V Twin 90 Deg. George Britnell

e.picler · May 11, 2021

Hi to everybody!
It's been a long time I do not post anything here.
My last project was the Bob Shore V4.
I'm currently building the V Twin from George Britnell. This project has been a very challenging one for me because it is a very detailed design. Very nice project.
I have almost 85% of the parts finished. I will try to post them in the sequence I machined them.
I would like to thank George for the hints and information he gave me. He was very kind and patiently with me.
Here is the engine.

Tks,
Edi

e.picler · May 11, 2021

Hello!
I started with the block/Crankcase. Front or Gear side. It is composed of two parts.

This is the front side.

In order to reduce the amount of machining on the backside of the gear side block, I drilled some holes on the block as shown on the photo bellow

Lots of material to be removed.

I had to make three pieces because of the error on the G Code.

Next will be the Flywheel Block Side.

Thanks,
Edi

kuhncw · May 11, 2021

Edi,

Interesting projects and very nice work.

Chuck

gbritnell · May 12, 2021

Hi Edi,
I'm glad to see you are presenting your work on the forum. Looks great!

e.picler · May 17, 2021

Hello!
Some more details about the V Twin construction.
Next, I machined the Ignition/Timing Cover and the Front Crankcase Cover.
For both parts, I machined the stock to the final Thickness and glued it to a base for the vise holding. It works very well for some thin and complex parts that you can not fix it directly on the vise.

The same process for the Front Crankcase Cover.
I first machined the flat side then glued it for machining the upside. For this operation, the stock was held directly on the vise because I had enough height for fixing.

To be continued.
Edi

e.picler · May 17, 2021

Continuing.
Machining the upside.

The next part was the Crankcase Flywheel Side.
TKS,
Edi

e.picler · May 17, 2021

Continuing with the Crankcase.
A lot of material to remove for the crankshaft space.

To avoid deforming the machined side, I supported the inside as shown on the photo bellow

In order to get the center of the first machined side, I indicated the crankshaft hole.

To be continued.
Edi

gbritnell · May 18, 2021

Really outstanding work Edi! I have never used super glue as a fixturing tool. I guess mainly because I've never had too much luck with bonding smooth metal surfaces together.

cwelkie · May 18, 2021

Beautiful work Edi. Truly showcases the mental processes required to find those parts in the raw material.

George - some of the challenges with bonding smooth surfaces using CA might be resolved with an intermediate medium ... e.g.,

Charlie

e.picler · May 18, 2021

Thank you, Chalie!
Geoge,
In order to ensure good anchoring of the part, I provide the surface with rough finishing facing it with a high feeding rate so it produces small grooves where the glue bonds the part.
I do not use the taper, I bond the part directly and use heat to release the finished part (around 200 Celcius degrees).

Edi

e.picler · May 19, 2021

Some more info on the building.
Boring the cylinder hole.

Turning the Cylinders.
First I used a thinner tool then the one with the final width

Tks,
Edi

e.picler · May 19, 2021

Continuing
For drilling the holes for the lifters, I used a shaft in order to find the center of the camshaft hole then set the block to the specified angle

Next, I started on the Crankshaft
No pictures of the turning process

The screw for holding the crank gear

Tks,
Edi

gbritnell · May 20, 2021

Outstanding work Edi!

e.picler · May 31, 2021

Hi to all!
Thanks, George.
Next was the turn of the Connecting Rods.

I also used the bonding process. Again, it worked fine.

The inner rod

The bigger rod

First side finished for both connecting rods

Second side machining

Machining the slot for the Inner rod

To be continued.
TKS,
Edi

e.picler · May 31, 2021

The crankshaft assembly and finishing.
Machining the counterweights

For this operation, I shimmed the two halves in order to clamp the assembly to the vise

Shaping the 20 degrees angle and the radius on the corner of the throw

After truing the two halves on the lathe, the throw pin was positioned with #4/0 taper pin on the flywheel side

Thanks,
Edi

e.picler · May 31, 2021

The rocker arms were also machined using the bonding approach

After machining the profile, I flipped it 90 degrees for the pushrod pocket and the adjusting screw thread.
I found the center of the hole and the center of the width of the first part and knowing the pitch between the two parts was easy to drill the second one

The second side was machined on the lathe

At this point, I decided to make the Flywheel

Back to the mill, I started on the Cylinder Heads.
Setting the 9° for the Spark Plug

First I machined the pocket

Then I made a program to machine the angled surface of the Spark Plug boss

Getting the center of the Spark Plug hole

With the Valves seats in place. Made out of cast iron

More on the heads to come
TKS,
Edi

e.picler · May 31, 2021

In order to ensure the perfect alignment/seat of the valve, I made a tool to touch the Valve seats

Grinding the relief angle

For the following operations, I hold/bolted the head on a square block.
Here it set to 8.34° for both sides of the top

Now machining the fins

Turning the Valves. Stailess Steel

The groove for the Keeper Clip

Thanks
Edi

kuhncw · May 31, 2021

Very nice work Edi. Thanks for all the detail photos. I especially liked the way you held the small end of the connecting rod while machining the second side.

Chuck