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Hi Hawkeye, Thanks for reaching out to get in touch. I've been on vacation, sorry for the delay in getting back to you. It sounds as if we are at a similar stage of progress, I'm doing the cylinder liners at the moment, and preparing to hone them. I'd like to stay in touch and exchange our...

Peter, Yes I agree, the reamer idea is off the table. I've done some machining tests and now bored and turned one liner. I'm fairly happy with the result, the bore is smooth and regular about as you say 1.5 thou undersize. If I can do one I should be able to do another - good since I have 12 or...

Of course, but its a lot of work, means 2 setups and consequent reduced concenticity between inner and outer diameters.

Thankyou Gentlemen for taking the time to reply. Your advice, from your experience is extremely valuable. My small lathe will not accomodate reamers of the bore size, so I will continue with single point tools for the boring and outside dimensions. For that my machining tests lead me towards...

A very good day to you all, The cylinder blocks and crank case now largely completed I am turning my thoughts to the cylinder liners. These I will make from 4130 seamless steel tube in the annealed state. My first tests seem to show this material to be quite readily machineable. I know this...

Many many thanks to all of you that have taken the time here to offer your advice. I really appreciate all your help. The casting defect is of a pin hole size but will certainly cause a coolant leak from the water jacket. The defect is at the end of the casting where heat distortion would...

Hi Allan, I'm in central eastern France, near Geneva close to the Swiss border. So I guess we are about as far away as one can get!! Nevertheless, it's good to hear from you, from someone else making the merlin. Are you working with Richard Maheu's castings and drawings? How far have you progressed?

Good day to all, Whilst machining one of the cylinder block aluminium castings for my 1/4 scale Merlin project I have discovered a small defect, perhaps a porosity that has generated a small hole ~1mm wide by ~2mm high at one end into the cooling water volume. Light shining through makes the...

Thankyou Dan, Yes I did fairly recently come accross this extremely detailed and informative account. It is in fact what lead me to this forum. I was by then a distance into the project but I have dipped into Terry Mayhugh's (Mayhugh1?) text from time to time. He it seems started out with the...

Firstly, thank you for accepting me into this forum. I have always had a soft spot for the grace of the Spitfire and the sound that its iconic power plant produces. So back in 2009 I bought investment castings from Richard Maheu in California for a quarter scale V12 Merlin engine. I have lost...