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Hi ignator, yes I thought that "Booker rod" would cause some comments, My 1890s lathe has a 6TPI Cross feed screw and the marks (if they can be seen) represent 0.017 off the diameter, not counting backlash, not very useful. The Lifan setup is an alternator with a magnetic pickup for the...

Todays progress on the Onan opposed twin half scale engine. Photo 1 fitting the Lifan Chinese magnito, 2 machining the base for the magnito on the timing cover, 3 how to get it all the right shape, this photo more detail of the rotery table can be seen, 4, 5, & 6 travel stops on the old lathe...

The crankshaft? Most weed eaters have a single shaft through 2 bearings then a plate with an open crankpin, much like the model aero engine, some motorcycle crankshafts are made up with roller bearings and all pressed together, even multiple cylinder ones, the Suzuki 3 cylinder 2 stroke Jeep...

The chuck is 10 inch, I cast the timing cover from lost foam, photo 1 in the green sand ready for the next box, 2 shows the internal shape, 3 the outer shape, 4/5 it came out very rough but it is cleaning up OK. The ringgear I slowly bent in the vice until it nearly metup then I clamped it in...

Another day on the Onan opposed twin half scale. Photo 1 I have set up the crankcase on a spigot to turn true bolted the timing case on and bored through for the crankshaft, faced back the case ready to fit the Lifan Chinese ignition coils and flywheel, photo 2 turning the seal seat inside the...

Yes Ignator, a bit of overkill, I'm sure they won't bend in a hurry. Ted.

Some may question the rotary table? I was given a 97 tooth gear about 30 years ago. What can you do with a 97 tooth gear? It is mild steel, I counted the teeth on a Holden ringgear 135, cut 15 out and carefully pulled it in and welded it, giving me 120 teeth which can be divided by numerous...

Last couple of days work on the Onan opposed twin, 1 the rear bearing housing, drilled one hole in the wrong place? 2/3 decided to lighten the rods, poor little pistons are the lightest parts in the whole project. 4/5 cutting an oil groove. 6 looking good

As you say, it is very difficult to make it run true, I am yet to find out if I am successful. I found on the drawing board that there was insufficient clearance between big-ends and the cams so opted for roller bearings without bolts through, I might yet regret that decision. On your full sized...

I hope you are wrong but the crank pin is only 12mm so putting it in tension under an 8mm countersunk bolt will stiffen it up, I have built another engine that only has an 8mm bolt through a ballrace bearing with a locknut and it runs fine. I worked for a service station back in 1968 and used...

Thanks ignator, valve seats should be no problem as any auto repair/ rebuild shop have them in all different sizes. Photos today 1/ trueing up the crank 2/ almost finished the final cutting, only have to split it up and mount the conrods then Locktite final assembly trueing it up as I go.

Yes congratulations are in order

Wow we learn something new every day

Hi Basil, the 2 gears for this oil pump came out of early Toyota Crown Wagon rear window winders, they were about 2 inches long and hardened steel. My friend Gil has a 4 inch angle grinder setup for toolpost grinding and it works magic with a very thin disk, just worked back and forth over the...

Yes that is the way it is done, a bit like lost wax casting, the job turns out a little rough but I need finer sand. I have used wood patterns with good results but sometimes it very difficult to make a shape that will come out of the mold without making complicated cores. All good fun. Thanks Ted

Congratulations on a great job, keep up the good work.

Your crankshaft looks long and spindly, you can setup a toolpost grinder using a small angle grinder, this will avoid the cutting forces pushing things out of line, finish off with finer and finer grades of emery tape. Should be fine. Ted from down under

Thanks ignator, I have some 2inch cast iron to make the sleeves, the Honda pistons are 39mm, the alloy cylinders will be built up from cast pieces, the valve guide and seat will be one piece glued in with J B Weld, picture 1/ polystyrene pattern, 2/ a casting, the fins will be cut in the mill...

Todays progress, photo 1/ setup between centres on Gils Harrison Lathe 2/ the shape beginning to appear 3/ conrods finished one Honda piston fitted, roller bearings fitted 4/ crankshaft ready for assembly. Thanks for watching, Ted from down under

More on the Onan opposed twin, picture 1/ nearly ready to press together, so far I have reduced a 20 pound piece of 3 inch round bar to just 4.2 pound i e about 2 kg, 2/ a good piece of Queensland Rail steel becoming connecting rods, 3/ boring the bigends and litttlends.