Finally got back into the workshop

[Weldsol]

After getting the Sealion engine finished ( apart from maybe a cooling fan and drive to it plus some more tarting up) at the end of March an old problem flared up and the doctor said you need to change medication as we now recommend this new one so I believed her two weeks in I ended up with all the side effects no to man and to the point where I couldn't even walk a straight line let alone drive or use equipment with nice sharp cutters whizzing round so i was banned from the workshop for 4 1/2 months
Whilst brooding trying to find something to do I decided to go through all my business paper work to see what I could shred.
That's when I came across a set of drawings all rolled up with a rubber band. These turned out to be for a "Hoppy " horizontal four stroke engine designed in 1989 by B&R TITE so sitting and getting fed up I started think how I could make one of these.
Obviously B&R TITE used to supply all the castings etc so went online and nothing came up.
So I knew I would be safe typing on the keyboard and a PC mouse has never bit anyone to my knowledge so I re-drew all of the main castings then drew a square / oblong around each part to give the size of aluminium blocks to order going over the smaller parts I knew I had 90% of the materials kicking around in the workshop.
OK some round parts had to come out of square and visa versa but that just meant another sack of swarf to get rid of
So here are the GA drawings

 

[GreenTwin]

Nice engine.

I have had my share of health issues, including COVID.
I had COVID very early on, before the vax'es came out, and so I never had any problems after than.

Luckily I am still functioning somewhat well, but some days its a challenge.

Nothing like a good engine design/build to clear the mind.

.

 

[Weldsol]

Nice engine.

I have had my share of health issues, including COVID.
I had COVID very early on, before the vax'es came out, and so I never had any problems after than.

Luckily I am still functioning somewhat well, but some days its a challenge.

Nothing like a good engine design/build to clear the mind.

Thanks Green twin
After going through everything with the meds 5 weeks ago I got covid via the wife so that didn't help but hey Ho of we go again got my alloy blocks and have made a start will start posting some pic in the next couple of days

Paul

 

[Weldsol]

Paul

Made a start on the cylinder block, squared up the ends and one side
(the reason for only doing the ends and one side was once marked out for the ends all the rest of the sides will be profiled on the mill.)
The mandrel allows me to face the ends for mounting the cylinder to the crankcase and to transfer to the mill
you can see on the mandrel there is an undercut this allows the 10mm clamping to lock the cylinder in place and when removing the mandrel it will not damage the liner seat bores due to the raised edges caused by the 10mm grub screws.
Now I can face back to reveal the mounting faces, once one end is done it is just a matter of releasing the grub screws slide the block off the mandrel turn it end for end and refit and lock up the grub screws, now I can face to the correct length and then do the mounting face.
Then to the mill
Paul

 

[Richard Hed]

Nice engine.

I have had my share of health issues, including COVID.
I had COVID very early on, before the vax'es came out, and so I never had any problems after than.

Luckily I am still functioning somewhat well, but some days its a challenge.

Nothing like a good engine design/build to clear the mind.

.

When you had the covid, did yuou have 'dead brain' for a few weeks? I had a hard time breathing for 6 weeks after, and had what the butchers, oops, I mean doctors, called something like 'dead brain' but it was some other term where you had very fuzzy thimpfking. I had that for about 10 weeks. Some say I still have it or always had it.

 

[Weldsol]

When you had the covid, did yuou have 'dead brain' for a few weeks? I had a hard time breathing for 6 weeks after, and had what the butchers, oops, I mean doctors, called something like 'dead brain' but it was some other term where you had very fuzzy thimpfking. I had that for about 10 weeks. Some say I still have it or always had it.

No this was only 5 1/2 weeks ago and I was over it (well tested negative ) in 15 days
paul

 

[GreenTwin]

When you had the covid, did yuou have 'dead brain' for a few weeks? I had a hard time breathing for 6 weeks after, and had what the butchers, oops, I mean doctors, called something like 'dead brain' but it was some other term where you had very fuzzy thimpfking. I had that for about 10 weeks. Some say I still have it or always had it.

COVID definitely knocked me for a loop for about 4 weeks.
Ivermectin, vitamin C and D, and zinc has cleared the brain fog for me.

.

 

[Weldsol]

Made a start on the cylinder block, squared up the ends and one side
(the reason for only doing the ends and one side was once marked out for the ends all the rest of the sides will be profiled on the mill.)
The mandrel allows me to face the ends for mounting the cylinder to the crankcase and to transfer to the mill
you can see on the mandrel there is an undercut this allows the 10mm clamping to lock the cylinder in place and when removing the mandrel it will not damage the liner seat bores due to the raised edges caused by the 10mm grub screws.
Now I can face back to reveal the mounting faces, once one end is done it is just a matter of releasing the grub screws slide the block off the mandrel turn it end for end and refit and lock up the grub screws, now I can face to the correct length and then do the mounting face.
Then to the mill
PaulView attachment 141443View attachment 141444View attachment 141445View attachment 141447View attachment 141448

Got a fair bit done on the mill yesterday



Paul

 

[Weldsol]

Got a fair bit done on the mill yesterday

View attachment 141497View attachment 141498View attachment 141499View attachment 141500

Paul

Hard at it again today, got the inside milled out to give 1/8" wall then shaped a 2.5mm piece for the top plate and TIG welded all round then filed the radius around the outer edge.
I can't do the mounting holes yet as these have to spotted from the crankcase, and I want to do the liner as this will help lining up to the crankcase
Paul

 

[Weldsol]

Hard at it again today, got the inside milled out to give 1/8" wall then shaped a 2.5mm piece for the top plate and TIG welded all round then filed the radius around the outer edge.
I can't do the mounting holes yet as these have to spotted from the crankcase, and I want to do the liner as this will help lining up to the crankcase
PaulView attachment 141538View attachment 141539

Got onto the crankcase which involved a lot of metal removing (thank God for ripper cutters) and at the same time to remember what bits to leave .



One thing that came to light was because I had to use a 1/4" cutter for the internals the radius at the front corners interfered with the cylinder mounting bolt heads so had to make a small spot face cutter insert it through the 1/8" hole from the rear ( it wouldn't clear the main bearing blocks) then put a hand drill on it and pull whilst cutting. It worked out ok



Next job will be the base / fuel tank

Paul

 

[Weldsol]

Got going on the Base / fuel tank (yet another bag of swarf to go for recycling) cut out all the inside and did a rebate for the bottom plate ( to be TIG welded in ) then onto my adjustable angle plate to do the 5 degree
tapered outsides


Paul

 

[Weldsol]

More bits done, yet even more swarf but then that is to be expected
Got the crank sorted out it is a made up one and according to the drawing is held together with high strength epoxy but I have used Loctite 620 and once set drilled and pinned probably not needed but it made me feel better.
Also I was able to put the tapers on crankshaft for the flywheels while it was one straight bar (before assembly)


I decided to do the flywheels next and as I'm trying to use what material is in house these were made from flat bar mainly done on the lathe with the spokes and counter balance weights done on the mill


Just got to do some fettling then probably give them a coat of paint
Paul