While I was making the guide I made a small collet to slide over my 90 degree

cutter to enable me to keep it square while I cut the seat for the guide.

The guides are screwed in with green permanent Loctite

the holes drilled in the cylinder head actually

came out in the correct place in the combustion chamber. I am happy to say the jig did its job.

You can see from this picture were the drill breaks into the valve guide.

The cylinder liners are made from seamless 4130 aircraft grade tubing. The tube will only

need a light hone ready for use.

I made an expandable reamer to hold the tubing while I cut the short lengths so I didn't

crush it. I turned a small chamfer on the inside edge to make it easier to fit the pistons.

These will be a push fit held in with Loctite

The crankcase has a timing gear fitted inside, this is one of the few items I need

to buy for the engine. It is an internal ring gear , 60 tooth , 48dp which I managed

to buy from HPC gears . The gear will need reducing in width and diameter so I

turned a boss on the end of some alloy bar. The gear was then tapped onto the boss and this was enough to hold it

in the lathe.

I then transferred it to the mill and drilled the holes for mounting .

After turning the ends square I started to turn the inside to the dimensions shown

in the plans. These consist of shoulders and pockets for the bearings, ring gear and clearances

for the crankshaft.

The crankcase is transferred to the mill and a flat is milled at 120 degree intervals

and a .75 inch hole is turned central on each flat for a snug fit of the cylinder liner.

8 holes for each cylinder so 24 in total, on the 20th hole this happened,

Once the chemical metal had set I finished the remaining holes then moved on to drilling

the holes for the 6 push rods [ 2 per cylinder ]

A flat is milled and centre drilled ready for the carburettor mount hole. I am not sure on the

carburettor I will be using yet so I will complete this when I buy the carb.

The locating holes for the timing gear are drilled and tapped inside the crankcase. For this I

had to buy an extra long centre drill and make an extension for the M2 tap.

You can see the timing gear resting on the mill table