Brian Builds the Kerzel Hit and Miss I.C.

[Brian Rupnow]

And here it is in the lathe, between centers--no lathe dog required--The one end fits between the chuck jaws to drive the Corian ---It is not being gripped by the chuck jaws.(There is a center hiding in there too.) the outer diameter has been machined to a "full round" except the bit between the chuck jaws. The ends will be trimmed off in a final step. Second picture shows mew tapping one end.

 

[Brian Rupnow]

Here we are thru-drilling the 1/32" center hole for the electrode. A few more chapters of turning, and we are ready to assemble it with the two brass bits which form the main body and the threaded rod that screws into the top end to attach a wire. At this point, everything went promptly to Hell, and the insulator broke into 3 seperate peices. I have almost a day invested in this sparkplug----Just because I wanted to be able to say I made my own sparkplug. At my usual rate of billing, I now have $300 invested in this failed attempt at making a sparkplug. What have I learned??? Corian can be easily cut on my vertical 14" bandsaw. It machines very well with conventional HSS tooling at 950 RPM. If you notice the pictures, I was doing all the turning with a 0.094" wide parting off tool. If you ever do this, do the tapped thread and the .031" thru-hole BEFORE turning the o.d. down to its final size. I WILL make another attempt. Then it may well be a $600 sparkplug!!! Oh well, I'm having fun---fun----fun----fun

 

[Brian Rupnow]

A question was posed on the other forum I post on about why the ignition cam has such a strange shape. I gave a brief explanation that is probably worth repeating here.

The points remain open most of the time. No current is flowing to the primary winding of the coil. When the flat portion of the cam rotates around to the contact block on the points, they close allowing current to flow through the primary windings of the coil. Then very shortly after the points close, they open again, stopping the current flow to the primary coil windings. It is the collapse of the electromagnetic field created by the stopped current flow to the primary winding that "excites" the secondary coil winding and makes it give off a high surge of voltage to create the spark.

 

[tel]

Thanks for clearing that point up Brian, it's something that was bothering me a bit, being the exact reverse of the way points are usually set up.

 

[Brian Rupnow]

Marginally better success with the second try at a sparkplug. I got it all together, then went to install the 1/32" rod that I bought from the local hobby shop.---wouldn't fit!!! What the heck---Get out the micrometer. Drill mikes at 0.031 like its supposed to. Rod from hobby shop mikes at .039"---Aw $hit---They sold me 1mm rod. now I have the dilemma---Do I buy a 1mm drill and drill everything out to 1mm or do I try and find some 0.031" dia rod. I need about 3" and I don't know if I can get that in Barrie. I am beginning to think that maybe my machining skills aren't up to making my own sparkplugs. I'll probably buy a 1mm drill tomorrow, as thats the easier of the two routes. Arghhhh--maybe I'll end up buying a plug after all!!!

 

[dvbydt]

1/32" TIG Tungsten?

Ian

 

[bearcar1]

As "funky-doo" as it sounds, could you try to reduce your 1mm rod down in diameter? I know it is a bit of a challenge but still, it would save you driving all over creation for a 3" piece of rod.

BC1
Jim

 

[Brian Rupnow]

Funky-Doo indeed!!! Like the old story about trying to shove a dew worm up a wildcats----Oh, never mind. I'll buy a 1mm drill tomorrow.

 

[rleete]

How is it that a Canadian doesn't have a set of metric drills?

So, to back up a few posts. You said that the first insulator broke into 3 pieces. Can you elaborate? Was it too brittle a material? Too deep a cut on a small diameter? Too much torque from the threading?

Is it possible to glue the pieces back together? I know that they glue/epoxy the seams when installing countertops. I also know most epoxy is an insulator. Could you stick it back together and have a spare?

 

[kjk]

Although Canada has been metric for decades you can't get a set of metric drills to save your life.

 

[bearcar1]

Well it was just a thought, besides, that wildcat might enjoy it :big: :big: :big:

BC1
Jim

 

[cfellows]

Thanks for clearing that point up Brian, it's something that was bothering me a bit, being the exact reverse of the way points are usually set up.

Actually, Tel, that's always the way ignition points work. The spark occurs on the break, not the contact...

Chuck

 

[Brian Rupnow]

How is it that a Canadian doesn't have a set of metric drills?

Well actually, I don't have a set of any kind of drills. I buy them as I need them. I find metric to be a Bastard abomination, foisted on us by a government who were a complete pack of fools. I use it if my customers want on engineering documents, because as of about 1976 or so it became "official" here. However, I work with what I learned as a young pup and am most comfortable with, British Imperial. As a matter of fact, the use of metric seems to be dieing out here. Most of my customers and most of my machine shops have reverted to British Imperial.

 

[rleete]

Interesting. I've always heard that the US was the last holdout, and they were just waiting for us to switch over for a perfect unified system.

 

[Brian Rupnow]

As long as USA remains our major trading partner, (and I don't see that changing anytime soon) we will probably do what USA are doing.

 

[kcmillin]

Interesting. I've always heard that the US was the last holdout, and they were just waiting for us to switch over for a perfect unified system.

I could be wrong but I think Liberia still uses the Standard System.

As of the 50's or so the official length of an inch was changed 2.54mm, I guess to simplify the calculations for the "Rest" of the world.

(Does this mean if I have a pre-WW2 micrometer or measuring device, it would no longer be an accurate measurment????


Your post on machining corian is great, and will come in handy for me in the near future. (I have 8 spark plugs to make)

Kel

 

[Maryak]

As of the 50's or so the official length of an inch was changed 2.54mm, I guess to simplify the calculations for the "Rest" of the world.

Kel

Methinks you decimated it ;D 25.4mm=1ins.

Best Regards
Bob

 

[kcmillin]

Oops' :hDe:

I think thats how NASA screwed up the Mars Lander a few years back :big:

Kel

 

[tel]

Actually, Tel, that's always the way ignition points work. The spark occurs on the break, not the contact...

Chuck

;D Yeah. I knew that Chuck, even if I am from Orstralia! What I meant was that most systems I've seen work with the points closed thru the cycle until the point of firing, when they are lifted by a cam lobe.

 

[tel]

As long as USA remains our major trading partner, (and I don't see that changing anytime soon) we will probably do what USA are doing.

Hooooo Boy! Talk about leading with your chin! There are just sooooo many snappy come-backs for that, but I'm too much of a gentleman to use 'em.