Ball Hopper Monitor - Casting Project

[GreenTwin]

I recall starting the BHM flywheel, and had two different attempts to get the spokes looking approximately correct.
I did not get the flywheel as far along as I thought.
That is the problem with getting on and off of a project; it is easy to forget where you left off.
I could fix this flywheel, but I think I would rather have it as a generic 5-spoke flywheel pattern half, for some other engine use.

I have some work projects I need to focus on, so I will have to pause the printing for the moment.
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[GreenTwin]

Not a bad start for now.
Not really what I want it to look like in the end, but a good start.

The bed adhesion on the XL is most impressive.
I struggled to get this print off the bed.
This printer absolutely does not need any draft shields, enclosure, etc.

I have a large window air conditioner that blows cold air directly onto, over and around the XL, and there is absolutely not adhesion problems caused by this.
There is no way my old Prusa MK3 would ever be able to do this.
It was very draft sensitive, and the bed adhesion was almost always poor.
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[GreenTwin]

The fumes generated by 3D printing PLA filament are pretty minor, but after printing a number of parts over a matter of days, my eyes are starting to burn.
I can't detect an odor, but I am going to need to ventilate the Prusa XL to the outdoors.

For now I will make a simple box, with door, and use an inline fan to draw air to a vent mounted on the outside wall.

I will use a solid top, and mount the filament reels on the top.
If this works, I will consider building a more elaborate enclosure, but I don't need or want anything fancy.
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[GreenTwin]

They have some printable enclosures for the XL, but I don't really need plexiglass walls, since plexiglass is not really inexpensive.
I have some small square metal tubing that I think will work well, and then some 24" translucent stretch wrap will get me going for now, and if I want to add plexiglass later, I could do that.
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[GreenTwin]

I have to get ready for a work project tomorrow, so no time to get involved in the details of the remaining patterns at the moment.
Just for fun, I will place some parts on the printer and print them.
I need to refine the 3D models for these a bit more for patterns, but we will test the multi-part print today.
I suppose that if the print fails, you lose all the parts at once, but it would be nice to print multiple prints at the same time.
I don't recall trying a multi-part print before, so here we go.
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[Jasonb]

Pat have you given any thought as to how you will fit and do up the conrod bolts?

There is a reason the original engines had a hinged big end and that access panel on one side of the crankcase.

Even if you are going to use that conrod what happens when you saw the cap off as you have not elongated it to allow for the kerf of the saw and clean up.

Also why print things like screw holes and the piston grooves. Talking of the piston what about a chucking spigot so it can all the critical bits be machined in one setting

Seems some more design work is needed as I said a few days ago before you waste more filament.

 

[GreenTwin]

I have some old filament that is borderline brittle, and so I want to use it up before it becomes totally unusable.
Today is just a fun print day.
No time lost since I just watch it.
I have to work on a work project today, so no time to tweek these parts like they may need.
All these pieces need to be converted to patterns, and that has not been done yet.

I will have to revisit the conrod; I think you are correct on that.
The conrod and crankshaft would be good candidates for ductile iron, if I can get my reaction chamber finished.

This is fun print day, nothing serious.
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[Jasonb]

Must have been the file names that made it look like they were patterns

 

[GreenTwin]

This is a sit back day, grab some coffee, and for me, work on a project that has a conference call tomorrow.
The serious pattern work will have to begin again next week.
There is no rationalizing a fun print day; it is just for fun.
Basically these are desk ornaments, but it is nice to have something in hand to get a feel for the parts.
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