Lister Diesel Engine

[EnnechParticipant @ennech]

This is my design for the Lister Diesel Engine Crankcase Casting from Vol. 210 No. 4448 – 25 January – 7 February 2013. I intend to manufacture the patterns and core boxes using my CNC equipment,

Edited By Katy Purvis on 08/02/2013 12:28:04

[EnnechParticipant @ennech]

[JasonBModerator @jasonb]

Nice rendering and judging by your other photos a very nice pattern should follow.

Bit hard to tell from the above but have you added machining allowance to the surfaces that need it or will you produce another version with them included before it goes into the CNC?

Do you also do your own castings and if so what metals can your furnace handle.

Look forward to some pictures of teh pattern being made.

J

[EnnechParticipant @ennech]

Thanks for the compliments!.

Yes I have included machining allowance of 3mm on machined faces.

I use the basic model as shown and develop the pattern from it scaling up for shrinkage and adding core prints etc., and then feeding that into another program that works out cutter paths.

I intend to make both aluminium and grey iron castings as I think that iron was the chosen material for the original.

I don't cast them myself, I have a good small foundry in my locality.

[martin perman 1Participant @martinperman1]

Just out of curiousity what scale are you building it to and what model, I collect full size Lister's and my L type has the same crankcase base.

Martin P

[EnnechParticipant @ennech]

I have designed it to the dimensions given in Model Engineer, ie 1/6 scale

[EnnechParticipant @ennech]

This is my design for the cover plate for the engine

[HobbyNutParticipant @hobbynut]

I sure would be interested in 1 of those cover plates.

[EnnechParticipant @ennech]

I have not yet produced the pattern. I am thining that the best option will be to make the pattern by 3D printing. I will let you know how it proceeds. Eric

[JasonBModerator @jasonb]

Or you could use something like Slater's letters and stick them to the basic cover which would be easy enough to produce on your CNC.

Just had a glance at the governor cover thats going to be a fun one to pattern make & cast, looks like a candidate for lost wax.

Hobby, you could always waterjet out each letter from say brass and sweat then onto a coverplate, just don't let them drop to the bottom of the tank.

J

[EnnechParticipant @ennech]

I have modified the casting design to flare out the base to be a truer representation of the full size Lister CS 6-1 engine.

I have also increased the vertical distance from the base to the crank centre to give clearance for the flywheel.

[Jeff DaymanParticipant @jeffdayman43397]

So what is the base to crank centre dimension on your revised casting design?

[EnnechParticipant @ennech]

Hi Jeff. The height from the machined base to the crank centre on my design is 80mm.

In the original design according to Jason's thread was 77.13 which results in an interference of 0.87 with the OD of the flywheel.

Eric

[Jeff DaymanParticipant @jeffdayman43397]

Thanks very much Eric. JD

[EnnechParticipant @ennech]

Machining the back half of the crankcase pattern

[EnnechParticipant @ennech]

Machining the pattern front half.

[EnnechParticipant @ennech]

Just arrived the 3D printed pattern for the nameplate. I have added the chucking boss to facilitate machining the back of the casting. Now to see how well it casts!

[EnnechParticipant @ennech]

Truing the flywheel pattern on the lathe after the CNC router. I have included a chucking boss.

[EnnechParticipant @ennech]

Crankcase pattern halves finished

Crankcase pattern and core boxes

Flywheel pattern

[JasonBModerator @jasonb]

Eric is that half of the flywheel pattern as itf it is it looks like you will get some very oval spokes when they should be almost round to oval in the opposite direction

I'm also not sure about those scallops above the feet as I've not seen them on full size engines such as this

Lister6/1

[EnnechParticipant @ennech]

It is the full pattern. I decided that if I attempted a half pattern approach there could be mis-match on the spokes which apart from looking bad would weaken the casting. The flywheel is designed to be recessed at the other side by machining.

The scollops are there to enable me to flare the casting bottom and still be in scale for the feet dimensions. I decided the scale by comparing the OD of the flywheel with that of the full size Lister CS and decided it was a scale of 1/4. The feet spacing on the original is 13" and so that the spacing on my casting is 3.25"

Eric

[EnnechParticipant @ennech]

Crankcases direct from the foundry in iron and aluminium

Pair of cast iron flywheels

Crankcase and flywheel

[JasonBModerator @jasonb]

They have come out nicely, infact you can hardly spot those scallops above the feet now, probably they caught the light on the 3D renderings.

J

[EnnechParticipant @ennech]

Thanks Jason, yes the scallops blend in nicely. The foundry did a good job on them and very quick too.

[Sub MandrelParticipant @submandrel]

Congratulations Ennech,

Neil

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