Mega Cyclone

[Powder keg]

I think it will be around 10" in diameter Chuck. I got the metal for the con rods cut out today. In the morning I'll start squaring up the blocks.

 

[cfellows]

Ugh... con rods are my least favorite things to do. Very nice when done right, but a lot of work. I probably need to spend some time standardizing my methods and making some jigs.

Chuck

 

[Powder keg]

I've only made a few engines. I think Con rods are my least favorite part. These won't be too fancy. They'll be on the inside. I seem to have a hard time making them look nice. Maybe these bigger ones will be easier?

 

[zeeprogrammer]

Was I reading that right? 0.125" off the diameter in one pass? That must be a sizable machine...I get scared around the .01 mark with my mini-lathe.

Appreciated seeing the video. It helps me a lot as I've still got a lot to learn about speeds and feeds.

 

[Powder keg]

We have an Ameraseiki CNC lathe at work with a 30 HP spindle motor on it. 2 weeks ago we were roughing some shafts with 1 inch cuts off the diameter. Other than it sounding like someone was shooting gravel at the door you couldn't tell that we were taking such a big cut. The load meter was hitting 110% at times ;D

If you have any questions Zeep just ask. But experience is the best teacher. You just have to make lots of chips.

 

[Powder keg]

The crank valve has been bugging me so I decided to work on that some today. I set up my dividing head and lined everything up.

I set up my height gauge to the center of the valve then scribed some indexing lines on it.

I couldn't find my edge finder, So I used a piece of paper. That will be close enough for these slots.

I then started machining key ways around the shaft the "hard way". It went pretty good. My Chinese end mill went dull, but I made it through.

After I had the keys machined I needed to drill a port to connect the intake port to the hole in the center of the shaft. I started with a center drill.

I then drilled the hole to size.

Here Is what I have now. There are a few more holes that get drilled and tapped yet. It will take a few more setups to get them though.

 

[stevehuckss396]

I'm making this engine twice as big as the plans call for. This engine is neat because the engine spins and the crank is stationary.

I found this funny because I am about 95% done with a 5 cylinder that works like yours only i shrunk it down from mega to 1/3rd size.

I'll be watching!

 

[Deanofid]

Thanks for the progress shots, Wes.
Man, I hate it when an end mill starts giving up the ghost in a cut. That's how it always happens. ; )

Dean

 

[Powder keg]

I managed to donate 2 con rods to the scrap bin today. Having troubles. I have a .3125" reamer that is chattering BAD!!! I was going as slow as my mill will go????? I might just drill the holes? Maybe I'll do a few more test holes???

 

[Deanofid]

Sounds like time for the mythical D reamer, Wes.
: )

Can you drill them large enough to bush them, and save the ruined rods?

 

[Maryak]

Wes,

A short steep taper at the start of the hole sometimes helps get a reamer started without chatter.

Hope this helps and bad luck about the rods.

Best Regards
Bob

 

[Powder keg]

I'll have to look into those D reamers. I have a heat treat oven now\o/ I could have a chance to use it ;D There's not enough room for sleeve I don't think?

 

[Seanol]

I made a d bit reamer for my rocking engine bore and it worked perfect. It was brass though.

I followed the instructions given here before and had no problem making it.

I did file the relief on the front and side before heat treat and I used water hardening rod, quenched in oil with no temper done.

Worked really well. Another way to go might be a tool makers reamer. Just remove metal on the bias, like slicing a rod on the diagonal.

Haven't tried that yet.

Good luck, and sorry about the rods,

Sean

 

[Powder keg]

Well I have some drill rod to make the D bits out of. Just no time now ??? Maybe after work tomorrow? I'm curious to see how they work now. It can't be much worse than the reamer I used thats for sure\o/

 

[1hand]

PK;

When you make them, could you take some pics? I like to see how you go about doing that.

Matt

 

[Powder keg]

You bet!

 

[Powder keg]

I have a good start on my D bit reamers.

I just need to grind the end relief on it. I don't think I'll even heat treat them? I'm just cutting brass.

 

[Seanol]

Wes,
You might want to mill the side, not the top. That will give a gradual taper to the tool instead of an abrupt end. This stress riser could make the tool prone to crack at that joint.

I heat treated mine because I wanted it around for a long time. I don't know if it will matter otherwise.

If you need a pic I will get one up tomorrow as the camera is at work :

Sean

 

[Powder keg]

Thanks for the tip Sean. I'll reember that for the next one)

 

[Powder keg]

Tried a couple test holes. the bits need to be heat treated. I messed the bit up that I made. Well, I decided to go back and see what's up with the reamer. Turns out that I drilled the hole to small and the reamer was cutting too much. I now have three Con rods drilled and reamed. I think I'm going to finish them up on the rotary table.