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Trust me Microsoft and other big companies are no better - my 2 year old printer won't work with my pc on Windows 10 but works on my wifes pc with the same operating system - no obvious reason. There is always an example of somebody who got screwed by Linux or Windows. I could list dozens of...

Rich, No credit to me on the heads, those are castings from Bruce Satra (vernal engineering). No idea if they are still available. I can't imagine making them other than casting. Bob, Milling does a couple of things that are beneficial in this case (to me and my amateur efforts in the shop)...

Wow - almost 8 years! Being the originator of this thread I'm going to be the one to bring it back from the grave. I finally succeeded in cutting the fins on all 9 cylinders in a repeatable, controlled manner that has a nice looking final product. Here is the recipe I finally used...

This assumes that you have not clamped the part and / or vise to the machine table - which can be a very dangerous way to operate, especially with larger drills. I strongly disagree with this and would not recommend it to anybody.

I created a log in for the KHK and it does generate dxf outputs for taking into your cad program. As can be seen the internal gear tooth profile gets modified at the root and the ID is smaller as well, the left side was the original gear as drawn by the add-in to Fusion 360, and the right side...

I've been struggling with making these cylinders off and on (mostly off) for what appears to be 8 years! I have actually made real good progress only recently, as the major stumbling block has been the cutting of the fins. I believe I've finally figured that part out but I'm in no place to...

Using software you can determine the shape of the cutter. I used a free add-in for Fusion 360 from FM Gears that lets you draw very easily an internal (or external) gear. You could then model your cutter from the resulting gear. If you don't have Fusion 360 the same author of the add in offers...

First I've never made the engine so this is just my thoughts... Out of context its hard to say without seeing the assembly for that section. What is the purpose of the .437 diameter? Why is it chamfered from there to the .190 diameter? Is it important or is it drawn from an "as made" point of...

You can skip the arduino if all you want to do is drive the stepper forward or backward at a fixed or variable speed. https://www.amazon.com/dp/B077SFDMFJ/?tag=skimlinks_replacement-20 Its a stepper pulse and direction generator. The link is amazon but available from many sources. Mike

Ken, attached is a DWG of the drawing - I can't export a DWG of the model itself. Also attached is the pdf for convenience of those looking for it.

There are drawings in the Downloads section. Looks like its on the 2nd page now, and the link I posted previously doesn't bring me there anymore, but a quick search should let you find it. The pdf's should have all the needed info to build your own. As mentioned in this thread I'd make it a...

No - the spindle dimensions for the D1-4 style are only listed in the ASME spec which is copyright protected - you can find some of the details on-line but I eventually gave up and bought the spec.

I'm definitely a proponent of Fusion 360 at the moment (rare for me !) The integrated CAM is a huge benefit as you learn the general work flow of the Fusion system and it applies to CAD and CAM, plus if you change something in the model its dead simple to go update the CAM. Plus - if you do...

Mach 3 is not CAM, nor is Linuxcnc, Alibre Atom 3D and though I didn't look it up I would believe that Alibre Design isn't either. The Alibre are just CAD, and Mach 3 or Linuxcnc are the motion control. CAM is Computer Aided Manufacturing - i.e. take your 3D design and convert it to tool paths...

not sure about "best" but as far as cost goes try this -$32.25 plus shipping https://hobbyking.com/en_us/replacement-complete-ignition-set-for-single-cylinder-gas-engines.html similar to the link natalefr sent but I'm always a bit suspicious of Aliexpress (had one bad experience) - I have...

Shipdisturber: Where about are you in Canada? your best bet is a used mill, one somebody else bought and has either outgrown or never fully used properly. A bit of patience on Kijiji will have one pop up in a month or less, the other secret there is to expand your search radius - you need to...

Calibration is not the same as maintenance. You should be able to justify a qualified technician doing an inspection and service on it, especially if not done for over 12 years. Catching something before it breaks is far less expensive and time consuming than after. Mike

The justification is as you say for obvious reasons - inspection of a part after the fact doesn't make it right, if the cost of potentially scrapped, high tolerance parts is high then calibration is justified.

Brian, don't make the spring too strong, one of the unwritten items on the Poppin is that the vacuum holds the valve shut as long as it need to be with a weak spring, too strong and it opens prematurely reducing the effectiveness of the engine and / or making it hard to run. This is why the...

I really wouldn't use cast iron for the spinny bits like the spindle, I'm assuming you're talking about cast iron. Failure could result in death. Just think about how cast iron can be broken and imagine your spindle breaking right at the main bearing - sending the spindle nose and the chuck...