Author Topic: Bodging with Boris........  (Read 11615 times)

Offline Stilldrillin

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Bodging with Boris........
« on: September 29, 2016, 08:16:18 AM »
Hello, everyone..... I'm still around!  :wave:

After another painful year, I'm managing to get into my workshop, once more.

The Doc put me on statins, three years ago. I've finally realised, just what has been causing me such grief, for so long.  :bang: :bang:

I stopped taking them, a month ago, and now feel a new man! And, the walking stick has gone back into the cupboard......


Another needy orphan/ doorstop, arrived in July. I call him, Boris.........




Does anyone recognise the build?  Are there any plans out there?




The usual problem. Power cyl volume too large. Both cylinders, almost the same swept volume.




I turned up a better/ temporary crank assembly.........




No joy.......




So....... He's all in pieces, on my bench. Awaiting rebuilding materials.

It's nice to be back at it, once again!  :D

David.

David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline philf

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Re: Bodging with Boris........
« Reply #1 on: September 29, 2016, 09:00:17 AM »
Hi David,

Good to see that you're back in the workshop.

Thankfully, I'm not on any tablets - probably because I never go to the doctors.

Cheers.

Phil.
Phil Fern
Location: Marple, Cheshire

Offline John Rudd

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Re: Bodging with Boris........
« Reply #2 on: September 29, 2016, 09:08:08 AM »
Hi David, it has been a while....

Good to hear your health is on the up and you got into the shop..... :beer:

I'm sure with a bit of tlc Boris will soon be up and running  :dremel:
eccentric millionaire financed by 'er indoors
Location:  Backworth Newcastle

Skype: chippiejnr

Offline sbwhart

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Re: Bodging with Boris........
« Reply #3 on: September 29, 2016, 11:02:19 AM »
Hi Dave

Good to see you back in the shop looking after the little orphans

Stew
A little bit of clearance never got in the road
 :wave:

Location:- Crewe Cheshire

Offline Joules

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Re: Bodging with Boris........
« Reply #4 on: September 29, 2016, 11:25:21 AM »
Hi Dave, glad to see you back at it.   Enjoy the engine posts.
Just get doing and make swarf, you can decide what its going to be later.   :thumbup:

Offline millwright

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Re: Bodging with Boris........
« Reply #5 on: September 29, 2016, 02:18:20 PM »
Hi David nice to know you are back in the workshop, been on statins about the same length of time, i dont seem to have any problems with them but ive heard of some who have. waiting now to see what you can do with Boris.

john

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #6 on: September 29, 2016, 03:15:50 PM »
Phil, John, Stew, Joules, John.
 Thanks for your kind replies.  :thumbup:

I believe, I became part of the drive to have everyone over 55, on statins. I was 70, at the time.
 My reading was 4.2, (and no problem). After 3 months, it was 3.6. "You've gained five years, extra life".  :D
After 3 years of pain, blamed on sciatica and old age. My son persuaded me to try without them.
 I wonder how many old people are feeling 20 years older, because of someone's bright idea.   :palm:


Anyroad!
 Boris is in bits, awaiting tubing, bearings, 6" flywheel casting etc.

I have some 30mm graphite in stock.
 I guess the main mod will be to reduce the power piston to 29mm, from 35mm dia.

Pics and words, as n when........   
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline krv3000

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Re: Bodging with Boris........
« Reply #7 on: September 29, 2016, 06:14:04 PM »
Hi Dave, glad to see you back at it

Offline S. Heslop

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Re: Bodging with Boris........
« Reply #8 on: September 29, 2016, 06:16:47 PM »
Nice, i've been missing these threads.

Offline Pete49

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Re: Bodging with Boris........
« Reply #9 on: September 29, 2016, 11:43:30 PM »
Dave just because the doc says you need to take them  you really don't have too its an option. I assume its for cholesterol in which case they are many proven alternatives to statins which IMO are the worst thing you can take.
Glad your back at it though and look forward to more orphans being made new.
Pete
oops..........oh no.........blast now I need to redo it

Offline RobWilson

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Re: Bodging with Boris........
« Reply #10 on: September 30, 2016, 12:41:42 PM »
Good to see you back on sorting out those orphan engines David  :thumbup: 



I thought you must have run out of badly built engines that needed your touch  :dremel:


Rob




Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #11 on: September 30, 2016, 05:48:48 PM »
Bob, Simon.
 Thanks Guys!

Pete.
 They asked me! I had a perfectly reasonable level. I reckon it's some grand experiment. Where the drug companies make a fortune.......
 I won't go back on them again!

Rob.
 Nomate! The supply seems endless. Somehow, they always seem to find my door......  :scratch:



Anyway! Enough!

I did attend a few shows. Here's a member's random video. My table, after 30secs.......

<a href="http://www.youtube.com/watch?v=pW_fZnx0aRA" target="_blank">http://www.youtube.com/watch?v=pW_fZnx0aRA</a>



Also..... I came away from STL, with "Best in Show". For the second year running........




Happy!  :thumbup:

David.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline krv3000

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Re: Bodging with Boris........
« Reply #12 on: September 30, 2016, 05:52:16 PM »
brill

Offline tom osselton

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Re: Bodging with Boris........
« Reply #13 on: October 01, 2016, 12:22:34 AM »
Very nice! Congratulations!  :beer:

Offline Will_D

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Re: Bodging with Boris........
« Reply #14 on: October 01, 2016, 05:26:07 PM »
Congratulations. Great to see Meccano still at work!

BTW: What scale are all those traction engines/showmans etc in the first 30 seconds?
Engineer and Chemist to the NHC.ie
http://www.nationalhomebrewclub.ie/forum/

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #15 on: October 01, 2016, 05:37:44 PM »
Bob, Tom.
 Thanks Chaps!  :thumbup:

Thanks Will.
 I've no idea of scale......  :scratch:

They are mostly Mamod steamtoys. http://www.mamod.co.uk/shop-categories/1313-traction-engine

David.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline millwright

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Re: Bodging with Boris........
« Reply #16 on: October 01, 2016, 05:58:16 PM »
Well done David, some nice models there.

John

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #17 on: October 16, 2016, 08:40:15 AM »
So.... The initial rebuild begins. With the displacer.  :dremel:

I really, don't like copper pipe for this purpose. Too heavy. Too much heat absorbtion/ conduction.

Lots of handy diameters and lenghths, of s/s exhaust available on Ebay. This is 42mm......




Bored out, to lighten. Now, around 20 thou' wall thickness.......




8mm thick, s/s offcut, friction turned, to slide in the displacer's bore.......




Chopped the inside away, to give 1mm wall thickness......




Drilled through boss. Silver soldered in, a 12mm long extension. Then drilled to spigot depth, and tapped M5.

Rough cut end cap, in background Awaiting friction turning........




Silver soldered in, both end caps. Cleaned up.

That looks better! Even though, it will not be seen........




Next up.... Reducing the power cylinder bore. From 35mm to 29.5mm.

I used two more lengths of s/s exhaust pipe. They have very accurate and consistant, bores and o/d's.
 A couple of thou' removed, allowed two to be sleevelocked together.
Topped to just below original bore size. Then bore opened out to 29.5mm.

Lots of time spent oscillating, to achieve a decent finish, and remove the 1 thou' taper.......





Looks ok, I think! The joint can just be seen, at 10 and 4 o'clock positions. close to the bore's chamfer.......





Frankly..... I'm not impressed by the little end's arrangement....... 




There's only poverty, holding the big end in place........  :bugeye:



Guess, we now need a new conrod!  :(

Thanks for looking in.....  :thumbup:

David.


David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline DMIOM

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Re: Bodging with Boris........
« Reply #18 on: October 16, 2016, 09:44:34 AM »
...Thanks for looking in.....

and thanks for taking us along with you  :beer:

Dave (IOM)

Offline Manxmodder

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Re: Bodging with Boris........
« Reply #19 on: October 18, 2016, 05:52:13 AM »
Hey David, nice to see you back at the machines. Really pleased to hear you are suffering less pain.

As with all your other orphan rebuilds,I will be following along with interest.....OZ.
Helixes aren't always downward spirals,sometimes they're screwed up

Offline PekkaNF

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Re: Bodging with Boris........
« Reply #20 on: October 18, 2016, 07:06:06 AM »
Very nice.

What is friction turning?

What abrasive you used to hone the displacer cylinder? SIC?

Very educational to see your setups.

Thank you much,
Pekka

Offline fcheslop

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Re: Bodging with Boris........
« Reply #21 on: October 18, 2016, 02:39:27 PM »
Nice to see you getting back into the swing
Not sure these engines will catch on though :palm:
cheers marra
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #22 on: October 18, 2016, 03:59:24 PM »
John, Dave, OZ.
 Thanks! Much appreciated.......  :thumbup:

Very nice.
What is friction turning?
What abrasive you used to hone the displacer cylinder? SIC?
Very educational to see your setups.
Thank you much,

Pekka.
 Friction turning? ..... Machining a disc, (usually), trapped between two faces. Held together by pressure from a live centre, in the tailstock.
 Here's where I first started practicing. Straight onto the chuck jaws..... http://madmodder.net/index.php/topic,566.0.html
Now, I use a couple of pieces of plastic, around 30mm dia. The piece in the chuck is faced with h/duty insulation tape.

The wooden lap, is made from an offcut of curtain pole. (Brush handles are just as good).
 Turned to bore size -.002". Start off with coarse valve grinding paste. Plus a spot of oil. Progressing to fine, as things settle down.

Thanks for your kind words......  :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline fcheslop

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Re: Bodging with Boris........
« Reply #23 on: October 18, 2016, 04:48:51 PM »
Cheap rolling pins are also handy but dont let the big boss know and the broom shank in the garage is getting a wee bit short.For clock parts I also use MDF but it soon blunts youre tooling its also good for making spinning former's for a small run of parts.
cheers
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #24 on: October 18, 2016, 05:27:10 PM »
Nice to see you getting back into the swing
Not sure these engines will catch on though :palm:
cheers marra
Heyup Frazer. Thanks mate!
 It certainly seems an uphill struggle! Why are so many of them, made wrong?
Why do so many people spend so much precious time, making a doorstop. Just by altering the ratio??  :scratch:

Still....... It has kept me amused, for a few years now.......  :thumbup:

Cheap rolling pins are also handy but dont let the big boss know and the broom shank in the garage is getting a wee bit short.For clock parts I also use MDF but it soon blunts youre tooling its also good for making spinning former's for a small run of parts.
cheers

Hadn't thought of a nice chunky rolling pin!    Good thinking!
 One of my backing pieces, is from a chopping board.......
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline fcheslop

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Re: Bodging with Boris........
« Reply #25 on: October 18, 2016, 05:44:03 PM »
]I can never understand it either . Is it the builder knows better and uses whats available not knowing that the ratio has to be near ish
Although some well known designers have goofed in the past just look at ET Westburys version of the Robinson the ratio is badly wrong and he had not appreciated the rather unusual displacer and the cold well  the full size one had and yet published drawings :doh:Thats why the one I started now resides under the bench with the spiders unless it finds a new home
Ah well we live and learn although the older I become the less I know
Just had a good glass breaking day :palm:
Good luck with her .Just love that conrod set up :Doh:

cheers
« Last Edit: October 19, 2016, 02:54:15 PM by fcheslop »
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #26 on: October 18, 2016, 06:01:09 PM »
That made interesting reading! (If you're into these frustrating things)........   :thumbup:
 Seems, even the engine heirarchy don't realise the laws of physics!  :palm:

Are you teasing test tubes, again?  :loco:

David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline fcheslop

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Re: Bodging with Boris........
« Reply #27 on: October 18, 2016, 06:17:34 PM »
Oh I breaking test tubes again on the the Ridders Wiggers. Had everything nicely cut then picked up a bit of paper forgetting Id safely wrapped the hot cap in it :palm: they dont bounce
Back to the drawing board
That exhaust pipe you snaffled whats the OD as Im looking for some 1 7/8 for the orphan or may use a barby grill block.
Hit lucky for once and found some heavy walled stainless seamless tubing for the Ryder so should get back on with it shortly and yep still blaming you :D
cheers
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline fcheslop

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Re: Bodging with Boris........
« Reply #29 on: October 19, 2016, 02:50:34 PM »
Thanks :thumbup:
We have a runner.Just needs stripping/cleaning and getting rid of the oil in the glass dispacer :doh: May be simpler to make another with a blind hole.
The tube is for the Ryders displacer.
Good luck with the rebuild Il stop clogging up youre thread :beer:
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #30 on: November 06, 2016, 09:39:25 AM »

Managed to get some Boris work done, over the past week.

I'm used to catching up on household, gonna do's. But, after all this, "almost crocked" time, I'm having trouble with, whatabout's, whenyergonna's, and havyerforgotten's.......  :bang:

A piece of 1/4" brass, spigoted/ screwed to the end of 8mm dia bar.......




6mm, far end. 4mm, this end. 110mm apart.......




Taper turn. Mill little end flats........




That looks better, to me........




Graphite piston. Roughed out, and parted off. (Most of the mucky work done)......




Thanks for looking in!

David.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #31 on: November 06, 2016, 09:49:43 AM »
I've got a bit behind, with the write up...... :Doh:


Delrin mandrel, to mount piston.......




Held on, with M6 caphead. Finish turned, until it almost enters the bore. Mucky stuff!




Six inch rule. Supporting reversed emery cloth.

Polish the outer end o/d, until the piston enters the cylinder. Then, polish the centre section. allowing it to enter some more.

Then finally, polish the skirt area. Allowing full length entry to cylinder.......




Obviously, both hands needed for polishing control. I needed my left hand for the camera!

Reversed emery cloth is used for polishing graphite.
Fine emery cloth. Correct way around, for brass etc.

The steel rule backing, gives much better control, than fingers....

Thanks for looking in!

David. :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #32 on: November 06, 2016, 09:55:03 AM »

I slotted and cross drilled/ reamed. The clevis.......




Drill/ tapped M4 through. Reducing shank to 6mm dia, to locate in piston......




That looks better, than original........




This afternoon, I finished the piston/ cylinder fit to each other. Then sleevelocked the cylinder liner in place, in the original cylinder.

Assembly, tomorrow. Wonder if we'll have a runner, soon?  :scratch:

Thanks for looking in!  :thumbup:

David.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #33 on: November 06, 2016, 12:25:50 PM »
We've now caught up to, last Friday.  :thumbup:

Finished piston/ rod assembly........




Commence assembly.........




Not happy with the offset scotch yoke, link. It wants to bend the  unsupported displacer shaft.......




Now, we just need a flywheel.......




I have a suitable casting. Though, it is made of unknown bronze. Rather tough stuff!  :palm:

That is a 4" dia chuck. I like to make my machinery work hard, when necessary.........

 


The belt had done 3 years, since I modded the lathe to lower the gearing. Can't grumble! 

All good Engineers have a spare! It was up and running, after 20 mins fumbling. But, I'd had enough, for one day........    :bang:

Thanks for looking in!  :thumbup:

David.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #34 on: November 06, 2016, 05:28:51 PM »
Finally got the flywheel, proof turned. Sufficient to be in balance.......

Put a small light under. And, after a few seconds.........

<a href="http://www.youtube.com/watch?v=fUDvX5kEnQw" target="_blank">http://www.youtube.com/watch?v=fUDvX5kEnQw</a>


It's a great feeling!   :D

David.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline sbwhart

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Re: Bodging with Boris........
« Reply #35 on: November 07, 2016, 02:44:34 AM »
Blimy Dave your knocking these engines out like drinking tea :D

Great Job

Stew
A little bit of clearance never got in the road
 :wave:

Location:- Crewe Cheshire

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #36 on: November 07, 2016, 03:25:31 AM »
Blimy Dave your knocking these engines out like drinking tea :D

Great Job

Stew

Thanks Stew!

I reckon, I've got the hang of them, now.....  :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline millwright

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Re: Bodging with Boris........
« Reply #37 on: November 07, 2016, 01:29:56 PM »
Another success story from the 'Waifs and Strays Orphanage' somewhere in deepest Derbyshire. well done David long may you keep churning them out.

John

Offline fcheslop

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Re: Bodging with Boris........
« Reply #38 on: November 07, 2016, 01:40:35 PM »
Congratulations  :bow: :bow: :thumbup:
Whats next
 :beer:
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #39 on: November 07, 2016, 02:15:02 PM »
Another success story from the 'Waifs and Strays Orphanage' somewhere in deepest Derbyshire. well done David long may you keep churning them out.

John

Thanks John!  :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #40 on: November 07, 2016, 02:27:48 PM »
Congratulations  :bow: :bow: :thumbup:
Whats next
 :beer:

Thanks Frazer Lad!  :thumbup:

Next? Why? Is this one finished?  :scratch:    Not by a long way.......

Redesign scotch yoke. Add another crank disc, and bearing. Sort out water jacket.

Just started on new burner. Got a show, this Saturday.......

Sheesh!  :palm:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline fcheslop

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Re: Bodging with Boris........
« Reply #41 on: November 07, 2016, 05:16:27 PM »
Ah well it will keep you from getting under youre lasses feet
Gave up for today just to cold for a wimp like me
cheers marra
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #42 on: November 07, 2016, 05:40:04 PM »
It was certainly cold, out there!

So, I did some silver soldering......  :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline fcheslop

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Re: Bodging with Boris........
« Reply #43 on: November 08, 2016, 02:08:50 PM »
So you found the brass monkey then
cheers
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Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #44 on: November 08, 2016, 03:16:39 PM »
So you found the brass monkey then
cheers

Yes! He's all attached again. For now........ 
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline John Rudd

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Re: Bodging with Boris........
« Reply #45 on: November 08, 2016, 03:29:13 PM »
Nice job, good to see something come of all your hard work... :bow:
eccentric millionaire financed by 'er indoors
Location:  Backworth Newcastle

Skype: chippiejnr

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #46 on: November 16, 2016, 05:22:23 PM »
Thanks John.
 Lots more work to do. Ran it at Saturday's show, and after 1/4hr the whole crank assembly was wagging about, loose!  :bang:

The bearing column, isn't fixed on to anything substantial.......

It's more of a "looking at", engine.......  :scratch:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline jcs0001

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Re: Bodging with Boris........
« Reply #47 on: November 16, 2016, 09:23:01 PM »
Nice little engine - I enjoyed the photos and video.  Thanks for taking the time and trouble to post them.

John.

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Re: Bodging with Boris........
« Reply #48 on: January 04, 2017, 08:33:05 AM »
Thanks John!
 I'm afraid, I don't agree with the "little", comment. To me, it's just, big. Very poorly designed, and built......  :hammer:

(Just the sort of project I like).......  :thumbup:


After a few weeks silence. I can only report, more negative progress, on this frustrating project.......  :palm:

After some 10mins running, at Earl Shilton. The crank assembly began rocking from side to side, on it's single, 6mm wide upright!

Reminded me of stepping into a rowing boat/ dinghy........




Secured with M3 countersunk screws.......




Up close. "You could stick yer cap neb, under there!".......




It's almost stood on tiptoe! The column base isn't flat:bang: :bang:

You can see the rub mark, of the "keel". Inboard of the outer two screw holes.......




I'm now planning a new crankshaft assembly. With bearings at each end. As it should be.......  :wink:

Thanks for looking in!
David.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #49 on: September 23, 2017, 05:40:04 PM »
Yikes! It has been almost 9 months, since I last wrote anything about this, shambles!   :Doh:


As we can now, all, see the previous Pbucket pics, using the appropriate add ons.......

Firefox.....  https://addons.mozilla.org/en-US/firefox/addon/photobucket-fixer/

Chrome..... https://chrome.google.com/webstore/search/photobucket_hotlink_fix?hl=en


I'll continue with, Blundering with Boris. Hope, there's still some interest!  :scratch:


I wondered, why the new displacer insisted on catching the inside of the hot cap.

The shaft guide was at an angle, having been hammered into the bulkhead......  :bang:




Time to strip, completely. And, totally rebuild......




I've taken the pics, as I've gone along. Not always, in sequence.....

First job, was to get rid of the unnecessary/ leaking, water jacket.

Four inch dia. Made  from tough stainless steel. Not easy to machine, with a mini lathe's power.....




What a mess, in there!




I intended incorporating the end flange, into the cooling fins.......




But. The darned thing fell off. After I'd drilled the new screw holes.....




Yet another "interesting situation", needing a solution........  :palm:

More to follow. Thanks for looking in.  :thumbup:
« Last Edit: October 16, 2017, 08:50:53 AM by Stilldrillin »
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline tom osselton

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Re: Bodging with Boris........
« Reply #50 on: September 24, 2017, 02:07:44 PM »
I always look forward to your posts it's to bad about photobucket we all hope there's a special place in hell for them! :wack:

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #51 on: September 24, 2017, 03:24:57 PM »
Thank you, Tom! ... I'm pleased I haven't been forgotten!   :wave:

Don't forget, you can now see any/ all Pbucket pics. Simply by Installing the appropriate add ons.

Firefox.....  https://addons.mozilla.org/en-US/firefox/addon/photobucket-fixer/
Chrome..... https://chrome.google.com/webstore/search/photobucket_hotlink_fix?hl=en

What a tremendous own goal, Pbucket have scored!  :loco:


So..... While thinking what to do, about the detached flange. I set to, making the cooling fins.

Around 4"/100mm diameter.

Started with, square, 5mm thick blanks. And, one off at 8mm thick, to screw to the bulkhead.

Using 3 stops, on the mill table. Means I can locate/ relocate all blanks, accurately. Every time......




Making it easy, to mill off the corners. Instead of sawing......




Also, to drill a central, 6mm hole.......




A piece of 4" dia steel, in the chuck. Faced with wide insulation tape. Plus a lump of spare nylon......




Friction turned the remaining corners away........




Giving, a handful of discs, all the same diameter.


Moved onto the mill.......




Removed the centre areas. Just undersize, to the hot cap o/d of 47mm......




Parted off, Five, 63mm dia blanks. From bar stock, and removed the centres, too.......




After finish boring, on the lathe. A quick mock up......




I think that looks ok.....  :thumbup:

Thanks for looking in......

David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline awemawson

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Re: Bodging with Boris........
« Reply #52 on: September 24, 2017, 03:44:22 PM »
Proper Job  :thumbup:  (said in a west country accent )
Andrew Mawson
East Sussex

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #53 on: September 24, 2017, 05:51:27 PM »
Proper Job  :thumbup:  (said in a west country accent )

Thanks, Andrew!

Happy memories of Scrapheap Challenge, and the wonderful things they, "found", to Moderfy.......   :smart:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Pete W.

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Re: Bodging with Boris........
« Reply #54 on: September 25, 2017, 05:10:21 AM »
 It looks good but I'm puzzled!   :scratch:   :scratch:   :scratch:   :scratch:   :scratch:   :scratch: 

Is it a VFD for the lathe?   :lol:   :lol:   :lol: 
Best regards,

Pete W.

If you can keep your head when all about you are losing theirs, you haven't seen the latest change-note!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #55 on: September 25, 2017, 06:37:56 AM »
Is it a VFD for the lathe?   :lol:   :lol:   :lol:

Oooohhhh........ Pete!  :bugeye:   ....... I love it, when you Lekky Lads, talk dirty.....  :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #56 on: October 16, 2017, 07:58:32 AM »
I eventually, got my head around the hot cap, sealing/ retaining problem.

Finding a piece of correct diameter, tube. (It just happened to be bronze). I silver soldered a ring, to replace the original flange.....




Recessed, the new holding flange.......




The cylinder/ spigot, protrudes through, by "a couple of thou'". To make a positive location/ seal, against the bulkhead.......




Held on, by three, neater than original, screws........




Secure......




Thanks for looking in! 
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #57 on: October 16, 2017, 08:36:46 AM »
I hate to see engines, held onto their wooden bases using, obvious, wood screws. I prefer engineering screws. Button heads, look ok.

Or, in this case. Countersink.......




The two rear fixing holes are now, under the bearing pedestals.

Had to drill a central hole.......




I drill, clearance holes, for the screws.
Underneath. I counter bore 15mm deep. The same diameter, as the nut's a/f measurement.

I can then pull the nuts, captive, into the recess......




Thanks for looking in!
« Last Edit: October 17, 2017, 01:11:15 PM by Stilldrillin »
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #58 on: October 16, 2017, 02:24:52 PM »
New, improved, crankshaft location.....

The two uprights, are made from 6mm thick angle iron. Cleaned up, square, on the mill. Dowelled and screwed in place, from underneath the base plate. Allowing removal, and accurate replacement, when necessary.....

The two, outer bearing housings, are a sliding fit, in the uprights. Held in place with slidelock........




The inner bearing housings, slide over the smaller diameter.......




Butting against the upright. Also, held with sleevelock.......




Should be much more effective than the wobbly, original assembly.

Thanks for looking in!
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #59 on: October 17, 2017, 01:46:40 PM »
The crank assembly, is finished....




It cycles nicely. No tight spots.......





The flywheel, is next. At 7" dia. It's a little on the large side, for a mini lathe......




The original bore was unsuitable. So, I drilled out, oversize, and plugged with a piece of m/s. Held in with the ever faithful sleevelock.

The rear boss, held in the chuck jaws, has been machined nicely true to the rim. Allowing me to set the rim running, within a thou'.

Now, I'm starting to open up to a 10mm dia bore. Hopefully. Perfectly true to the rim......

We'll see......
« Last Edit: October 18, 2017, 01:28:43 PM by Stilldrillin »
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #60 on: October 19, 2017, 02:14:40 PM »
Boring shallow recesses, for each size of drill. Then the 10mm reamer. Held them all, true to centre line.......




After re assembling. Time for a quick test run.......

<a href="http://www.youtube.com/watch?v=dlk_io15Ez8" target="_blank">http://www.youtube.com/watch?v=dlk_io15Ez8</a>


Only, the cosmetics left to do, now......  :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline tom osselton

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Re: Bodging with Boris........
« Reply #61 on: October 19, 2017, 02:20:59 PM »
I can't see the test run video.

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #62 on: October 19, 2017, 03:00:19 PM »
I can't see the test run video.

Sorry Tom.

I had forgotten to, "Publish". Hope, it's ok now.....  :thumbup:
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline philf

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Re: Bodging with Boris........
« Reply #63 on: October 19, 2017, 03:08:24 PM »
That's a cracker David!

 :clap:
Phil Fern
Location: Marple, Cheshire

Offline awemawson

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Re: Bodging with Boris........
« Reply #64 on: October 19, 2017, 03:26:08 PM »
Very nice  :thumbup:
Andrew Mawson
East Sussex

Offline fcheslop

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Re: Bodging with Boris........
« Reply #65 on: October 19, 2017, 05:34:08 PM »
Very nice.
If it had been in my shop it would have been a door stop or hiding with the spiders under the bench
Keep well marra
cheers
History is scarcely capable of preserving the memory of anything except myths

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #66 on: October 23, 2017, 05:30:38 PM »
Phil, Andrew.
Thank you, Gentlemen!  :thumbup:

Very nice.
If it had been in my shop it would have been a door stop or hiding with the spiders under the bench
Keep well marra
cheers

Nah!
You, would have made it correctly. In the first place..... 


Had a good showday, on Saturday.

It ran for over five hours. Only stopping for meths top ups.......




Thanks for looking in!
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!

Offline sbwhart

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Re: Bodging with Boris........
« Reply #67 on: October 24, 2017, 12:27:39 AM »
The master strikes again:- another great job Dave

Stew

PS I hope you and yours are all well

Stew
A little bit of clearance never got in the road
 :wave:

Location:- Crewe Cheshire

Offline Stilldrillin

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Re: Bodging with Boris........
« Reply #68 on: October 25, 2017, 05:45:21 PM »
Thanks Stew!
I think I might be getting the hang of these things. After all this time.....  :thumbup:

We are, "normal", here, thanks. Hope the same goes for you. Over your side of the Pennines.
David.

Still drilling holes... Sometimes, in the right place!

Still modifying bits of metal... Occasionally, making an improvement!