The Workshop Progress thread 2018

[Brian HParticipant @brianh50089]

Posted by Neil Wyatt on 07/02/2018 19:29:31:

I like that

Neil

Thanks Neil, I'm now working on the mechanism to raise the crankshaft so that the pinions on the ends engage with the internal gears in the hind wheels. Will post again when there is more to see.

Brian

[mechman48Participant @mechman48]

Small but progressing, remade ( 2nd time ) the swing arms for the Vert.cross engine…Just need to clean up …

George.

[Mark RandParticipant @markrand96270]

Posted by jimmy b on 11/02/2018 09:17:38:

Today I fell out with my ARC versatile milling vice!

 

Doing a job yesterday, it really tightened up trying to undo it. A load of crap had got into the threads and worked right into the nut. Its now demoted to No. 2 vice.

Its a flawed design, in that respect. Some of the "Kurt" ones have wipers on the thread and shim in the gap for this very reason.

 

Just glad I cleaned it out rather than carry on and bugger the tread right up! (I've seen that done at work, cast iron dust got in there and seized a £600 vice!)

 

Jim

 

Is it worth getting a Kurt brush seal and retro-fitting it? You'd still be about £400 ahead on the deal compared with a 6" Kurt.

Edited By Mark Rand on 12/02/2018 22:17:19

[mechman48Participant @mechman48]

Finally ! completed the swing arms for my vert.cross engine… on the third attempt

such a faff on… small fiddly bits… getting them aligned & set with Loctite, hopefully it'll stay together. Next up the con rod…

​George.

[Brian HParticipant @brianh50089]

I've spent the week remaking all the parts I made last week! (for my 1858 Burrell)

This was due to a variety of problems such as using some engaving brass on a silver soldered job and the brass behaved like plasticene on subsequent operations, and I changed my mind about how to make a couple of items. Also made a couple of mistakes in marking out. oh well.

On the up side I have discovered just how useful is the ER32 collet set is that was a Christmas present. I realised that I can use my mill/drill as a mill one minute and then use drills with only a change of collet needed. I'm so pleased with the set that I have ordered hex and square Stevenson blocks.

Brian

Edited By BDH on 18/02/2018 08:01:04

[Jim NicParticipant @jimnic]

Swing arms look good George. I think that's probably the trickiest bit.

Jim

[mechman48Participant @mechman48]

Posted by Jim Nic on 18/02/2018 10:57:54:

Swing arms look good George. I think that's probably the trickiest bit.

Jim

​Thanks Jim, hopefully the rest of it proves easier…

George.

[IanTParticipant @iant]

Very nice work Brian – but sorry to hear about your 'plasticene' experience.

I think you will find many good uses for the Stevensons ER blocks…

IanT

[Brian HParticipant @brianh50089]

Thanks Ian, I already have work lined up for the Stevenson ER Blocks, I need to mill squares on 2 shafts for handwheels and I have a couple of oilers that need hexagons milling in awkward places. I'm sure I will find lots of similar uses.

Brian

[Neil WyattModerator @neilwyatt]

Posted by JasonB on 10/02/2018 20:26:07:

Ow.

Crunchy cast iron with a chewy brass topping…

Did the cutter survive?

Neil

[JasonBModerator @jasonb]

Yes cutter was OK, a brazed tip one ground for external cutting with the boring head. It was a combination of a bit too much above the vice, reclaimed cast iron and using the quill feed rather than feeding the head down as I had done to shape the CI

Got the cylinder and top & bottom covers done this week and a few other odd bits

[duncan webster 1Participant @duncanwebster1]

I've always wondered how you get the sloping stay bar (which I assume goes on the left hand side) to line up properly. I can see how you would get the angle the same on the base and cylinder support bits, but getting them coaxial? Perhaps Jason could enlighten us.

[JasonBModerator @jasonb]

The joys of CAD

Yes you assume correctly, there will be a stay to support that side of the cylinder.

I'm sure that back in the day the draftsman would have drawn it out and then dug out his slide rule and log tables to calculate lengths and angles.

But CAD means we can keep out socks on. What I did was to draw a circle centrally on the pad where the rod will fix to the base and projected this upwards as shown by the blue shaft. I also drew part of the cylinder support at the correct height above the base.

I then treated this blue shaft as a cut (drilled hole) which cut a hole in all it passed through therefore giving me a hole in the cylinder support. I can then measure from the central axis to the ctr of this hole which gives me it's exact position which can be used when it comes to producing the 2D working drawings and then the actual part.

Once all the parts are assembled it is also possible to check for any interferences, here I have moved the hole by 0.01mm and the CAD shows the clash in orange which I have arrowed in blue. This is for a 4mm spigot on the end of the shaft into a 4mm hole, in reality I will drill with a bit more clearance than I would for a normal fixing as there are bound to be slight differences between theoretical and actual positions.

The Cad also lets me check that nothing hits as the engine turns over which I can simply do by holding the mouse button down on a rotating or sliding part and moving it about.

[Jim NicParticipant @jimnic]

My current project is Ray Hasbrouk's No 3 Rocking Valve Engine. This is a fairly simple engine with not a lot of moving features so I decided to reduce it's size. I did this by converting the imperial dimensions on the drawing to metric using a 15mm to the inch conversion factor.

After a set back involving a small BA tap and a ruined cylinder I have made a couple of design changes to allow the use of larger threads than the reduction in size called for and now have a completed cylinder assembly.

Jim

[JasonBModerator @jasonb]

Looks good Jim

Interesting choice of reduction, was there a particular reason for going with 15mm/1" ? I have done similar and found that 1mm to 1/16" works out nicely to round numbers and gives a very similar size reduction of 16mm/inch

[Jim NicParticipant @jimnic]

Jason

I went with that conversion for 2 reasons:

1. I happened to have a flywheel about 3/5 of the original design size.

2. I wanted to convert the imperial dimensions I had on the drawing to metric so I made a spreadsheet and 15 was a convenient number to end up where I wanted to be and seemed the logical way to do it.

3. I never thought of working the other way (which now you mention it would have been a heck of a lot simpler)

I wish now I had asked for advice on here, but next time ……….

Jim

[mechman48Participant @mechman48]

Well caught up a little with my Vertical cross, completed the swing arms, machined up the crosshead & did a trial assembly… looks fine so far…

cross head & swing arms fitted to piston rod…

Pre trial assembly components…

​Trial assembly…

George.

[JasonBModerator @jasonb]

The Postman dropped off some castings for the 1/2 scale Robinson X-Type last week so thought I may as well machine them up.

Fairly straightforward work on the base casting and bearing caps but as these were reject castings from when Alyn Foundry were trading and had been sitting in Graham Corey's damp workshop for several years there were a few flaws and a lot of chilled areas which slowed progress.

 

The 8.5" Flywheel was not too bad, just a couple of voids on the other side that will need filling and mean I will probably have to go with a painted rim but will make a pulley which can be left bright.

Edited By JasonB on 26/02/2018 18:53:45

[MuzzerParticipant @muzzer]

Finally machined up the cover plate for my X axis housing. I had this ready to go a week ago before I buggered my back. Turned out OK but I'm seriously pigged off with the alleged chamfer tool – I'd be better off with a countersink drill. Don't recall much about its parentage but I've struggled to find any uncoated carbide chamfer mills in the UK, so ended up ordering some from Aliexpress. After all, they really can't be any worse.

That's probably the last job I'll be doing on this machine with the Chinese controller. I've just taken delivery of a Centroid Acorn controller which will be going on the Shizuoka and the Chinese controller will be moving over onto the Bridgeport. It's not a bad deal for £400 but even for someone who is used to working with Chinese, the machine translated documentation is truly insurmountable.

Murray

[Brian O’ConnorParticipant @brianoconnor49474]

Just finished honing and lapping the cylinder and piston of my Star Hit & Miss engine to get a nice sliding fit. A first assembly and it's starting to look like an engine. The iron castings were a delight to machine, no blow holes, no chilled margins and all the lumps and bumps very accurately placed. Still a long way to go though.

B

Edited By JasonB on 01/03/2018 17:48:35

[JasonBModerator @jasonb]

Looks good Brian, the start is a nice engine.

[Brian O’ConnorParticipant @brianoconnor49474]

Thanks, Jason. You could probably built two of these by now.

When viewing the photo I realised that in reducing the size I had got the aspect ratio wrong. The image in my album has been corrected and although it has the same name as before, my post above cannot find it and I can not find any way of editing my post. Can you help restore the picture please?

B

[Brian O’ConnorParticipant @brianoconnor49474]

Many thanks, Jason, for sorting the picture. B

[JasonBModerator @jasonb]

I got a reject casting for the X-type exhaust block that had been consigned to a dark corner due to excess casting misalignment, some initial reshaping with the angle grinder suggested it may be a bit of a chilled casting so befoer doing any machining it was heated for 15mins and then allowed to cool slowly.

That did the trick and it machined up nicely today, also got exhaust valve, spring collet, tappet, eccentric rod guide and end plug done and now have an exhaust assembly that works from the epicyclic gearbox.

No 4-jaw chucks were used in the making of these parts or 3-jaws ones for that matter. All turning in the 5C and the micrometer made a rare appearance to measure the valve stem

Edited By JasonB on 03/03/2018 20:25:36

[Roderick JenkinsParticipant @roderickjenkins93242]

I decided I needed some mods to my little Denford/Sherline CNC mill to make it truly usable so I have added some bellows to protect the Y leadscrew, a sub table for easier attachment of the workpiece and a blower to stop the swarf choking the cutter.

 

 

Here's a little bit of video of the blower in action.  My little airbrush compressor can keep up a constant 30psi through this nozzle which seems to work OK.

 

What was the driver for all this activity?

 

 

 

Anybody recognise it?

 

Cheers,

 

Rod

 

Edited By Roderick Jenkins on 04/03/2018 16:58:42

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