3 cyl Pip engine

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3 cyl Pip engine

Home Forums Work In Progress and completed items 3 cyl Pip engine

Viewing 25 posts - 101 through 125 (of 167 total)
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  • #389902
    David K
    Participant
      @davidk77137

      Hopefully when the rings are removed they will stay with the gap formed and have

      a little 'spring'

      The rings on the bottom are heat treated , the rings above are not.

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      #390205
      David K
      Participant
        @davidk77137

        Valves first start off with a length of silver steel

        Reduce the shaft to just over the valve shaft diameter then cut the groove for the collet.

        #390206
        David K
        Participant
          @davidk77137

          Now reduce the shaft for the whole length of the valve until a nice fit into the guide

          #390207
          David K
          Participant
            @davidk77137

            Next turn the top slide to 45 degrees and cut the valve face

            #390209
            David K
            Participant
              @davidk77137

              Part of the valve

              Flip the valve in the collet and using a grinding stone finish the valve face

              #390210
              David K
              Participant
                @davidk77137

                Then repeat to make six plus two spare

                #391688
                Ryan Norton
                Participant
                  @ryannorton40317

                  Beautiful work!

                  #391768
                  David K
                  Participant
                    @davidk77137

                    Cheers Ryan

                    #391769
                    David K
                    Participant
                      @davidk77137

                      Rather than make each rocker individually I machined the rocker profile along a piece

                      of bar and then parted off each rocker from the bar.

                      Starting off with a 22mm round piece of Stainless mounted in the lathe , faced off and centre drilled

                      both ends then a 5mm hole is drilled then reamed through the centre.

                      The piece is then mounted on the mill using the rotary table and start milling the shape.p1040768 (medium).jpg

                      #391770
                      David K
                      Participant
                        @davidk77137

                        Next a set of 1.6mm holes are drilled p1040773 (medium).jpg

                        #391771
                        David K
                        Participant
                          @davidk77137

                          and then tapped m2 for the adjusting screws p1040773 (medium).jpg

                          #391772
                          David K
                          Participant
                            @davidk77137

                            The profile can be seen here

                            p1040774 (medium).jpg

                            #391773
                            David K
                            Participant
                              @davidk77137

                              Each rocker is then parted off

                              p1040775 (medium).jpg

                              #391774
                              David K
                              Participant
                                @davidk77137

                                To finish the rockers I then carefully milled the sides down to size p1040776 (medium).jpg

                                #391776
                                David K
                                Participant
                                  @davidk77137

                                  Then after a de burr and clean I pressed in a bronze bush , fitted an adjusting screw

                                  and then fitted them to the cyl head.



                                  You can also see the valve caps I made but forgot to take pics. p1040795 (medium).jpg

                                  #391779
                                  David K
                                  Participant
                                    @davidk77137

                                    Diffuser.

                                    The engine works similar to a 2 stroke in that the fuel is fed into the crankcase and then

                                    transferred to the inlet ports.

                                    The diffuser is basically a fan designed to push the fuel mixture around the crankcase.

                                    #391780
                                    David K
                                    Participant
                                      @davidk77137

                                      Starting of with some Alloy bar in the lathe the piece is turned to correct diameter

                                      and a groove is turned to mark the depth of the fan.

                                      A 5mm hole is drilled through the centre and this is then opened out to accept two

                                      press fitted bearings 9x4x4


                                      p1040812 (medium).jpg

                                       

                                      Edited By David Kenyon 2 on 18/01/2019 20:22:52

                                      #391782
                                      David K
                                      Participant
                                        @davidk77137

                                        The piece is then transferred to a rotary table placed on the mill table vertically.

                                        A series of holes are drilled 15 degrees apart either side of the 180 degree mark.

                                        These holes will have small pieces of steel inserted in them later to enable balancing

                                        the fan.p1040813 (medium).jpg

                                        #391783
                                        SillyOldDuffer
                                        Moderator
                                          @sillyoldduffer

                                          Good stuff David – please keep the updates coming. Don't get discouraged if not many people comment directly – build threads tend to be enjoyed quietly.

                                          Dave

                                          #391784
                                          David K
                                          Participant
                                            @davidk77137

                                            The rotary table is then placed horizontally and a 4mm hole is drilled .312 inches off centre,

                                            this is the same measurement as the stroke of the engine as the fan is driven from a pin

                                            inserted into the big end . You will see this in a later picture.

                                            The table is then tilted 15 degrees and a 3mm end mill is used to start cutting the fins at

                                            30 degree intervals.

                                            p1040816 (medium).jpg

                                            #391787
                                            David K
                                            Participant
                                              @davidk77137

                                              The mill is moved along the 'y' axis and a second set of cuts make up the rear of the blades

                                              Then its just a matter of removing the waste between the fins

                                              p1040819 (medium).jpg

                                              #391790
                                              David K
                                              Participant
                                                @davidk77137

                                                Back to the lathe the fan is parted off then I had to make a fixture to hold it

                                                onto the rotary table.

                                                Now I can mill out the back of the fan to create the passage for the air/fuel to pass through.

                                                p1040822 (medium).jpg

                                                #391791
                                                David K
                                                Participant
                                                  @davidk77137

                                                  With the drive pin and bearings fitted I can then balance the fan by putting small

                                                  off cuts of steel rod into the holes drilled opposite. These will be fixed into place

                                                  with Loctite.

                                                  p1040857 (medium).jpg

                                                  #392070
                                                  David K
                                                  Participant
                                                    @davidk77137

                                                    Picture showing how the diffuser is driven from the crankshaft big end. p1040860 (medium).jpg

                                                    #392071
                                                    David K
                                                    Participant
                                                      @davidk77137

                                                      Balancing the engine,

                                                      I bought a little 'jewlers scale' off E Bay so I could weigh each part.



                                                      Rather than explain I will just re print the chart from the plans with the weights

                                                      filled in.

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