3cc Diesel - My first ICE

[Maryak]

Thank you everyone for your thoughts and support

Best Regards
Bob

 

[SERCEFLYER]

Bob,

I'm happy to hear that the Mrs. is doing better. Best wishes.

George

 

[ksouers]

Bob,
Add me to the list, glad to hear Mrs. M is doing well.
Hoping everything continues to go well.

 

[Maryak]

First up, thanks guys for your support with Galina. After a restful night she is doing fine and managed to give our credit card a bashing today : : ::bow: :bow: :bow:

Back to the engine, I managed to get a little done today - completed the conrod jig and started to profile the rod.

The rod blank, jig and its pins assembled.

The set up for starting the profile. The jig pins are in the table slot and pressed against the back side of the slot. Hopefully this will give the correct angle for the rod side.

The conrod 1/4 complete.

That was all I had time for today as we had a meeting with our builder this arvo which went pretty well so things are pretty much back on an even keel.

Regards
Bob

 

[Maryak]

Today saw the connecting rod completed, fiddly little sucker

I can't tell you how glad I am I made that little jig worked a treat both on the mill table and in the rotary table.

I am starting to wonder now if aluminium will handle the forces involved without bending. I guess we'll find out if the thing runs : :

Pins moved over and milling the other side of the rod.

Milling the other side and overall height after turning over in the jig.

Profiling the ends using the rotary table.

The finished rod - sorry about the quality :

Have a good day

 

[jack404]

whats the size of that bob??

length ways

looks small but the rule is way blurry ( know the feelin with camera's)

am amazed at what you can do in a day or part there of

cheers

jack

 

[Maryak]

Jack,

Attached PDF gives sizes, to me it's bloody small

Regards
Bob

View attachment Conrod.pdf

 

[jack404]

yes bloody small

well done eh

your mounting must be very good all the small stuff like that i have either
given flying lessons too
or crushed, trying to stop the flying lessons

i'll try your way next time i do something small

thanks

and heck, well done

cheers Bob :bow: :bow: :bow:

jack

 

[ksouers]

Very nice, Bob. That looks nerve-rackingly small. Well done.

 

[SERCEFLYER]

As long as the engine does not get flooded and suffer from "hydrolic lock", aluminum should be ok for the con rod.

Nice progress today! What's next? Head?

George

 

[Maryak]

Thanks Jack, Kevin and George for your support and input :bow:

Next will be the gudgeon pin followed by the crankshaft. If that's all OK, will make a jig for drilling the holes in the crankcase, cylinder base and head. Then the head etc.

Jack, leave lumps on the ends, sides called chucking pieces so you can hang onto things, put them in the place where you can do most of the work before removing them. Then you've got some anti flying in place which wont damage the actual part this + patience and small cutting depths ;D

Best Regards
Bob

 

[Philjoe5]

Hi Bob,
I just picked up this thread and read the 9 pages with keen interest. First of all, glad to hear your Mrs. is not going through a serious medical issue. Thanks for your great documentation of this build particularly the details of making the lap. Being a newbie myself and quite ignorant of how this process is done correctly, I've made what I thought qualified as a lap but now I'm not so sure. I guess we can judge by the end result, which is a running engine, which I have in fact made. But honestly I don't think I've ever achieved a "mirror" finish in a bore. Is this a more important or necessary requirement for an engine of this type/size? I may try your technique on a Stirling engine I made but has never run properly. I know for a Stirling a "mirror" finish bore is likely a requirement for it to run.

Cheers,
Phil

 

[wareagle]

Bob, glad to hear you and the Mrs. are in the clear! That's great news!

Your connecting rod came out well. Thought it is small, I think that it will be just fine for the purpose. It is small, but so is the volume of the engine. There shouldn't be enough push on the piston/rod assembly to hurt anything. I'm with you, it is small, but in perspective to the rest of the engine... Not so much.

Keep up the great work!

 

[Maryak]

Dear Philjoe5,

Thanks for your kind words

I'm a novice too when it comes to this lapping business, just read a couple of old books I had about the place. I would not call my cylinder or piston a "mirror finish" - Polished yes. In the good old days, things were finished off with white lead and tallow, enabling a mirror finish but white lead is not available any more and I'm sure long term lappers had a good dose of lead poisoning from their efforts.

I believe a good sliding fit to 0.0001" is required, (about the same level of accuracy as diesel engine injectors/fuel pumps, and again I would call the look of such parts polished but not mirror.

As I found out, the relative length of lap versus lappee is important, about 2-3 to one, i.e. a cylinder lap is longer than the cylinder and a piston lap is shorter than the piston. You can get really high tech and make fancy expanding laps and truing laps, (which are shorter than the lappee).

Hope this helps but as I said I'm a novice at this lapping game.

Regards
Bob :-\

 

[Maryak]

W/E,

Thanks again for your continued encouragement and concern for Galina, a CT scan next week should put the whole matter behind us. That's you and George who think the Al will be OK in the conrod, so I'll stick with it. :

Best Regards
Bob

 

[Maryak]

Achieved less than I was hoping for today, the gudgeon pin took much more time to lap and fit to the conrod than I anticipated. For some reason I had great difficulty in getting the lap to charge with abrasive and initially managed to transfer brass from the lap to the pin. Maybe a brass lap was not a good idea and I should have used cast iron or copper ??? ??? ??? Got the little sucker in the end ;D

A better picture of the finished connecting rod

The pin and crankshaft laps.

The finished gudgeon pin.

The gudgeon pin and dummy piston and conrod assembled.

The piston and conrod ready for screwing and soldering.

A lump for the crankshaft being faced.

And that was my lot for today as we had a meeting with our builder in the afternoon which went pretty well

 

[kustomkb]

I Have really been enjoying this thread, alot of great tips and techniques, keep up the great work!

 

[CrewCab]

Bob,

I've not posted a lot in here but I have been watching avidly, much better than Mrs CC's choice in TV .......... anyway, I'd just like to say thanks for your hard work in both machining and posting .............. and explaining ........... don't arf' elp us newb's

Thanks Bob .............. keep it coming ;D ............ please 8)

CC

 

[Maryak]

CC and Kb,

Thanks for your support and encouragement. :bow:

I have derived a lot of pleasure myself from the discipline of documenting my progress and/or lack thereof.

Every post from other members has only added to my determination to keep it up. It's also given me warm fuzzies to be a part of a great bunch of people.

Thank you all. :bow: :bow: :bow:

 

[CrewCab]

It's also given me warm fuzzies to be a part of a great bunch of people.

Just watch out for the Fluffy Bunnies ;D

CC