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Coming along Bob, I see you have smooth sides on the conrod now. I have a couple of suggestings. It looks like you are doing a slot cut, this is fine and when starting a machining operation and it can't be avoided, but be aware this is OK for a roughing pass only. As the tool is cutting the...

Wow, awesome, sounds great. Congratulations on your first run. The pull starter is epic.

Terry, Your parts look amazing, like they were die cast. How much hand finishing do you do before bead blasting?

Offy – Camshafts The Offy has two overhead camshafts, here I will machine the exhaust cam shaft. The intake camshaft will follow the same process, but with a different cam lobe profile. Cam Blank diameter .430″ Cam Base Circle Diameter .25″ Nose Radius .025″ Lift .090″ Flank Diameter . 743″...

Looks good Andrew. What speeds and feeds are you running the gear cutter on the 4130?

I try to organize my files by cutter size. For example, I might run the 1/4" flat end mill program first. This single file could contain an "adaptive" or "pocket" strategy that clears most of the material (leaving about .015"), a "horizontal" strategy to finish the top flat surfaces, and a...

I agree, I use F360 and have always been able to get it to do what I want. Not always straight forward and some time you need to "trick" it. But it works very well for me. I agree with @Jasonb, it is important to use the correct machining stategy. I will use an "adaptive" to clear the bulk...

Looking Fabulous, really coming along Terry. The "Ford" radiator mount is a nice touch. Interesting story about GM's use of the Cooling System Seal Tabs in early aluminum headed engines. I just went and boungt a life time supply (one package) on Amazon for $4.02.

Offy – Crankcase Breathers One of the most distinctive features of the Offy is its crankcase side breathers. These are highlighted in the photos below. On the early engines these were quite low, over time they were raised and additional internal baffling was added. Only the right side of...

Wow, that is pretty cool, and a nice finish!

Yeah, your are probably right, I built the analog circuitry first, then decided to use a micro controller. When it is all said and done, the majority of the analog circuitry may not be needed.

The electronic ignition I am working on is a simple embedded solution, no RTOS. I have an analog circuit that uses the hall sensor to create a 4ms pulse, firing the spark plug about 3 degrees after top dead center on the compression stroke. When the engine is running below 500 RPM (for example...

Offy – Cylinder Sleeves The sleeves are made of cast iron and I start by removing a lot of the material on the OD, but do not bring it to final dimension. I drill most of the material from the bore by stepping up in drill sized until I am a 1/16″ from final dimension. The techniques I used to...

Andrew, I was playing around with some numbers and found that if you use a 1 module cutter, very common by the way, a 20 tooth gear and 30 tooth would have thier shafts about 1" apart. Just a thought.

20 teeth gear blank OD of 1" is a DP of 22, 30 teeth 24 DP gear blank OD is 1.33333. 30 teeth, DP of 22 is a gear blank OD of 1.455" Do these gears mesh? then they need to have the same Diametric Pitch. What is the distance between the shafts and what is the reduction ratio you want? We can...

@willray The coil I am using likes to see as you say, about 4ms of dwell. This is the time to charge the coil and determines the energy of the spark. If my engine is running at 4000 RPM and I am using wasted spark where I fire both spark plugs every revolution of the crankshaft, I need to...

Ray, I will be using a UNO for my microcontroller, actually I will just be using the ATmega328P chip on my own board. It sounds like your code is more advanced than my version. I use two interrupt routines, one triggered by the hall sensor which starts a timer for the pulse width and a second...

Thanks for the kind words George and Terry, and the advice. I have ordered a 1 foot, 1.25" round of 1144 and it will be here on April 6th. There are plenty of other things I can be working on until then. I have not worked with 1144 before and this will be a good opportunity to see what...

The ignitor is built into the COP, that is why they are so nice. All you need to do is provide a simple 5 Volt, low current pulse to trigger it.

Offy - First Gear The Offy has a lot of gears in the timing gear train and I want to have the gear tower populated before I fabricate the camboxes to insure I have the proper gear mesh between the gears in the gear tower and the camshaft gears. This sequence is how I make gears. I make a...