anyone interested in a radial team buid

[maverick]

10 sets connecting rods - 100 % complete
10 collets - 40 % done
10 flywheels - material cut up

Have been busy with 2 large projects for work, one ships tomorrow morning and the other Monday.
Will finish the collets then start on flywheels. I don't want my machining to drag into the holidays
as there are gifts to make for family, including a new grandson. Now I just need some ideas, got any?

 

[joe d]

10 steam chests: 100% done
10 port flanges: material on the bench
10 orbital valves: did 4 in steel, turned out like crap, so switched and am now doing them in cast
iron, 1 done, looking way better

There will be a small delay, as I am leaving town tonight for 7 days....

Joe

 

[Path]

I was planning to use cast iron for the pistons, the same i used for the liners. Is there any problem using the same material for both? If so, I think I could use aluminum or brass (maybe fosforous bronze too).
For the wrist pin, is it ok if i use shafts scavenged from old printers? They would be like 3.95mm, so they'll slide nicely in reamed holes in the con rods.

Actually Cast Iron is called out for the Liner and Piston, I guess they make a good combination. I'm only changing the Piston material due to the mess the Cast Iron causes. I also scavenge parts from discarded machines ... not knowing what the material is ... you will have to decide. The size, however (3.95mm), may be a problem. A bit loose for the Con Rods and pin won't want to stay in the Piston it may rub against the Liner. You could ream the Piston to 3.95mm or maybe a little Loctite applied during final assemble. In any event try it out and see what works.


Pat

 

[chrispare]

I am about 80% on the bearing case.

Does anyone know what is suppose to go into the m5 hole. I am assumine that it is for oiling or a vent. Any ideas?

 

[SBWHART]

Does anyone know what is suppose to go into the m5 hole. I am assumine that it is for oiling or a vent. Any ideas?

Its for oiling, I made a small oiling cup just to tidy things off.

I also made a small brass tube to screw into the exhaust, again just to tidy things up.

I'll have a look to see if i've got a picture, my engines packed up ready to go to London for an exhibition.

Stew

Her you go

You can see the bits I added.

Stew

 

[dalem9]

Thats the frist picture of our build that i've seen .Sure looks nice ! Thanks Dale

 

[Path]

Thought I would post a few pictures ...


Here is where it all started ... 2" x 8' Aluminum stock ... cut so that I could make 3 cylinders at time.

Turned it down to about 1.8" then cut in 3 pieces (this should look familiar see Stew's build log).

Here are 18 future Cylinders 3 extras

All 18 with the .75" hole for the Liner

Machining the fins OD using a cutoff blade ... last cut .002 or less. Using a maderal.

Jumping ahead a little. This chunk of Aluminum was milled down about .1" while in the vise.
This insures that the Cylinders are perpendicular to the spindle. The bottom was machine
on the lathe so it is also be perpendicular the hole. The Co-axial was used to find the center to set
G54, G55 and G56 XY locations on the CNC. The XY was adjusted for zero deflection while the
spindle was turning at about 50 RPMs. Once done the tops caps were installed to provide the hold down
force while machining the top sides. This operation Drilled, Taped and formed the rectangular top.

Ready to push that start button ...

After about 4 minutes this is what you get ...

To be continued ... I have about 6 more pictures that I will post later.


Pat

 

[Path]

Continuing on ...


After repeating it 6 times I have all 16 ... if you look carefully you can see that I lost 2 Cylinders to
dumb mistakes. Now I have only 1 spare. :

I repeated the process for the bottom. Using a different fixture.

Here all 16 ready for the Liners.

Measured each Cylinder and turned down the Liners OD so that I would have about a .001" - .002" interference fit.

I heated the Cylinder just enough so that the Liner would drop in ... if not I added a little pressure.
Using Loctite 680 for sure tight fit.

Another fixture to mill the 10 degree slope ...

Finally these only need a little dressing and they are ready to go.

Each Cylinder was then honed for a smooth finish.

That's it for now. Hope to get the Pistons done early next week.


Pat

 

[SBWHART]

Wow Pat that was a neat bit of machining, I always marvel at the capability of CNC and the guys who work them.

Stew

 

[maverick]

Pat, those cylinders look great! It's quite impressive how much work everyone has been doing on this build. What kind of mill

did you use to profile the cylinders? Nice fixturing also.

 

[Path]

Stew ...

Thanks ... Yes CNC is nice to work with , but I still do a lot with the manual.

Mike ...

Thanks... I have a Haas TM-2p with Rigid Taping, Wired for 4th axis, high flow cooling pump, programmable nozzle and 10 tool ATC.
Sure would like to get the 4 axis ... maybe someday.
I'm thinking I might use it for pistons ... we'll see.


Now the good stuff ...

Received your con-rods ... fantastic job :bow:. Looks like they went for a nice tumble. Very nice finish. Thm:

I ordered and received some 4mm drill rod. After a little rod finishing they fit nicely.
With a little run in they will work perfect.

I have a plan for the pistons ... hope to get to it Monday. Just need to figure out a holding method.
Then do a few samples to see how the Con-Rods will fit. Then ... make them.

Will keep you posted...

Again ... Thanks guys.


Pat

 

[dalem9]

Parts 3-4-5 were mailed today . Dale

 

[Path]

Dale,

Looking forward to getting them.

Thanks,

Pat

 

[warranator]

Yes also looking forward to getting them.

Crank shaft and crank return were posted today except for Otoboni, I have sent him a pm with regards to his address.

 

[Path]

Dale,
Got your parts today ... very nice.

Fits perfect. Thm:

Nice touch with the extra tubing and a picture of the builder (I guess :big.

Thanks,

Pat

 

[dalem9]

Thanks Pat I am not sure how the tubing is going to fit so I thought it would be wise to include extra. That was some shipping they were mailed monday afternoon . Dale

 

[pcw]

got the heads and tubing today. looks very nice. ty Dale
Pascal

 

[Path]

About the Piston and Con Rods ....

Stew ...
....
My thoughts would be to increase the 9.46 square a little (the amount to be determined) and machine a radius at the four corners ... in short
follow the picture.
....

See reply #268 for additional information.

I was able to test the Piston and Con Rods today and I have changed the 9.46mm square hole to 9.86mm with a 1.50mm radius.
This allows a little wiggle room for the Con Rods. So far no other changes have been made for that assembly.

However, you may need to file a small radius on the Con Rods during assemble for a better fit due to varying part dimensions. You'll have to decide that.
I haven't tested at the assembly level yet, but it should work. It looks good using the CAD.

T-ottoboni (or anyone else) ... If you like I can send a new Piston Drawing #3009 Rev B.


I started to build a fixture to machine the 9.86 hole and Wrist Pin hole for the Piston ... hope to have it mid week.


Pat

 

[t_ottoboni]

Path, can you e-mail me the new drawings?
Thanks a lot!

 

[Path]

On its way


Pat