Postman Cometh Part 2

[Nick_GParticipant @nick_g]

Posted by JasonB on 22/11/2015 10:07:43:

No, I saw a photo you uploaded

.

Ahhh. The drills made from blu-tack. Now I understand. (I think)

Nick

[mechman48Participant @mechman48]

Hi Nick

Nice work to date; intrigued by the boring bar in one of your pics… any details, where from, size etc ?

George.

[JasonBModerator @jasonb]

Nick if you have not silver soldered before then do a few test joints on some scrap, you have a lot of time invested in the crankshaft parts and it would be a shame to have a muck up with them.

Oh and get a move on, I have a video to upload once I can find some organ music to go with it

Edited By JasonB on 22/11/2015 10:59:58

[Nick_GParticipant @nick_g]

Posted by JasonB on 22/11/2015 10:59:40:

I have a video to upload once I can find some organ music to go with it

.

I like Bach.

Might scare the kids at the fair ground though.

Nick

[Neil WyattModerator @neilwyatt]

Wow! I'm convinced I have some sort of musical dyslexia as I struggle to follow even simple tunes, but that made complete intuitive sense to me.

I have a marvellous old Russian stereo sample LP from the 60s that has a brilliant example of T&FinD on it, you can here the stops thumping in and out, and it makes the worlds shake! I also saw Sky performing it whiel Joh Williams was still with them.

If Bach had been alive today, I'm sure he would be into heavy metal.

Neil

[Nick_GParticipant @nick_g]

Posted by mechman48 on 22/11/2015 10:56:55:

Hi Nick

Nice work to date; intrigued by the boring bar in one of your pics… any details, where from, size etc ?

George.

Ello George,

It's an iscar one that I nabbed on ebay as 'new old stock'

The info stamped on the side says it's this one **LINK** Except it does not look like that one. Only similar.

Nick

[mechman48Participant @mechman48]

Posted by Nick_G on 22/11/2015 13:11:16:

Posted by mechman48 on 22/11/2015 10:56:55:

Hi Nick

Nice work to date; intrigued by the boring bar in one of your pics… any details, where from, size etc ?

George.

Ello George,

It's an iscar one that I nabbed on ebay as 'new old stock'

The info stamped on the side says it's this one **LINK** Except it does not look like that one. Only similar.

Nick

Thanks for the info.

G.

[NJHParticipant @njh]

Nick

That is fantastic ! ( In this case I mean the Bach – as well as your engineering progress of course!) I am very familiar with that Toccata and Fugue but the graphic gives a further indication of its complexity.

I have loved music, especially classical music, all my life but sadly never learned an instrument. A couple of years ago I decided to take some piano lessons so turned up weekly to torture the ears of a very nice lady teacher. She was very patient but I stopped after about a year – I realised that I was never going to pose a threat to Barenboim! I still tootle a bit each day and, with an electric piano and headphones, only I have to suffer!

Norman

[Nick_GParticipant @nick_g]

Posted by JasonB on 22/11/2015 10:59:40:

Nick if you have not silver soldered before then do a few test joints on some scrap, you have a lot of time invested in the crankshaft parts and it would be a shame to have a muck up with them.

.

Did a test joint using the off cut surplus of the crankshaft I had turned and the waste from the parting off from making one of the webs.

Once done I but the crankshaft scrap stub in the lathe and made a few facing cuts. Then took some cuts off the diameter of 40 thou with 8 thou per rev feed to test it's strength. As you can see it held. Then rubbed on some emery to see the joint better.

These are the bits waiting for the flux that Jason recommended to arrive. As said I have taken quite a bit of time with these parts so if I make a dogs danglers of it I am going to dress in drag, joint the WI and take up jam making and flower arranging.

Nick

[julian atkinsParticipant @julianatkins58923]

hi Nick,

why dont you loctite then pin the crankshaft joints? this is how virtually all miniature loco crankaxles are made these days.

cheers,

julian

[Nick_GParticipant @nick_g]

Posted by julian atkins on 23/11/2015 23:23:39:

hi Nick,

why dont you loctite then pin the crankshaft joints? this is how virtually all miniature loco crankaxles are made these days.

cheers,

julian

.

I am very tempted. …………….. But that Jason guy-bloke has forbidden me.

Nick

[Nick_GParticipant @nick_g]

.

Just so you all know I have not been slacking.

Still need to dress and finish the webs properly. If I cannot get a decent finish on them I will cheat and paint them.

Nick

[JasonBModerator @jasonb]

Looking good, now don't spend all your time twirling the flywheel round, get on and finish the rest

[Nick_GParticipant @nick_g]

Posted by JasonB on 30/11/2015 07:19:17:

now don't spend all your time twirling the flywheel round,

.

Ehhh. ……………………… You mean it's supposed to turn.??

Oh dear.!

Nick

[Nick_GParticipant @nick_g]

.

Is this a chilled casting.???

Nothing will put a cut onto the outer corners. Crobalt tool or carbide inserts just get wrecked.

Cheers, Nick

Edited By Nick_G on 06/12/2015 13:05:49

[JasonBModerator @jasonb]

Yes

Get your blowlamp out and heat it to bright red and hold it there for about 15mins then allow to cool as slowly as possible. Should then be able to machine it. I would mill with indexable carbide if you have it but the holes should be OK with a HSS drill as they are in from the corners.

Alternative if you have an open fire or woodburner put it in there for the night (you will need a lit fire) and leave to cool in the ashes overnight.

J

[Nick_GParticipant @nick_g]

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Cheers Jason. It's cooling.

I will try again in a bit.

Nick

[Steve SharmanParticipant @stevesharman33815]

This is where a pair of night store heater bricks come in handy because they retain heat. Warm up one brick, cook your part on the other brick then place the first brick on top. Your Celcon-style brick won't retain the heat and you may still end up with chilled edges.

Regards, Steve

[Exmoor309Participant @exmoor309]

I had to do something similar with a brake shaft bracket that I couldn't machine. I heated it up to bright red, held it for a while then wrapped it in some ceramic insulation – It was still cooling down about 8 hours later, but it machined lovely the next day!

Edited By Exmoor309 on 06/12/2015 23:15:54

[Nick_GParticipant @nick_g]

.

About time I made the engine taller, so onto the cylinder.

I know there are several ways to do a cylinder but chose to use a 4 jaw. So after checking overall 'trueness' I set up the best aproximation to the bore.

Then faced off using the distance between the cast inlet ports as a long center. A compromise had to be taken as this would have left the point of inlet into the cylinder uneven due to the steam passage casting to being even.

Casting was reversed and reset with a parallel behind the already machined face and the chuck face. The bar and a dial indicator was used for best guesstimate of the bore center.

Machining to the other face and the bore proceeded.

Short clip of video.

I am happy with the result.

Then over to the mill to face off the ports.

Used the 'button' tool in the fly cutter again to do this.

Last time I used this tool in the mill it caused some interest to how it performed. So here is a short video of some quick roughing cuts. (forgive the wobble as I am holding camera with one hand and cranking with the other.)

Nick

[Martin ConnellyParticipant @martinconnelly55370]

I have used a 6mm button tool in the same way for long parts in stainless steel where possible wear of a HSS tool would have been unacceptable. The part was curved but with an average width of about 30mm and had six Ø20 holes in it. the button tool worked well and had no issues with the interrupted cutting required.

Martin

[EmgeeParticipant @emgee]

The sound from that fly-cutter tells you it's working a treat, typical of cast iron.

Emgee

[MM57Participant @mm57]

Neat fly cutting! Any ideas about who sells the tool and inserts?

[Nick_GParticipant @nick_g]

Posted by MM57 on 09/12/2015 17:20:10:

Neat fly cutting! Any ideas about who sells the tool and inserts?

.

I got it (I think) from Chronos. **LINK** The one I have is a Glanze listed as XC40 due to the fly cutter taking an 8mm toolbit. Yours may of course be a different size.

When the insert loses it's edge, just rotate it a few degrees and you have a different new cutting edge. They seem to last quite a while.

Hope this helps, Nick

Edited By Nick_G on 09/12/2015 19:21:57

[Nick_GParticipant @nick_g]

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Progressing on with the valve chest.

Nick

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