Howell v-2 four stroke gas engine.

[gus]

Hi Dave,

Gear cutting is not tough but just a different ball game. Takes at least 4----6 bad gears before getting good gears. Gus is ever ready to help from books to tools etc. Cutting own gears is a must when you get into serious 4 stroke IC Engine building which have timing gears.SPDI sometimes ran out of stock for the gears you want.And they are not cheap. Made my own Rotary Table and Dividing Head. Indexing plates. I go for direct indexing which does away with the messy calculation and indexing. With direct indexing,you can't go wrong. Its fishiiiiinnng again on Sunday.

 

[Davewild]

Hi Dave,

Gear cutting is not tough but just a different ball game. Takes at least 4----6 bad gears before getting good gears. Gus is ever ready to help from books to tools etc. Cutting own gears is a must when you get into serious 4 stroke IC Engine building which have timing gears.SPDI sometimes ran out of stock for the gears you want.And they are not cheap. Made my own Rotary Table and Dividing Head. Indexing plates. I go for direct indexing which does away with the messy calculation and indexing. With direct indexing,you can't go wrong. Its fishiiiiinnng again on Sunday.

Thanks Gus. It will be very soon that I progress to gear cutting, what books are available? Enjoy your fishing!!!

 

[Brian Rupnow]

Gus--something I have found to be very helpful---if the gears are made perfectly to "specification" then the center to center distance is the sum of each gears pitch radius added together. However, I have made gears which looked perfectly fine, but the teeth were cut a bit shallow and consequently the pitch radius changes. I calculate the "perfect" center to center distance and drill/ream two holes in a scrap piece of aluminum for the correct shaft size and drop the gears onto the shafts. If they mesh fine, then no worries. However--if the bind, then you can shift the hole pattern a bit to accommodate that in your gearcase. If you drill the holes in the gearcase first and then find out your gears "bind" then you are in trouble.----Brian

 

[gus]

Gus--something I have found to be very helpful---if the gears are made perfectly to "specification" then the center to center distance is the sum of each gears pitch radius added together. However, I have made gears which looked perfectly fine, but the teeth were cut a bit shallow and consequently the pitch radius changes. I calculate the "perfect" center to center distance and drill/ream two holes in a scrap piece of aluminum for the correct shaft size and drop the gears onto the shafts. If they mesh fine, then no worries. However--if the bind, then you can shift the hole pattern a bit to accommodate that in your gearcase. If you drill the holes in the gearcase first and then find out your gears "bind" then you are in trouble.----Brian

Hi Brian.

Thanks for info. I am playing by ear. May try a mock meshing on a test piece and from go on to finale. Wish use the thin cigarette paper shim.

Bad day fishing. Engine Starter burnt. Fortunately by pouring on ice cold water,it did spin and start engine.

 

[gus]

Cannabalised or rather call it recycling a not so good RT built 4 years ago. Need a FacePlate like tomorrow to machine the blind pit holes in the gear case. Did surface skimmimg to make faceplate look good. Been looking around for a FP. Was a buy or DIY decision.Buying an Original Sakai FacePlate would cost me a bomb even though the Japanese Yen has gone down to 110 per S$. Buying M.I.China faceplate make not fit in.

 

[gus]

Making jigs and fixtures is part and parcel of machining the 1001 and parts for the Howell V-2 Engine. Have had no experience or requirement to use faceplate to offset machine parts when the 4 jaw chuck can be used. After putting on and clamping the gear case,I get a bit worried. More worried about collision with cutters while boring the blind holes. The clamping proved to enough to hold GC during trial run. More to follow.

 

[gus]

Job holding for the GC while boring the blind pit holes for the cams gave me some headaches. Due to the big offset, clamping would be restricted. While turning GC over I found the three M5 holes for the spigot used to hold Faceplate for facing could be used. Simple solution found. A M6 fastener used to secure GC to FP.

Fishing been good today. Three 1.5-----2 kg Snappers. Gave me a good fight. Nellie very happy,Gus brought back some fish for three weeks dinner.

 

[gus]

The Timing Gear Train is at last planted in. Some mini rework required. I am first timer using DIY faceplate.

 

[Art K]

Gus,
The gear box looks good.
Art

 

[gus]

Boring the Cavity for Oil Pump.
Setting up took more half morning. As a precaution took a dry hand spin to ensure the boring bar clears the clamps and fasteners. The Warner 3/8 Boring Bar did a great job. Its another FacePlate job and its last turning job. The gear case has some more work to do. The oil holes and oil passages.

 

[jimjam66]

Great work Gus - well done!

 

[gus]

Oil Pump Suction Elbow.

This mini brass elbow wasn't easy meat. I moved away from making it from a solid brass piece which take up too much time and not having to make a fixture hold solid brass bar to turn/drill the elbow.
My method was to make from 2 pcs.
Same elbow also functions as a drilling jig to drill the crankcase inlet hole. Jerry Howell gave good work instructions to enble a good elbow to crankcase fit. Deviating from Jerry's method will come to grief and misfit and a scrapped crankcase. Entire job took 2 mornings.

 

[gus]

Oil Passage from Oil Pump.
After a week's holiday in Thailand,with batteries fully charged,did some work today.

Drilling Jig
Drilling the inclined oil passage was scary and to hit spot on to oil pump discharge even more scarier.Broken drill will mean scrapping Gear Case. Best go slow and steady.
1.5mm hole is another scary task. Broken drill while drilling is another incident,I dread. Took me weeks to mentally design jig. Making the jig,set up.alignment and dry run took two hours.
Job done in 5 mins and oil passage did meet pump discharge port.;D
I have another 3 more oil holes to drill and a jig is not necessary but on after-thought,decided it as safest way to get good oil holes and no broken drills.

 

[Cogsy]

It's looking great Gus. Getting close to being finished by the looks. Are you still looking to have it finished by Christmas?

 

[gus]

Hi Al.

The Gear Case has too many details to be done. I have 4 oil holes for the cam lube and 4 M2 Holes to drill and tap and the Gear Case is done. However I am not happy with the gear train and may have to cut some gears.I also dropped 2 gears over the window and thats gone forever. By End Nov,I am about done. Trying very hard not to rush. Howell V-2 can be very unforgiving. After this engine,I could take other engines. Plan to do a 3 Cylinder Radial which is also very scary. Hopefully Gus gets to be ''Scare Proof''.

 

[gus]

Four Oil holes to lubricate the cam shafts after careful marking/scribing/centre popping. No jig and fixture required as I have earlier thought. Marking and scribing and dry run took an hour.Best to spot drill before final drilling so as to get drilling spot on. Oil passages to cam shaft must be spot on. Drilling 1.3mm and 1.6mm holes is scary for me. Any broken drill and taps would scrap Gear Case. Took frequent tea/pee breaks. Gus is goof proned and hammer-fisted. I still have some minor milling to do. Hopefully GC all done by tomorrow.
Going for eye operation to remove cataract and pull in new lens in a fortnite and this will set back completion. Eye Surgeon will decide ops date.

 

[jimjam66]

Nice work Gus. My dad was told yesterday that he is not allowed to drive until he gets his cataracts sorted - he is hoping to have the first one done in the New Year.

 

[gus]

Nice work Gus. My dad was told yesterday that he is not allowed to drive until he gets his cataracts sorted - he is hoping to have the first one done in the New Year.

The doctor confirmed the cataract but I also have Glaucoma.Scan showed have some damaged optical nerves. However his boss gave me eye drops to apply for my entire life.One drop every night should lower the eyeball pressure. Next appointment 6 weeks away. Hopefully the medication works.Usually does work but some folks do better with changeover to other drugs.

 

[ShopShoe]

Gus,

I'll be thinking good thoughts for your operation. I enjoy your posts, be they about machining or about fishing.

--ShopShoe

 

[gus]

Gus,

I'll be thinking good thoughts for your operation. I enjoy your posts, be they about machining or about fishing.

--ShopShoe

Hi ShopShoe,

After the last night's eye drop,right eye seems better. Perhaps this eye drop works. Nellie is reading up and Glaucoma and getting a ''bottle full'' and gave me not so bad news.That is Gus won't go blind so easily. I still have the lazy left eye. Medication can help prevent eye condition from going worse. My kid brother having same eye disease for last 5 years and he's doing OK w/o eye ops. However after 6 weeks,the M.O.and his Glaucoma Consultant/Specialist Boss will decide best course of cure. For now health supplements like Bilberry and Lutein seems to give better eye sight and right eye pressure seems diminished. Neliie is a trained senior nurse and Gus is having the best care. Sure glad I married a nurse!!!

Take Care.