Ellery Single Cylinder 50cc Design & Build

[cbooth]

Hi all,
So this is going to be my design for a single cylinder 50cc petrol engine. I am going to use a lot of the same geometry as my Vtwin100, I'm sure you'll see the similarities.
I have been using the same software to draw it up, Autodesk Inventor.
Hopefully look to make some improvements along the way

1. Change the inlet/exhaust locations to the side allowing a more uniform bolt pattern.
2. Increase the diameter of the cam meaning smaller tappets. Can do this as not trying to squeeze between the 90deg V
3. Change taper on cylinder fins to give better access to bolts
4. Add an option for an electric starter motor

 

[cbooth]

Got a new order of material (M-Metals, no connection, just think they provide a great service), so managed to make a start last weekend.

First up was the cylinder head. The main thing changed here is that I reduced the wall thickness from 2.5mm to 2mm. With the steel liner, just don't think it needs any more.

On the lathe to face and turn to diameter, centre drilled for a live centre to hold it firm for cutting the fins.

Then bored to diameter and parted off, reversed and the base faced to the right length

On to the mill to mill the octagon and drill bolt pattern.

Happy to get it started.

 

[cbooth]

This weekend I made a start on the main crankcase and used the portable bandsaw then flycutter to trim to size.
I wanted to have a play with engraving and anodising so left all sides a little oversize, then used my MPCNC (mostly printed CNC) for the engraving.

Anodised just the protruding side section, then trimmed all sides to final dimension leaving just the anodizing to the engraving.

Sorry, no photos in action on the lathe, but carried out 2 steps, firstly the bore through for crankshaft with centre counterbore for piston clearance. Then the top bore for piston sleeve and counterbore for o-ring seal.

 

[Art K]

Looks good so far!
Art

 

[JoeBrubaker]

This weekend I made a start on the main crankcase and used the portable bandsaw then flycutter to trim to size.
I wanted to have a play with engraving and anodising so left all sides a little oversize, then used my MPCNC (mostly printed CNC) for the engraving.
View attachment 123650
View attachment 123651

Anodised just the protruding side section, then trimmed all sides to final dimension leaving just the anodizing to the engraving.

View attachment 123652

View attachment 123653

Sorry, no photos in action on the lathe, but carried out 2 steps, firstly the bore through for crankshaft with centre counterbore for piston clearance. Then the top bore for piston sleeve and counterbore for o-ring seal.

View attachment 123654

Where can I learn the program you are using? Looks freaking awesome. I’m a machinist as well, alumni of Thaddeus Stevens of Tech in PA!!

 

[cbooth]

Where can I learn the program you are using? Looks freaking awesome. I’m a machinist as well, alumni of Thaddeus Stevens of Tech in PA!!

Hi, There is a huge amount of training and help for Autodesk inventor on the internet and youtube

 

[cbooth]

A bit of work on the crankcase. On the mill to drill and tap the rear bolt pattern that will take the rear crankcase cover, and to drill and counter bore the hole that will house the camshaft.

 

[cbooth]

And the front cam cover. This will house one of the roller bearings to locate the front of the cam shaft, and fix to the front of the crankcase.

On the mill to square the edges and drill bolt pattern.

Completely unnecessary but I do like to tinker so I anodised the part and used the CNC engraver to engrave its name "S-50". Single cylinder 50cc!!

 

[cbooth]

A bit more work on the top of the crankcase. Slot for cam followers milled and M3 holes drilled and tapped.

 

[a41capt]

More great lookin’ work! Congrats!

John W

 

[cbooth]

Steady progress. Tappet holder, tappet sleeves(colphos), piston sleeve (Cast Iron), and cylinder head blank made.

Here it is next to the Vtwin. You can see the similarities.

 

[mnay]

Did you get your twin running?

 

[cbooth]

Did you get your twin running?

yes, should be a link to the video on the other thread. I've had it stripped down as I wanted to check everything before I ran it too hard. Just re-assembling it again now.

 

[cbooth]

Filled a bin full of swarf today making the crankshaft. Has some problems with getting the feed right but eventually succeeded. I only have a manual change lathe so plenty of pully changes needed moving from the large diameter to small.

 

[Richard Hed]

Filled a bin full of swarf today making the crankshaft. Has some problems with getting the feed right but eventually succeeded. I only have a manual change lathe so plenty of pully changes needed moving from the large diameter to small.

View attachment 125334
View attachment 125335
View attachment 125336

Your lathe seems to cut nice threads, however.

 

[cbooth]

Your lathe seems to cut nice threads, however.

Thread was done manually. Threading on the lathe is something I have never attempted (yet).