deeper into the chair. No excuses allowed, I guess. I agree that nothing is faster...

snip ........................ Many years ago when I was a kid on a construction site, I was told by the diesel mechanic trying to get a motor grader running, to pour some gas on a rag and hold it over the diesel air intake. I thought he was just looking for a good laugh at the "kid's"...

Jason, from your posts, I sometimes think that you, like several others here, have built or worked on just about one of everything. A few years ago, we were visiting our son in law's parents in Sussex (not to far from Surrey?) and spent some time at the BlueBell railway. Son in law and I were...

What a great find! You KNOW at least one of those gears is going to come in handy very soon. I disassemble almost everything that I have to throw out and add the "goodies" to the "for future needs" collection. It is amazing how, after awhile, just what you can make without having to buy...

This 3d metal printing is both encouraging and discouraging, for me, at least. It is encouraging because of the seemingly limitless possibilities that are available right NOW, and for the new ones that will be developed in the future. The new processes are being developed sooooo fast. And at...

I have a bunch of 35mm O.D. x 1.2mm wall (standard 1-1/4 Type L) copper tube. The 42mm you want is very close to 1-1/2" Type L or Type M. (41.3mm x 1.5mm or 1.2mm). A good possibility might be an old established plumbing business in a city where codes required lots of copper pipe. They still...