Second laser cut flywheel

[Sub MandrelParticipant @submandrel]

[Sub MandrelParticipant @submandrel]

This is how I have finished the second of the two laser-cut blanks. This one is 10mm thick and is a replacement for a Lady Stephanie casting that was badly dished. I annealed the blank and was able to machine it using HSS.

The original flywheel has a very small hub – I drilled six holes then sawed and filed out six 'dairylea wedges' to replicate the smaller hub. Possibly slightly too small in proportion to the width of the spokes on reflection. Drilling before the anneal was a tough job, sawing and filing afterwards was fine.

The spokes have been turned to a taper (from 5/16" to 3/16" although this may not be obvious from the pics. The groove around the rim was done with a 3/32" wide parting tool in three cuts without incident – though I had to weigh down my motor to stop the drive belt slipping!

The finish left by the laser is like a fine hacksaw , but without any wandering from the line – perhaps more like a bandsaw cut. I broke the corners with files and a deburrer then fettled all the unturned surfaces and the outside of the spokes using miniature sanding drums on a rotary tool.

Thebeam engine has been stalled at the cylinder and frame stage for a good four or five years, hopefully this will restore my interest in finishing this project.

Neil

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