Swifty's build of Rupnow engine.

[gus]

Hi Swifty,
Gus is watching every move and every step to prep ahead in case he falls to temptation to build this new engine.Will be months away.Will print and study the plans before I plunge into unfamiliar waters.
As usual I take a break for two three months admiring my just done DIY engine. Will be making the simpler no brainer
stuffs like tools and odds&ends. Come this weekend will be fishing in Southern Thailand.
Still cannot believe I got Webbie running two hours ago,even though engine seems to run but firing seems not smooth spinning. Guess somewhere I goofed again. Will ungoof the goof.

 

[Swifty]

Hi Gus, don't leave it too long between engines, what's life without challenges. You sure do get around with your fishing.

Paul.

 

[gus]

Hi Gus, don't leave it too long between engines, what's life without challenges. You sure do get around with your fishing.

Paul.

Hi Paul,

You are right. Just taking a break in South Thailand.Koh Samui.
I heard about the beaches with gorgeous beauties. Will try very hard not going
to the nudist beaches.:hDe::hDe::hDe:

 

[Swifty]

Hi Gus, nudist beaches!!! So your not going with your wife then?

Paul.

 

[Swifty]

Well, despite having to keep my grandson amused all day, I managed to turn a couple of bits during his nap time. Here we have the crankshaft and spacers, just have to be drilled.



Paul.

 

[Brian Rupnow]

Looks very good Paul.---Brian

 

[gus]

Hi Paul,

Will wait for Brian to make PDF prints available. Then decide to plunge in.

I admire your Tool & Die making experience. Though

I did Trade School for two years,skill was very basis. My instructors did advised it will take years of trade practice to be very competent.
Wasn't until 2004 when plugged enough courage to jump in and buy lathe & mill & bench drill and this was after many years of buying/reading occasional copies of Model Engineer's Magazine whenever I dropped by Oz. Wasn't until 2010 when I joined HMEM and from here skills improved with advice,guidance and encouragement from forum members. Webbie was a good example though Firefly engine was show piece that refused to run. Will first rework this very unforgiving engine.

Thanks for the support,advice and encouragement.

 

[Swifty]

Not much work being done the last couple of days, my mother was getting her carpets cleaned yesterday, so I was over there most of the day. Today an ex employee called in to see me and we chatted for a few hours, so lost machining time.

Managed to finish the assembly of the flywheels, crankshaft and axles. I might use Luc's idea of making the cylinder from steel with a finned aluminium sleeve shrunk on, and then make the piston from cast iron.



Rear view.



Gus, I failed nearly every subject in High School except for woodwork, metalwork and mechanical drawing, managing to top every class in these subjects. I finally found my calling when I started my apprenticeship at a toolmakers, managed to come out top of the class each year at trade school. I really enjoyed the work, and it showed as my skills increased. I finally found out what trigonometry was all about, and that was the days before pocket calculators. I still find working in metal very rewarding.

Paul.

 

[canadianhorsepower]

Hi Paul really looks goodThm:Thm:

 

[Swifty]

Nothing much on TV this evening, so left the wife watching Big Brother, and off to the workshop for me. Scrounged around and found some 4140 that I can use for the cylinder, and some aluminium for the finned sleeve.

Parted off a length of the 4140, drilled it 13mm, then 19mm and set up a boring bar to machine the bore out. The outside of the material is still rough, I plan to bore to size and then turn up a mandrel and finish the outside. Because I'm converting some of this engine to metric sizes I decided to make the bore 20.00mm finished size. 4140 sure machines nicely, bored it out leaving 0.03mm for honing, checked each end with the telescopic gauge and it is perfectly parallel, lathes working well.

Next, I parted off some 50mm aluminium bar, drilled it 13mm, then 25.4mm. Stopped work on this for the moment, I will finish the bore once I have turned the outside of the cylinder, then shrink it on the cylinder and use the mandrel again to finish the sleeve off.

Will be busy with other things tomorrow, besides being our 38th. wedding anniversary, might be asking a bit much to hide out in the workshop, so will probably not get any work done.



Luc, I'm not sure at the moment which way I will go with the ignition.

Paul.

 

[Brian Rupnow]

Very impressive work. I am so happy to see someone going ahead with the air cooled version.---Brian

 

[jwcnc1911]

Nice Swifty! I'm looking forward to seeing the air cooled version.

 

[gus]

Very impressive work. I am so happy to see someone going ahead with the air cooled version.---Brian

Hi Brian,

Gus will go water-cooled. Seen hopper cooled work horse engines operating
in Taiwanese Rice Fields. Quite a sight,when water boiled over or engine take a break so did the farmer. Seen these engines powering small trucks in China. Though a bit slow.

Will continue following your thread and Paul's too.

Come tomorrow will in South Thailand enjoying the "Smells like hell,taste like heaven" fruits. Will sneak in a decent shot. Hope Gus won't get banned.

Kubota makes Hopper Cooled Engines in Thailand.

If WiFi is available will follow your threads.

 

[gus]

Hi Paul,

Plan to cut DIY bevel gears too. But will "monkey see,monkey do''. Please advise Metric Gear Module No. to buy gear cutter in advance.
Will be fun .Gus will goofed till he gets it right. May cut gears in advance. Will read up Japanese KG Gear Cataloque.

 

[Swifty]

Hi Gus, the only set of gear cutters that I have are mod 1. I will check if that size will be OK for the bevel gears, although I intend to cut the spur gears with them. If you are going to use module gears, you will have to alter the centre distance of the pivot hole for the larger spur gear that is in the side plate.

Paul.

 

[gus]

Engine frame and flywheel assembly looks great.

 

[gus]

Hi Gus, the only set of gear cutters that I have are mod 1. I will check if that size will be OK for the bevel gears, although I intend to cut the spur gears with them. If you are going to use module gears, you will have to alter the centre distance of the pivot hole for the larger spur gear that is in the side plate.

Paul.

Hi Paul,

Thanks for the tip. May go for "bought out" gears similar to Brain's.
May not be wise to veer off from prints with the sensitive governor drive and the hit & miss device. Been view quite a few YouTube posts on same engines.

Have a hunch,I could buy off the shelf new HT Ignition Coils in Thailand since they do not scrap ten/twenty year old cars.Just worried the existing dinosaur coil may kaput. Webbie has taught me a great deal with her unforgiving temperament.

 

[Swifty]

Managed to get a bit more done, despite several interruptions. Purchased a wheel cylinder hone this morning and used it straight away, I'm very happy with the results on the steel cylinder. Next thing was to make a mandrel so I could turn the outside of the cylinder sleeve.

Here's a picture of the mandrel, cylinder sleeve and hone.


Next job was to bore out the aluminium that is going to be shrunk onto the steel sleeve, left 0.025mm interference.

Here's a picture of the cylinder and sleeve before fitting together. Sorry about the picture being a bit blurry.



The aluminium is in the oven now heating up, so hopefully next post you will see them as one unit.

Paul.

 

[Swifty]

Well guys, here we are a short time later, the cylinder and the aluminium sleeve are one unit now. The sleeve expanded enough to fall on the cylinder easily. I mounted the cylinder unit on the mandrel that I made earlier and machined the outside and steps on the end. Next, I set up the grooving tool that I made a couple of days ago and cut all the grooves. I'm happy with the result

Here's a photo just after I slipped the sleeve on.


This photo is the cylinder unit mounted on the mandrel ready to be machined.


Finished cylinder.


Cylinder loosely fitted to the engine.


Paul.

 

[gabby]

Hi ya Paul, You are coming on great with this one, I like the use of the heat/shrink process I must try it myself someday'
Cheers
Graham