The Workshop Progress Thread 2020

[iNfParticipant @inf]

Having drilled and tapped the various holes in the cylinder, I decided that I wasn't happy with the fillet around the cylinder boss, so out with the filler and a bit of sanding.

[iNfParticipant @inf]

Having made the crankshaft as per Jason's build thread but before I cut out the middle and pinned it, I did a trial fit with the bearings in the frame only to find it didn't fit! After several 'oh dear me's' I realised I had made the journal 1mm too wide I think that I had been concentrating so hard on getting a good fit in the crank web I had neglected the width. OK I thought, as I had used threadlock to fit it together not having any of the 'proper' stuff , a bit of heat and a gentle tap will soon have it apart….. no chance. Resorting to the hot air gun and bashing with an aluminium mallet so hard the end of the crank resembled a well used cold chisel! After rectifying the problem I realised that I wouldn't need to pin the crank when completed as it wasn't going to come apart anytime soon!

A picture of the crankshaft during a trial fit/run.

[peak4Participant @peak4]

A few home made 250 size toolholders for the quick release post on my Warco GH1330;

Four newly completed toolholders to add to my collection for the Big Warco GH1330.
I used most of the machines in the shop on these; Roughed out on the shaper as one block, with the dovetails finished on the Centec mill. Knurled nuts done on the big Warco and finished on the 720 (Myford clone), Toolholders sawn to length on the Denbigh power hacksaw and finished with a combination of shaper and surface grinder.
Final finish with gunsmith's blue.
Not really cost effective to make these, as the originals are about £25 each, but my time's free and it saves getting bored. Also the knurling tool won't fit in the shorter standard toolholder size, such as those three at the front, and as far as I'm aware, you can't buy ones with the through holes to take boring bars.

Bill

[iNfParticipant @inf]

The main components ready for painting.

[iNfParticipant @inf]

Finally the finished engine. It's not perfect but I'm quite pleased for a first attempt.

Hopefully here is a link to the engine running on an old fridge compressor, including some slo/mo

**LINK**

[JasonBModerator @jasonb]

That turned out very nicely and runs well too.

[Jim NicParticipant @jimnic]

Congratulations. Another fine example of Jason's Jowitt and with a result as good as that on your first "real engine" perhaps an encouragement to others to give it a go.

Jim

[OldironParticipant @oldiron]

Posted by peak4 on 27/09/2020 21:19:45:

A few home made 250 size toolholders for the quick release post on my Warco GH1330;

Four newly completed toolholders to add to my col

lection for the Big Warco GH133. Also the knurling tool won't fit in the shorter standard toolholder size, such as those three at the front, and as far as I'm aware, you can't buy ones with the through holes to take boring bars.

Bill

Nice job Bill. I have made 9 of these 250 style holders for myself. I made 5 of mine so they will take 20mm tools. Instead of the std 12mm lip at the bottom I made it 7mm. Never had a problem with the smaller dimension.

The boring bar holder is 250-204. It has a 25mm ID hole and a 25 OD x 19mm ID split sleeve for smaller bars. I also made split sleeves for 16 & 12mm bars.

regards

[iNfParticipant @inf]

Thanks for the comments Jason and Jim. I probably wouldn't have attempted it without Jason's build thread to guide me. I certainly learned a few things along the way. I have no idea how Jason can produce such stunning engines so quickly!

Thanks

Dave

[SteviegtrParticipant @steviegtr]

Made 2 chuck spacers to help with ring making. Little magnets attached.

Steve.

[peak4Participant @peak4]

Posted by Oldiron on 28/09/2020 18:21:53:

Nice job Bill. I have made 9 of these 250 style holders for myself. I made 5 of mine so they will take 20mm tools. Instead of the std 12mm lip at the bottom I made it 7mm. Never had a problem with the smaller dimension.

The boring bar holder is 250-204. It has a 25mm ID hole and a 25 OD x 19mm ID split sleeve for smaller bars. I also made split sleeves for 16 & 12mm bars.

regards

Cheers, The original incentive was the knurling tool holder, as I was using an extended nose one I'd made previously.
The Boxford shaper has an 8" stroke, so it wasn't much harder to make four, adding up to a 7½" block.
In my case, I do have a 202 holder with the groove in the bottom housing a larger boring bar; these two are 7 & 12mm.
I don't have any other larger tooling, so these will suffice for the time being, unless I add a couple of dedicated parting tool holders.

Bill

[SteviegtrParticipant @steviegtr]

Posted by peak4 on 28/09/2020 21:12:43:

Posted by Oldiron on 28/09/2020 18:21:53:

Nice job Bill. I have made 9 of these 250 style holders for myself. I made 5 of mine so they will take 20mm tools. Instead of the std 12mm lip at the bottom I made it 7mm. Never had a problem with the smaller dimension.

The boring bar holder is 250-204. It has a 25mm ID hole and a 25 OD x 19mm ID split sleeve for smaller bars. I also made split sleeves for 16 & 12mm bars.

regards

Cheers, The original incentive was the knurling tool holder, as I was using an extended nose one I'd made previously.
The Boxford shaper has an 8" stroke, so it wasn't much harder to make four, adding up to a 7½" block.
In my case, I do have a 202 holder with the groove in the bottom housing a larger boring bar; these two are 7 & 12mm.
I don't have any other larger tooling, so these will suffice for the time being, unless I add a couple of dedicated parting tool holders.

Bill

I also made some of those a while ago. I have parting tool as seen below. This was part way through making it.

&

& nearly finished item.

Final item

Steve.

Edited By Steviegtr on 28/09/2020 21:39:31

Edited By Steviegtr on 28/09/2020 21:46:49

[Anthony KnightsParticipant @anthonyknights16741]

I have made a start on the "Grasshopper" engine by Stewart Hart after he kindly emailed me the plans. So far I have completed the horizontal beam assembly.

[JasonBModerator @jasonb]

The weekend saw a few more bits done for my Thompson engine, firstly the exhaust was bent up from 8mm copper tube, soldered to a threaded spigot and locking collar turned

Then then all the parts for the carb were made up, similar design to the one I made for the Midget engine with a few alterations

All was done by flitting back and forth between the lathe and manual mill with the exception of the throttle leaver which was less than a two minute job for the CNC to cut and no sign of any difference running it with the revised Free F360.

[JasonBModerator @jasonb]

After a brief interlude for some top secret pattern making the CNC was dusted down so I could get back to making metal swarf. Starting from the bottom this is the first part of a new engine based ob the 36cc Wall 2-stroke but scaled down from it's original 1.5" bore to 24mm it will be approx 11cc.

Part is 60mm long 6082 Aluminium, Adaptive cleared, ramp to shape, horizontal to tops of lugs, spot and then two different drill operations. The slight visible line between the tops of the two lugs is just a change in cutter direction where it did a cut all round at 12mm leaving a horizontal witness mark, all the others are at a slight slope being cut on a 0.33mm ramp. ( cutter goes all the way around with a constant downwards travel to bring it 0.33mm lower each loop.)

[DiogenesIIParticipant @diogenesii]

Always nice to see progress on the Thompson, I think it's a fascinating design – still can't work out whether it's the work of a genius or of the Devil, though..

And what's that carelessly-placed narrow-angle "V" on the bench behind?

[JasonBModerator @jasonb]

Thanks, Thompson has been running but is stripped down for tarting up and painting.

That's my Hoglet that I built in about 2010 and never quite finished, but have been doing the last few items on that recently.

[DiogenesIIParticipant @diogenesii]

Looking forward to seeing the finger mincer run – and progress on the Hoglet.. it's good to see some engines, thanks for posting

[David CauntParticipant @davidcaunt67674]

Seeing Anthony's Grasshopper Beam made me wish I'd chosen something simpler. This beam is a bit more complicated but when all the rivets lined up it was quite a gratifying moment.

This was in May at 2 hours on most days it takes a long while to get anywhere. Here is the cylinder and part finished poppet valve block.

[David CauntParticipant @davidcaunt67674]

Sorry Pics and writing seems to be all over the place and it was started in September. DOH!!

[John HinkleyParticipant @johnhinkley26699]

Spurred on by lockdown Mk2 and interest from steveiegtr on the "What did you do today" thread, amonst no others, I decided to go ahead with the construction of the low-profile rotary table. I have further refined and simplified the design and incorporated a few improvements and it now looks like this:

I also thought that I'd add a series of short videos to my YouTube channel to document the build and help pass the time. Suffice to say, I won't be planning a trip to the Oscars next year! If you want a laugh at my expense, have a look at this:

Low profile rotary table

Parts 2 and 3 are in production and will appear in due course.

John

[John HinkleyParticipant @johnhinkley26699]

Spent a goodly part of the day carving the vernier plate out on the mill. Lots of vibrations, so I didn't bother to video it all, just took a few stills and left the video to the "sweep-up" bit at the end. In the light of the experience, I amended the Atom drawings to reflect the final, final, version to reflect the changes I've made to make it easier to produce.

This is the vernier plate with the major machining completed and the vernier holes being drilled:

It's a little blurred as its grabbed from the video.

Still got to clean up the edges and then make the minor parts to finish the project.

John

[Anthony KnightsParticipant @anthonyknights16741]

Since my last post, I have made some more bits for the Stewart Hart "Grasshopper" engine.

These are – Eccentric assembly, Main axel and crank, Piston rod assembly.

I have also done some of the "fiddely bits" which seem to have taken forever.

These are – Cylinder base, The "A" frame assembly, The valve linkage assembly.

They all need "fettlling" to tidy them up a bit, but I don't want to make them too perfect as the original machine was probably made mainly from castings. The cylinder base is made from aluminium and is a bit too shiny for me, so I'll have to treat it some way (paint?) to tone it down.

Next job is the cylinder and the end caps.

[John HinkleyParticipant @johnhinkley26699]

Today, I completed the build of my low-profile rotary table with 1° vernier indexing plate. It's taken a lot longer than I thought, due mainly to producing videos of the build at the same time (and having to learn how to use the video editor). Here's the finished article:

The caliper reads 150mm, difficult to read in this photograph. The matchbox is not part of the design,just placed there for an idea of scale. The overall height is 26mm.

You can see the whole series on my YouTube channel HERE , should you so wish. Be warned, however, it's a long series, but you can always skip the boring (and turning) bits.

John

[SteviegtrParticipant @steviegtr]

Posted by John Hinkley on 28/11/2020 15:41:15:

Today, I completed the build of my low-profile rotary table with 1° vernier indexing plate. It's taken a lot longer than I thought, due mainly to producing videos of the build at the same time (and having to learn how to use the video editor). Here's the finished article:

The caliper reads 150mm, difficult to read in this photograph. The matchbox is not part of the design,just placed there for an idea of scale. The overall height is 26mm.

You can see the whole series on my YouTube channel HERE , should you so wish. Be warned, however, it's a long series, but you can always skip the boring (and turning) bits.

John

Very nice. Now on to look at your video.

Steve.

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