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Top End Assemblies Finalized Today I have gone back and attempted to "finalize" the assemblies that have no known design issues. I put "finalize" in quotes because nothing is ever final. I have decided to machine some coolant cavities into the head to allow for more coolant volume and better...

Really cool, what a great christmas present. I love the boiler door.

Camshaft My design criteria for the camshaft includes the following: Turns on two ball bearings (all shafts turn on ball bearings, crank, gears and camshaft) A center bush in addition to the two out board ball bearings Oil delivered to the four cam lobes and the center bearing Cam Lobe...

Top End Plan for the day is to define the Cam box end plate, cambox cover and the cambox top features. These include the bearing surface for the cam and a way to collect oil used to lubricate the cam and pass it down to the cylinder head. The cambox end plate may seem like an odd place to...

Head Design - Part 3 Continued work on the cylinder head by adding the features shown below. Oil is pumped through the camshaft to the cam lobes. This oil drips down through the cam boxes and collects on the heads where the valve cages are. There needs to be a trough machined to collect this...

Cool, thanks for the bump.

Bravo, she is a beauty!

Cylinder Head - Part2 Today I am looking at the head combustion chamber, valve, and valve cage. I start by pulling in a model of a valve I have used before and tweak it to fit. This is used in the Wallaby, a 1" stroke and 1" bore engine. The first thing I find is that there is not much...

Top End I have started looking at the top of the engine, the head, cambox, and camshaft. But I got sidetracked working some of the subtle shapes of the crankcase that bothered me. I did not like the way that SolidWorks generated the fillets circled below. I spent a fair amount of time...

Crankcase Bottom Today I turned my attention to the crankcase bottom. Since the crankcase is split I need some method of screwing the two halves together and I would prefer if I could hide the screws, the original engine has a one piece crankcase. One possible idea is to hid them behind...

Peter, You are right, I need to pay attention to the compession ratio design with a more complete model. I have not thought about the head yet, but when I do I need to insure I am satisfied with the compression ratio. I cannot add a head shim as it would raise the valve box and my timing gear...

That is awesome, I love it.

Upper Crankcase Half Today I worked on the upper crankcase, the crankshaft and its bearings. In the photo below a cut away exposes the detail of the upper crankcase and illustrates how the crankshaft is mounted. The center crankshaft bearing is still missing. I have highlighted detail...

Henry, If I were you I would not wait until casting prices go down to get your project underway. Yes they are expensive, but if you amoritize the cost over the time you will be building your engine you will be getting a great deal on your enjoyment. Compare the cost to some other activities...

Wow, you are making quick progress and the engine is looking great. The Kiwi Mk2 is a classic Westbury and one of my favorites. I will be tagging along for the ride.

Crankshaft Continued I continued to work on the crankshaft. I have already established the bore to be .75" and now I want to confirm the stroke. A stroke of .75" is a good place to start. I develop a model representing the volume inside the cylinder with the piston at the top of the stroke...

I own one of these LMS 8.5" X 20 Deluxe lathes and am very happy with it. This model has the DROs which are very nice. It is a small lathe and it is not as ridgid as a larger lathe, of course. The compound is not real ridgid and I often will remove it and bolt my tool post to the cross slide...

Gear Train Final(?) It is important to nail down the gear train as it dictates the engine geometry. The gear mesh tolerance has to be perfect and the distance between the gears defines the position of everything else. I think I finally have a solution I am happy with. These are the...

Crankshaft I need a break from timing gears, so I am going to turn to the Crankshaft. I import a scaled drawing and build a crankshaft on top. Notice in the drawing that the two center cylinders are pushed towards the two ends of the bock to make room for the center crankshaft bushing. Also...

Bob. I am attempting to maintain the distance between the crankshaft, water pump, magneto and the camshafts. When ever I change the diameter of the gears these dimensions are impacted. I am also fighting the fact that the camshaft gear has to be twice the diameter of the crankshaft pinion...