EW Aero V8 double size

[hdpreez]

HI All

Having built a couple of live steam locomotives i thaught it would be nice to do something different on the side.

I started construction of Eric Whittles Aero V8 yesterday. My equipment is slightly on the heavy side to build it in the 10.6cc version so i decided to double the size.

Here are some pictures of the progress.

Henk

 

[metalmad]

How cool is that !!
Will be watching thats for sure
Pete

 

[vcutajar]

I'll be watching also.

Vince

 

[Johann]

I like what I see Henk !

Van waar is jy ?

Johann

 

[hdpreez]

HI

Glad to see you like it, will keep you updated.
This is a joint project between myself and a friend, he will be joining the site shortly.

Johann, Im from Benoni.

 

[petertha]

This will be good! Just curious, are you basically doubling the paper-copy plans dimensions (excepting any non-scaling things like clearances & fits etc)? Or is it a complete new drawing/cad model/whatever? Reason I ask is there were some changes (errors?) people have discovered in the original SIC article/plans. But maybe (hopefully) this is already known to you. I believe there is a yahoo forum or similar groups of people who have built them to completion & possibly documented the changes. Possibly also on this forum. Rusty memory, but I thought some of the issues were rather major - cam setting or phasing or timing direction...?

ps - I'm kind of flip-flopping on a first engine to tackle for myself, but one of the things I'm working on is replicating EW's Robin engine (single cyl, 4S). For me, it's too teeny as-is. Im sure I'll bugger up the watch-making tolerances. But I'm going to model it in Solidworks & similarly 'scale it up' & see where that leads me.

 

[Jasonb]

There was a doubled up one serialized in Model Engineer not that long ago and I think the changes were mentioned there. Having seen it in the flesh its a nice engine when made at that size.

J

 

[Johann]

What material do you use for the conrods ? It seems that we have pro steel & pro aluminium camps... Johann

 

[hdpreez]

HI
Thanks for the tip, i was not aware of any errors in the plans, but 2 have found two on the crank case so far. Will be on the lookout for more errors, some of them sound quite serious!

In South Africa, i am battiling to find the equivalent for HE 15 Aluminium and have opted for 7075 which is also an aircraft grade. Do you think this will be OK for the pistons and con-rods?

Henk

 

[agmachado]

Yes... very cool !!!

More one project to us appreciate... I think this design very cool !

Cheers,

Alexandre

 

[hdpreez]

Made some progress on the engine block today. Line boring the center cam bearing was easier than I anticipated.
Engine block is now 85% complete, some holes, sump fins and finishing required. Next will be the crank shaft bearing housings.

Im a bit worried about the cam which doesnt have any bearings by the looks of it, runs in the HE30 Al, would that be OK on an engine this size?

Here are some picks

 

[ewapenaar]

Hi Henk,

the camshaft has two phosfor bronze bearings (front and rear). In the middle it's running directly on the aluminium of the block. Should not cause problems.

6061 T6 is equivalent to H30. H15 is known as Dural specified as 2024 T6511

Erik

 

[trumpy81]

Henk, I am currently modelling the Whittle V8 in Inventor at double size. Looking at the cam there will be sufficient space to add two additional cam bearings between each bank of four lobes.

Nice build so far, I will be watching closely

 

[hdpreez]

Completed the front and rear bearing housings. Here s the progress to date.

 

[trumpy81]

Henk, that is looking good

What size screws are you using, M3?

Here's a pic of my Whittle X2 Model.

 

[hdpreez]

Yes, they are M3. Fits in OK.
Henk

 

[Johann]

I think we have a sterling end result coming up here ! Johann (Middelburg)

 

[hdpreez]

HI
Had nearly wo full days on his project.

I managed to complee he botom half of he crank case. A large wire brush was used o get an almost casing-like appearance. Quite pleased wih the outcome.

I also completed the camshaft. Eric Whittle wrote that he was lucky that the camshaft did not distort during heat treatment. Luckily I planned for some distorsion and ground the bearing journals to size afer hardening. The rag on he lathe bed acts as a filter to catch some of the gringing gunk - dont want that stuff on he slides. the camshaft distorted during heat treatment and had a runout of almost 0.5mm. I clamped a smaller 4 jaw in the lathe chuck which allowed me to center the camshaft and play with the angle of the 2nd chuck to get the thing set up. There was just enough material left anf it cleaned up perfectly!

here r some pics of the weekend's progress.

 

[hdpreez]

forgot this one

 

[trumpy81]

Henk, that is looking sweet!! Much better than my model ... lol

Thanks for mentioning the wire brush too. I had almost forgotten about the finish you can get from a simple wire brush, and you're right, it does look like it's cast.