supercharged V12 2 stroke

[dean clarke 2Participant @deanclarke2]

Sure mate no problem, just drive on up, send me a p.m. i'll give you my contact details etc, lets arrange to hook up and have a show and tell. i have a few models (all c/l) and a few engines too. could run the v8 up again too. now off too the shed to finish this tool post and get the blimmin crank done, really want to see it finished tonight!!

dean

Edited By dean clarke 2 on 01/01/2014 07:15:36

[dean clarke 2Participant @deanclarke2]

WELL I finally got the big ends all finished, Wot a saga!!! well got the late afternoon and all night,way into the early just before sunrise time, in the shed and was able to get the tooling and problems solved for the big end journel turning and finishing setups. below is a group of photos showing the tools and set ups i used to turn and finish grind and polish all the big end journels. next mission is the same treatment for the mains and the final champhering and polishing. here's the end result…………………

here's the tooling etc

[dean clarke 2Participant @deanclarke2]

Actually…………here's the tooling etc

here's the nibbling of the journels being done

here's the flywheel faces being machined and radiuses applied to journel corners

so here's the fixture with the finished crank……..

sorry but i forgot to take a photo of the grinder setup, but here's a close up of the finished big end journels

So i will now go and get a few hours sleep and hopefully be up before my wife gets home, later today, and get the main bearings all finished as well. that would be just fantastic!!!!!

ny nyz all (briefly anyway). lol

dean

 

Edited By dean clarke 2 on 01/01/2014 16:45:24

Edited By dean clarke 2 on 01/01/2014 16:46:07

Edited By dean clarke 2 on 01/01/2014 16:50:10

[Sub MandrelParticipant @submandrel]

I hate it when people's jigs and fixtures look better than my finished work…

Neil

[dean clarke 2Participant @deanclarke2]

Well here's the finished crank, YAY!!!!!!!!!!!!!!!!!!

now its onto the next parts, carbys i think

cheers

for now

dean

[dean clarke 2Participant @deanclarke2]

Well been very busy this last week, unfortunately just not in the engine build department. I have been able to start the cylinder fin and head blocks. There is also a photo showing the crank finished and fitted to the block.

Off on holiday for 2 weeks now so wont be back in the shed till we get home, will upload the progress shots for the heads etc when they are all done.

cheers

dean

[dean clarke 2Participant @deanclarke2]

well, home again after a lovely trip to Aussie,Gold Coast with theme parks galor. Unpacked my bag and straight back into the shed to continue working on the 2 cylinder fin and head blocks. these are machined and drilled as one piece and then separated, surfaced and then bolted to the engine block and the cylinder bore holes machined in situ. here are some photos of the progress so far.

dean

will post the rest of the photos in a little while, duty calls

cheers for now

dean

[Michael GilliganParticipant @michaelgilligan61133]

Dean,

Nice work with that Slitting Saw !!

MichaelG.

[dean clarke 2Participant @deanclarke2]

Hey thanks had a bit of practice i must admit. here are a few more photos of the next stage of the fin/head block machining

cheers

dean

the pilot holes were drilled 10mm then milled to 12mm for the glo plug clearance.

next step is to set the cylinder heads and fin blocks up bolted together to the engine block and machine all the external shapes,ports and fins. will upload these later tonight.

cheers for now

dean

Edited By dean clarke 2 on 28/01/2014 21:45:16

Edited By dean clarke 2 on 28/01/2014 21:48:00

[dean clarke 2Participant @deanclarke2]

So it has been a very busy time in the shed lately, have managed to make and finish all 12 cylinder liners, all thats left to do to them is  hone and polish with diamond lapping.

I have also managed to machine the transfer ports into the cylinder fin blocks and machine the external profile shape to the heads and fin blocks

Next step is the machining of the exhaust ports and fins into the cylinder fin blocks. i will upload the photos as soon as i have finished this last step. I think i will tackle the elbow exhaust stubs after these are finished.

Cheers for now

Dean

Edited By dean clarke 2 on 02/02/2014 00:18:08

[dean clarke 2Participant @deanclarke2]

Well I have finally finished all the exhaust stubs, what a mission! This step of the build was probably the most challenging for me in many ways as I wanted to have the typical aero v12 looking stubs, but how to do that without castings. So i machined a bar stock to the top view profile and then cut off the correct number of biscuit slabs. These were then set up in the mill after marking out all the relevant dimensions for drilling the internal holes. The first slab was set up to a jig formation and the others just inserted to repeat the process. This saved a great deal of set up time as i had to do it only once for each step. Once both holes were drilled I made a mandrel to mount the stubs on for turning both ends. When all the lathe work was completed I then finished them off with a file to final shape and cleaned up with emery tape. here are some photos of the parts etc

So next its onto machining up the split main bearings and backplate along with the prop driver and spinner nut. This will complete the bottom end of the engine.

Cheers for now

Dean

[Martin WParticipant @martinw]

Dean

This is turning out to be more a work of art, its absolutely mind blowing as far as I am concerned. I am in awe of people with skills like this.

Thanks for sharing

Martin

[dean clarke 2Participant @deanclarke2]

No problem, thank you very much for the kind words. I must admit that the project has been somewhat challenging to my skills and patience but I have found it very rewarding to see such interest by other people ( helps keep me motivated to work through the problems I've faced machining some of the parts). As soon as i have the bottom end completed i will do another assembled so far shot.

cheers for now

Dean

[dean clarke 2Participant @deanclarke2]

Well i have just finished the spinner nut and prop driver and have started machining the split main bearing block. this has been sized and split, surfaced and the bolt holes have been drilled and tapped ready to turn the bearings.

here are some photos of them and some progress assembled shots, the prop is 16×6.

cheers for now

Dean

Edited By dean clarke 2 on 12/02/2014 08:13:46

[doubletopParticipant @doubletop]

Dean

The size of this wonderful creation has been coming clearer in the past few posts. Any chance of a shot of it in the palm of your hand?

Did you say what the CC will be?

I can also see the ME109 connection.

Pete

[dean clarke 2Participant @deanclarke2]

Hi Pete, this engine is nominal 70cc

cheers

dean

Edited By dean clarke 2 on 13/02/2014 06:50:11

[John OlsenParticipant @johnolsen79199]

Well, Cambridge NZ is just down the road from me, and as it happens I have a Dornier Do335 just about ready to go, but of course that would need another one of these.

John

[dean clarke 2Participant @deanclarke2]

LOL, Actually me too!! 85" span, don't know if I have the mental fortitude to make another one of these tho, well maybee. You are more then welcome to pop out for a coffee and a look see if you want.

dean

[John OlsenParticipant @johnolsen79199]

Would that be the ESM one? I have a 160 twin for the front of mine, and a 120 single for the back. A fairly small amount remains to be done, although I am not sure if I have the confidence to fly it yet.

12 of everything seems like enough trouble, 24 would start to seem like work instead of a hobby!

I'd like to take you up on dropping in some time. Actually we are living in the Big smoke and thinking of bailing out quite soon to retire somewhere nicer, and Cambridge is quite high on the list of possible destinations.

John

[dean clarke 2Participant @deanclarke2]

Well it's been some time since an update and things have been a bit less than ideal in some ways. Got all the main bearings done and sized to the block and crank and went to assemble them together and discovered that horror of horrors they didn't want to go all the way into the crankcase bore. BUGGER!!!!!!!!!!!!! upon investigation it was discovered that somehow the crankshaft had become not so straight in the main journal department! so after a great deal of swearing and tanty throwing i finally decided it was time to leave it alone for a bit and have a strong sedative cup of tea. Having thought about it for awhile i decided to mount the crank in a Collette chuck from the front main bearing and fit the 2 ball races to the rear main and set them up i a small scroll chuck in the tail stock. having done this i could plainly see that the front two center main bearings were not rotating at all in the same line as the rest of the crank whilst the rear three were not so bad, not perfect either i might add but not too far out. Now how the hell did that happen??? And more importantly how the heck am i going to fix it!!!!!!!!!!!!! So after i bit of thought i simply remachined all the mains down to a smaller size also remachining the flywheel diameters and chamfers , thrust faces etc, reground and polished to an acceptable finish. Now everything turns as it should between the two main end bearings. Now to make replacement split mains and the then refit the crank to the case. I will also take the time now to make the sump plate and the engine mounting holes so the case will be completed in the next workshop session. Here is a photo of the remachined crank and the split main bearings. I will update the photo album and thread when the rest of the case is also all done.

cheers for now

dean

Edited By dean clarke 2 on 02/03/2014 04:46:11

[Michael GilliganParticipant @michaelgilligan61133]

Dean,

Top Marks for Anger-Management !!

Keep up the amazing work … it's a joy to see.

MichaelG.

[Ian S CParticipant @iansc]

Maybe a case for machining almost to size, then leaving it for a time to settle down, then take off the last few thou. Good rescue job. Ian S C

[dean clarke 2Participant @deanclarke2]

Thanks yea it was a close thing, i will have to look at how i go about machining the crank and change the sequence i think. nearly got the whole bottom end finished and i will update everyone with progress and photos in the next few days (hopefully)

cheers for now

dean

[Jeff DaymanParticipant @jeffdayman43397]

Great work so far Dean, well done! JD

[dean clarke 2Participant @deanclarke2]

Ok so after a great deal of time spent doing everything but engine building i have finally been able to advance this v12 build project a little bit.! after the last debacle with the crankshaft and its "not so straightness" i must confess to suffering from a little bit of the depressive can't be bothereditess so it has been somewhat longer then intended between workshop sessions.( that and being flat out with work and whatnot). So where do things stand at present? Well the engine block is now complete with conrod grooves and mounting holes and a very nice polish finish i think also. The crank is now final fitted with split mains complete with pressure fed lubricating holes. front and rear covers on to stay and also the rear drive for the supercharger is made and fitted. Here are some photos showing the latest bits and assy etc.

cheers for now

Dean

Now its onto the conrods and pistons, or maybee the blower rotor and vanes, we'll see.

Dean

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