Team CAD build engine poll

[Flat32]

Is this the beginning of a team effort??

I get like a dog on a bone when I start something. Ordering an Objet 30 Pro tomorrow, trying to find existing 1/4 scale spark plugs, figuring out how to hot forge valves, getting my wax printer running and I've reached the point where I can see a completed running 1/4 scale Flathead Ford engine as attainable. Wish there were an existing 1/4 scale Stromberg carburetor. Could be fed propane or liquid fuel via a remote hidden single injector run off my Megasquirt.

Flat32:fan:

 

[aonemarine]

I have a guys e mail that modeled a stromburg carb. Ill see if i can dig it up and ask him if he would mind sharing. Im not so sure he will, he wanted to be the first to build a complete scale running flatty.
I mailed him a block to model from, but havent heard from him in some time now. Doesnt hurt to ask though..

 

[Flat32]

My email is [email protected]. I need yours to set up a shared Dropbox for file transfer.

Flat32

 

[petertha]

Found out they offer different materials including brass and bronze. I thought it would be in some kind of faux material simulating the real metal, but it turns out they print in investment wax and cast the part. Quite expensive, but...

Flat32

Nice cad work. Can you elaborate on 'expensive'?
It's too bad they can take it to investment wax / casting level but cant offer aluminum parts. I suspect there is some logical reason or justification but beyond my pay grade. But there sure would be a lot of people interested in that alloy capability.

I hope some prototypes result from your guy's discussion, this is fascinating stuff.

 

[aonemarine]

Nice cad work. Can you elaborate on 'expensive'?
It's too bad they can take it to investment wax / casting level but cant offer aluminum parts. I suspect there is some logical reason or justification but beyond my pay grade. But there sure would be a lot of people interested in that alloy capability.

I hope some prototypes result from your guy's discussion, this is fascinating stuff.

Its likely outside thier bounding box. Ive done several jobs that they couldnt/ wouldn't do.
At a guess, to do this block in brass i would expect it to run about 2K, but its likely not to meet thier min wall thickness and clearance. That 2 k is what shapeways would likely want....iirc..

Flat32, i put my e mail in the first pm i sent you.. ill resend it...

 

[Flat32]

Castings that are cast iron will be a bronze or copper nickel, I hope. No aluminum casting. Crankshaft will be cast. Heads, water pumps and oil pump also cast. Steel stamping oil pan can be cast since the First Flathead Ford V8 had a cast pan.

I figure to farm out threading bolt and stud holes to a CNC shop. I understand they can thread mill as small as 1 millimeter. There are over 70 threaded holes, many blind, smallest 5/16-18 in real life.

Ford connecting rods had integral studs, no bolts. I figure to get them investment cast with pre-threaded studs cast in place.

Have to find the time to eat yesterday's breakfast.

Flat32:fan:

 

[aonemarine]

Surprisingly it does print as one piece without support. There is a few boogers i need to clean off but nothing too bad. But as far as casting, there are some really thin areas of investment that would likely fail under the lost pla casting process as well as some very thin walls. Still though, I think I should give casting it a try just to satisify my curiousity and see if it fails where I expect it to.

 

[Flat32]

3D printed stainless steel 1/4 scale Flathead crankshaft.



Flat32

 

[petertha]

3D printed stainless steel 1/4 scale Flathead crankshaft.
Flat32

That is nice. Any idea how something like that post machines & compares strength wise with a typical cast steel?

 

[Flat32]

I did some lathe turning on it with a HSS toolbit. I suppose it machines like a powder metal part although I don't have any real experience with PM. It is powdered stainless infused with bronze. Hard enough to be NOT file friendly.

You can buy a sample piece of it from Shapeways, which I had done a year ago, but only recently played with and determined it was near perfect for the crank. I drilled it, center punched, hammered on it, ground it, bent it a little before it snapped which took quite a bit of force. Did not try tapping threads since I don't have a tap designed for threading hard materials.

Flat32