Bugatti straight 8 cylinder with blower, design, 3D printed molds, castings , machining, assembly

[Foketry]

Overhead camshaft and holes for valve cages

I prefer to slide the tappet on a hardened steel bush instead of aluminum, this needs lubrication
To prevent the lubricant being sucked into the cylinder, I have provided an oil seal

 

[Foketry]

The valve

 

[Foketry]

drilling holes for valves

 

[Foketry]

first test of a complete valve , after a couple of hours of setup, everything works

 

[mnay]

Amazing work. I am just learning to use my 3d printer. Are you printing PLA? What do you use to smooth them for use as patterns?
Also do you design the draft angle on the patterns or are they smooth enough to remove without pulling the sand with them?
thanks for the inspiring build log.
Mike in Salt Lake City

 

[Badhippie]

May I ask how you plan on keeping the cams from walking is there a cam button on one end or are you using a thrust bearing on one of the camshaft caps??? Very nice work can’t wait to see a video of it running Thanks
Tom

 

[Foketry]

Amazing work. I am just learning to use my 3d printer. Are you printing PLA? What do you use to smooth them for use as patterns?
Also do you design the draft angle on the patterns or are they smooth enough to remove without pulling the sand with them?
thanks for the inspiring build log.
Mike in Salt Lake City

Hi Mnay
for patterns I draw a draft angle of 2.5 / 3 degrees and use a layer of 0.2 mm
Then I paint the model with a thick primer ( polyesters) , smooth the surface with sandpaper and repaint with topcoat
This is the fastest method I know.
You could also avoid the paint and sand directly on PLA, but the final result is aesthetically lower and the footprint in the foundry sand could be damaged while removing the pattern

Salt Lake City is famous in Italy for Garage Monkey, does it really exist or is it just a television fiction?

 

[Foketry]

May I ask how you plan on keeping the cams from walking is there a cam button on one end or are you using a thrust bearing on one of the camshaft caps??? Very nice work can’t wait to see a video of it running Thanks
Tom

Hi Badhippie
The cams will be fixed to the shaft by a sprig pin or conical pin
To axially lock the shaft, I will place 2 bushings on the ends that rest on the side of the final bronze bushings and cams
In a couple of weeks you will see the camshafts fully assembled , if everything goes without errors ....

 

[mnay]

Foketry,
Thank you the information on 3d pattern making.
Sorry but I have not heard of Garage Monkey. I will have to google
Mike

 

[stevehuckss396]

Are you talking about "Gas Monkey Garage"?

 

[Foketry]

Are you talking about "Gas Monkey Garage"?

yes, I'm talking about Gas Monkey garage, but I remembered badly, this is in Dallas, Salt lake city garage instead is in Salt Lake city, both have done a TV series, seen in Italy

 

[stevehuckss396]

I think gas monkey is in texas.

 

[Foketry]

machining of the intake head

 

[Foketry]

drilling and reaming holes for intake cages
the 8 exaust cages are already assembled

 

[Foketry]

overhead valve design with 4 mm oil seal

 

[Foketry]

valve spring retainer turning

 

[Foketry]

the complete kit of 16 valves, 8 valve cages already assembled in the heads

 

[thefishhunter]

Beautiful stuff

 

[Foketry]

I installed the cages using the hammer and a tool to avoid deformation, also putting Loctite 620 which resists high temperatures.
The diameter of the cages is increased 0.01 / 0.02mm with respect to the housing hole
After installation I made a very small chamfer (0,1/0,2 mm ) in cages with this small tool that is driven through the hole.

 

[Foketry]

After the bevel I lapped all 16 valves, 3/4 days of work , is very boring
I puts the valve into the cage with some lapping compound and then twirls it by special tool and finally by hands with very fine lapping compound