Re: TB5 proposal

[JorgensenSteam]

More photos from yesterday and today:

The outside rim of all the flywheels were turned on a mandrel.
Matt was dead-on with his CNC, so just a light face-off.

 

[JorgensenSteam]

Gaskets and gasket cutters.
Frame outer bearing support being silver soldered together.

 

[JorgensenSteam]

Mock-up assembly:

The piston looks great with Ken's stainless rod and brass rod end.

The ring gap on the piston ring closes down to a few thousands when installed in the bore.

Starting to look like an engine (Steam that is!).

 

[1hand]

Nice Job guys Thm:

 

[JorgensenSteam]

Bearings pressed into frame.

 

[steamer]

Sure looks good from here Pat!

Dave

 

[JorgensenSteam]

Thanks Dave.

Here are photos of the crank disk constrution:

 

[JorgensenSteam]

And here are some photos of the frame being squared.

It is really important to get everything as square as possible, and machine as many surfaces as possible without changing the position of the frame in the vice.

I faced surfaces in this order: bottom, top, right side, end edges, top edges, cutout edges.

Even though a piece of steel angle has a factory 90 degree bend in it, this shape is not nearly accurate enough to use for an engine, and all the sides have to be accurately faces flat, parallel and perpendicular to each other.

Once the outer bearing support has been silver soldered on, the holes for the main bearings should be drilled/milled with the frame bolted onto the mill table with the port face down. The crankshaft has to be exactly perpendicular to the port face of the frame.

A shallow recess was milled for the outer bearing to help align it, and a round spacer was clamped between the two crankshaft supports prior to silver soldering to get the bearing supports exactly parallel.

 

[Brass_Machine]

I may end up having to bow out of this build. Some personal and financial issues have arisen that are making this difficult. I had hoped to start my parts over a month ago... now it looks like it will be at least 4 to 6 weeks before I can start.

Is there any member that is not involved with this build that wants to be? Someone that can take my place?

Eric

 

[JorgensenSteam]

Eric-

I know the feeling all to well, and can cetainly relate.
The economy is the pits right now.

We will work it out, we are doing ok on the build, a little slow maybe, but we will make it. It is a trial and error thing for me, with much trial and a lot of errors, but we are getting there.

Pat J

 

[maverick]

Hello all- First post here.
I'd like to offer my help on this build since Eric had to bow out. What parts would I have to make?
I can start them within a few days.
Mike

 

[JorgensenSteam]

Hello Mike-
Welcome to the forum. Glad to have you.

Eric had cylinder heads.

I will have to send you the latest drawing set.
I can't get it loaded here due to size restrictions.
We are still tweeking the drawings, but they should be close.

Let me know if you have questions.

We need six sets.
Gray cast iron.

Are you up to it skill/equipment/material/money wise.
Our skill level varies among members, from advanced, to new people like myself.
This is intended to be an intermediate level build.

If you ship parts to me, I will distribute from here to all the team members.
Are you in the US or nearby?

Pat J

Chuck had cranks, crank disks and gland nuts.
Chuck, you still out there?

 

[JorgensenSteam]

Mike-

Here is the status of the Team Build No.5 parts as of today (03-09-11).

PatJ

We have the following parts (per engine):


Base (2 pieces, hardwood) - Ken (status - complete)
Bearings - main crankshaft (2, brass) - PatJ (status - started, not complete)
Bearing - cylinder pivot (1, brass) - PatJ (status - started, not complete)

Crankshaft (1, stainless or mild steel) - Chuck (status unknown)
Crank disk (1, gray cast iron) - Chuck (status unknown)
Crank pin (1, steel or stainless) - Chuck (status unknown)
Cylinder head - upper (1, gray cast iron) - Mike? (status - not started)
Cylinder head - lower (1, gray cast iron) - Mike? (status - not started)
Cylinder pivot bolt with nut - (1, steel or stainless) - Ken (status - complete)
Cylinder tension spring with nut - (1, steel) - (Each person provides their own)
Cylinder head screws (8, stainless) - PatJ (status - complete)

Exhaust pipe (1, brass) - (not assigned)
Exhaust fitting (1, brass, store bought) - (not assigned)

Flywheel (1, steel or aluminum) - Matt (status - complete)
Frame (1, steel) - PatJ (all started)

Gland nut (1, brass) - Chuck (status unknown)

Lagging (1, brass) - PatJ (status - complete)

Packing material for gland (1, standard material) - (Each person provides their own)

Piston (1, gray cast iron) - PatJ (all started, 1 complete)
Piston ring (1, gray cast iron) - PatJ (all started, 1 complete)
Piston rod with nut(1, steel or stainless) - Ken (status - complete)

Rod end (1, brass) - Ken (status - complete)
Screws (to secure frame to wood base) (3, steel) - (Each person provides their own)

 

[JorgensenSteam]

We hope to hear from Chuck soon, and pull this all together.

Chuck, please let us know as soon as you can where you stand.

Thanks very much.

Pat J

 

[maverick]

I notice the exhaust pipe and fittings are not assigned. I can do those if you'd like. Should be able to finish them before
the cast iron arrives.

 

[Brass_Machine]

I notice the exhaust pipe and fittings are not assigned. I can do those if you'd like. Should be able to finish them before
the cast iron arrives.

I was going to work on those as well.

Thanks for jumping in Mike

 

[AMS]

Hi guys,

I'm pretty new here, been following your build for quite sometime. I would like to offer my help if its needed if not I will look forward to the next group project that starts up.

Andy

 

[JorgensenSteam]

Andy-

Welcome to HMEM.
We are in the final stages of Team Build No.5.

I will be posting the "as-built" TB5 engine drawings on this site as soon as we have built at least one engine from them, and verified that they are correct.

I am sure the TB5 guys would be happy to guide you through building the engine if you choose to build one yourself.

I can certainly tell you what not to do.

Thanks for checking in.

Pat J

 

[maverick]

Finished with the exhaust pipe and fitting. Starting on the heads next.

 

[kjk]

Excellent - how about a picture?