Author Topic: What I am working on  (Read 33624 times)

Offline -steves-

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What I am working on
« on: October 20, 2011, 03:14:17 AM »
OK, brief intro, I had only made a couple of posts previous to this one, and they were to say hello.

If you don't know, I have never had a lathe or a mill before, and the other week I decided it would be a great idea to build a steam engine from castings, a "simple" Stuart 10V kit was selected.

I bought the book on how to build it, a couple of books on lathes and mills, and tool sharpening, and LOADS more, of which I am still on the first couple as I do find it hard to find the time to read with so much going on all the while.

So this is all from someone with virtually no experience (other than metal work class for 1 year at school around 28 years ago).

I will add some pics up later, but this post will contain my ongoing project of mainly my Stuart 10V build, but also bit and bobs that I do in the meantime.

Last night I decided to attack the kit, though some would say it was rather hasty after reading the book and not understanding what half of it meant.  :hammer:

So far i have milled down the top and bottom of the base, managed to drill and tap the base to 7BA and bolts actually went into them to my suprise. You need to remember I have not done this before so its all a bit exciting to me when something actually fits. i have also drilled the main bearing base, and to my shock, these holes actually lines up with the base and I could put all four bolts through to hold it on, now there was one happy puppy. I still need to take a tiny bit off the base to get it to size, but all feeling very pleasing so far, no cracked castings as yet, no missing fingers, life is great :)

I also managed to attack the flywheel a bit as well, after a bit of filing, I stuck it in the 4 jaw chuck and managed to centralise it pretty well in the end, though this did take quite a while it appears the time spent doing that is worthwhile, as I managed to machine down half of the outer flyweel, one side of the flywheel, one end of the flywheel and one side of the hub top of the flywheel, as well as centre drill it and drill it, and yet again, to my complete amazment, the side I have worked on seems to run quite true, like a dog with two, erm, tails.... :)

I will try and post up a couple of pictures later, I know its not all that interesting and I know its not much to most of you guys, but it's my first ever work, and even if if it was turning down a bit of ally by 1mm, I would have still been chuffed to bits  :D
« Last Edit: October 20, 2011, 04:24:13 AM by -steves- »
very new to all this....

Offline andyf

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Re: What I am working on
« Reply #1 on: October 20, 2011, 03:49:05 AM »
Hi Steve,

It sounds like you're off to a good start  :thumbup:

The books are a good idea, if (like me) you have no background in machining and no-one leaning over your shoulder telling you how to do things. And there's loads on the interweb about building the Stuart 10V on sites like this http://homews.co.uk/page42.html ; I'm sure you will already have Googled around the subject.

Pictures are always interesting, so do post some as you go along.

Enjoy yourself!

Andy
Sale, Cheshire
I've cut the end off it twice, but it's still too short

Offline -steves-

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Re: What I am working on
« Reply #2 on: October 20, 2011, 04:21:43 AM »
Hi Steve,

It sounds like you're off to a good start  :thumbup:

The books are a good idea, if (like me) you have no background in machining and no-one leaning over your shoulder telling you how to do things. And there's loads on the interweb about building the Stuart 10V on sites like this http://homews.co.uk/page42.html ; I'm sure you will already have Googled around the subject.

Pictures are always interesting, so do post some as you go along.

Enjoy yourself!

Andy

Thanks Andy. I think the enjoying myself is defiinately happening, the only downside is as like yourself, i have no one about to tell me if I am right or wrong, and no experience to of any of it, and everything is a first, I pretty much kack myself with everything i do at the same time as enjoying it, makes my heart go with each cut or movement, wondering if something is going to break, snap, fly off etc, working so close to the chuck frightens the ..... out of me , lol.

Can casting have different areas of material, as one part of the base just made horrid "hammer drill" type noises as I went over it, and it just didnt seem to "cut it", though changing the position of the work in the vice, changing the mill bit and changing the direction of cutting certainly seemed to help eventually, but I have no idea what caused it to happen?
very new to all this....

Offline AdeV

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Re: What I am working on
« Reply #3 on: October 20, 2011, 06:51:23 AM »
Steves,

That was me, about 18 months ago - brand new to machining, new (to me) mill & lathe... and all the same fears. In fact, probably the most risky time is as the fear starts to go away - cockiness can follow and you'll have a couple of broken tools or tool crashes on the lathe: At least, that's how it went for me. In fact, I went through a period of really not getting along with the lathe at all, everything was a damn struggle, nothing seemed to work; but, as my skill slowly improves, I now find it much better. BTW, the 4-jaw does get easier to adjust, but it's always a pain. On the other hand, so long as the jaws are holding straight, you'll always be more accurate with a 4-jaw independent than a 3-jaw scroll chuck. So if it's got to be bob-on to the nearest thou (0.001"), then the 4-jaw is the only real choice (unless your lathe does collets).

It's taken those 18 months, but I can be pretty confident now that I'm not going to break anything worse than a carbide insert, or take too much metal off whatever I'm cutting (which is bad enough).

As for your "hammering" issue; it does sound like you hit a hard spot in the casting. There are basically 4 things you can do in such a situation: a) Faster spindle speed, faster feed; b) Faster spindle speed, slower feed; c) Slower spindle, faster feed; d) Slower spindle & feed. Picking the right one is simply a matter of trying them (probably the slower options first) and seeing what happens. Beware blunt tools in steel! If your cutter and/or workpiece is getting murder hot (enough to discolour, or if there's visible redness in the tool), then your cutter is blunt and ruined; don't bother trying to carry on with it, put it in the "to be rescued" pile & carry on with a new cutter.

Carbide insert tools on the lathe are brilliant - although it takes a bit of finessing at first, you'll break a lot of inserts in your early days - but once you're past that stage, you'll find they cut anything, even relatively hard steel (e.g. driveshafts). In fact, pretty much the only HSS I still use on the lathe are taps & dies, even my threading tools are carbide.

The main thing is - enjoy it! As you say, there's nothing more satisfying than trimming a lump of metal to exact dimensions, and seeing it fit another piece you also cut. After 18 months, I still love standing in front of the mill or lathe carving stuff out.


Anyway:  :worthless:

Looking forward to seeing those progress pics, it sounds like you're off to a great start!
Cheers!
Ade.
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Location: Wallasey, Merseyside. A long way from anywhere.
Occasionally: Zhengzhou, China. An even longer way from anywhere...

Offline raynerd

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Re: What I am working on
« Reply #4 on: October 20, 2011, 09:14:38 AM »
Hi, good luck with your build - I made the same engine 12 months ago. Look forward to seeing to pics.

Here is my buildlog and there were lots of helpful tips from people on here:

http://madmodder.net/index.php?topic=3633.0
http://www.raynerd.co.uk/?cat=44

Offline Stilldrillin

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Re: What I am working on
« Reply #5 on: October 20, 2011, 12:25:40 PM »
Steve.
You're having fun.
You've still got all your digits.
A project is beginning to take form.
You're telling us about your progress.

THAT'S interesting to us!  :thumbup:

Keep on, keeping on......  :D

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

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

Offline -steves-

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Re: What I am working on
« Reply #6 on: October 20, 2011, 12:50:26 PM »
Well, I have taken a couple of very bad pictures, I have to say the items don't look as bad in real life as they do in the photo's, in fact, its made me look harder at them and I can see where bits need to be done again, maybe this is the way forwards, photograph it then do it again, lol  ::)

These are first attempts so please bare that in mind before slating it. I also need an end mill as the ones I have are old and small and don't do that greater job, its all a learning curve and so far I am loving it  :)

very new to all this....

Rob.Wilson

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Re: What I am working on
« Reply #7 on: October 20, 2011, 01:05:43 PM »
 :) good to see you have taken the plunge Steve  :clap: :clap: :clap:

 Looking forward to seeing the engine come together  :thumbup:


Will be watching , Rob

Offline saw

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Re: What I am working on
« Reply #8 on: October 20, 2011, 01:22:32 PM »
Good start, good luck with the rest.  :clap:
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Offline madjackghengis

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Re: What I am working on
« Reply #9 on: October 20, 2011, 01:31:20 PM »
Steve, definitely take pictures, don't think those who have been doing this for a while have forgotten our beginnings, we haven't.  I took a year of machine shop in high school, 28 years ago, and while I've worked at machining ever since, all my real education in the area is from practice and from reading everything I could get my hands on.  Books from Lindsey Book Company, they specialize in reprints of out of print old books, are great, good price, invaluable information, as you have as much tooling now, as many full time machinists had to work with a hundred years ago, and far more accurate measuring devices at your disposal.
    With metal, there are many which alloy together just like homogenized milk, and are consistent throughout, others, particularly stainless steels and cast irons, which will segregate with hard and soft spots in the castings.  Aluminum is almost always homogenous, good quality brass and bronze, ditto, virgin cast iron is usually very easy to machine, but that with scrap added often has hard spots.  Good advice has been given on machining those you run across, and the fact you drilled and tapped holes, and had parts line up already makes you ahead of the game already.  "The wise man learns more from the fool, than the fool learns from the wise man".  All that I see on this forum is instructive at some level, and your presence makes this forum last longer and do better.  Glad to meet you, and welcome. :beer:  cheers, mad jack

Offline -steves-

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Re: What I am working on
« Reply #10 on: October 21, 2011, 02:40:30 AM »
Thanks guys, you do know how to make someone feel very welcome  :D (I couldn't find the embarassed smiley..)

I am "hoping" to get some more time on this over the weekend, however I am not sure how much I can do before having to splash out £150 on a cheap 30mm / 32mm indexable face mill, a cheap indexable boring bar and a half decent indexable parting tool. So these items will slow down my project as money is very tight after forking out for the lathe / mill and other hundreds of pounds worth of "bits and bobs" to have something to do on them. My tools are very limited but I do have managed to purchase the following: a face plate, a 4 jaw independant chuck, quick change tool post, a fixed steady, a chuck and MT2 taper for the tail post, a set of indexable lathe tools, a dial gauge, a magnetic dial gauge holder, a set of large files, some very small files, centre drills, BA and Metric tap and die sets, a selection of ME taps and dies, a set of metric drills, a small selection of end mills, a grinder / sander, last but by no means least, a pair of safety glasses and thats all from October  :bugeye: hence I am skint now, lol...I have to say the outlay has been far more than I was anticipating and I dont seem to have 1/4 of what I need, still desperately need some reamers yet too :( I guess it will all build up over time, but its just so annoying and frustrating sometimes when you read, do this with "X" tool, and you dont have it, seems to be happening a lot at the beginning, but I guess its something everone goes through and even after a number of years no doubt there are items which you dont have and still need to get.

If anyone can see I have missed some form of "obvious" tool, please let me know as I have a tend to set up a prioritized list of things to work through to buy, thats how I bought all the above, ok, it meant selling lots of radio control plane stuff, but I kinda got there in the end.

I will not be able to do anything next week as i will not be near the house where the lathe / mill is, its going to be a slow process, so please dont wait up for updates  :coffee: I might have a bash at a couple of 16mm buffers from ali over the weekend, if I do mamage to get anything done I will of course take a piccy and post it up. Just got to go find some 7mm bar stock now to put my flywheel onto, the fun never ends does it  ::)

So far this seems like a very nice place to be and I can see why you have this smiley ico  :mmr:
very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #11 on: October 22, 2011, 10:03:53 AM »
Well its been a kinda busy morning today, making up for the fact I can't do any work next week.

As I dont have a decent face mill bit, I am leaving the rest of the Stuart 10V until I have a bit that will do it justice, its payday Wednesday, so hopefully I can get something ordered then, lol.

I decided to have a bit of a play and see what I could do.

So first of all I made a couple of 16mm train buffers for some rolling stock I am building, then I decided to make a new pulley wheel for my mamod stationary line shaft, just to see if I could, I didn't need one, I just wanted to see if I could do it. Also the grub screw was cut from a 3mm bolt and a head cut on it.

Here are a couple of the results, sorry about the poor quality of the pictures, I am not the best with a camera and the camera is only a cheapy, lol

very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #12 on: October 22, 2011, 10:08:05 AM »
Next on the agenda today was to do some more to the flywheel of the Stuart 10V, and here is how its going to be other than a bit of paint or varnish and a parting tool of some description down the middle of it.

Unfortunately the 5ba grub screw was missing from the kit, so I has a bit of steel bar, and a ba tap and die set, and sat down and made one myself.

Also the 7mm bar to do the work between centres, all I could find to hand was 8mm, so I had to turn that down to 7mm before I could start, all the joys of it all, lol

very new to all this....

Offline Stilldrillin

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Re: What I am working on
« Reply #13 on: October 22, 2011, 10:32:30 AM »
Very nicely done Steve!  :clap: :clap:

The best practice, is in the making of widgets. This builds your confidence for the important, (mustn't be scrapped) work.....  :palm:

The flywheel looks very good!  :thumbup:

David D
David.

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

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

Offline -steves-

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Re: What I am working on
« Reply #14 on: October 22, 2011, 02:09:18 PM »
Cheers Dave, glad you like the flywheel, I must confess I am quite chuffed with that as I managed not to break it, it all seems to be running fairly straight and is drilled to the right size as it just about goes onto the crankshaft, I am sure it could be much much worse. Once I get my new parting tool I am hoping to put a slot down it.

Its been a very good day today for me, these little nick nacks as you say, do build the confidence a little and of course build experience which is something I seriously lack. Today I had part of the lathe pulled apart as it had some slack in it, I ended up replacing 2 stripped screws and tightening up a few bits here and there. I cant say what everything is called as I have no idea, but where it slide back and forward and whre it slides side to side and has 3 adjustable screws to make is slide properly, all had to be adjusted on both bits. I have absolutely no idea if I have done this right or wrong, or even if I was supposed to, but its made everything less slack feeling but nothing appears to be binding when turning the "knobs" and "stuff". This is when it would be really useful to have someone experienced about to say if I am doing right or wrong, and to show me once, how to do things and what to do and what not to do. Its really difficult when you simply don't have a first clue, just general knowledge and guess work, lol

Showed my Suzi how to use the lathe this afternoon and she also made a mamod pulley for the line shaft. As it was in effect "my/our" second attempt I made a couple of changes on how she should turn it, and I have to admit, hers did come out better than mine, but of course this was down to the "designer" LOL :) She did good  :ddb:
very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #15 on: October 29, 2011, 12:40:56 PM »
Well I dont know what happened to all my previous pictures, they all seem to be missing :(

Anyway, I spent some time on the Stuart today, and managed to get some bits and bobs done.

I polished up the flywheel a bit.

Managed to get the main stantion machined out and topped and bottomed as well as the brass bit in the middle done too. I have no idea of the names, but I have some pictures below :) Its quite a good fit not too tight but not loose either, a bit of oil and it slides in and out quite nicely, though it will need some running in. I managed to get some more tapping done and some more bits bolted together. This is my first use of my lathe and mill, so I don't expect everything to go quite as well as it did today. :)

very new to all this....

Offline Henning

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Re: What I am working on
« Reply #16 on: October 29, 2011, 02:25:16 PM »
Looks like quality work to me!

Remember everyone has been new at this some time and the gents on here is top notch, so no need to be afraid to ask questions or tell about the mishaps. Usually you'll get loads of good advice on what to do to avoid that in the future!

Henning

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Offline -steves-

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Re: What I am working on
« Reply #17 on: October 29, 2011, 02:35:19 PM »
Looks like quality work to me!

Remember everyone has been new at this some time and the gents on here is top notch, so no need to be afraid to ask questions or tell about the mishaps. Usually you'll get loads of good advice on what to do to avoid that in the future!

Fear not, I am sure there will be lots of questions on their way, and no doubts lots of mishaps as I learn, but its all part of the fun :)
very new to all this....

Offline saw

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Re: What I am working on
« Reply #18 on: October 29, 2011, 03:25:40 PM »
This V10 is looking realy good, Stuart are making a very good casting, but I must edmitt I am not impressed by their drawings  :doh:
They could be much clear and better.  :D
However good luck with the rest.  :thumbup:
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Offline AndyB

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Re: What I am working on
« Reply #19 on: October 30, 2011, 02:06:38 PM »
Hi Steve,

Looks like you are cracking on really well!! :clap: :clap: :clap:

I am on my first engine build, a lot slower than you are!

I spent quite a long time making tools and tooling before I started on a real engine to get practice and to experiment.
Don't be shy or embarrassed, ask whatever you want to know; there are some real 'fonts of all wisdom' here, but there are also people like you and me who have tried and experimented and their input is just as valid and helpful.
Even I, unworthy as I am, have given advice and had it taken to result in success...I can't describe how that made me feel! :smart: And the confidence takes an almighty boost that helps me through the next step.

I have the brown trousers moments when attempting something new and difficult...look at my log for the Rider Ericsson! But there are ways round booboos and they teach you as much, if not more, as getting it right first time.

I have to say, making your own tools is a lot cheaper than buying ready made, and gives a lot of experience along the way. I had a large boring job to do for my work (I was that chuffed that they asked me!) that needed a long boring bar...so I made one out of a length of key steel and an odd carbide tip that I got in a box of bits.  Worked a treat...and makes me laugh when I see the prices they charge for ready-made ones. Since then I have made some more. Getting the angles right is trial and error, but they are made out of scrap so it doesn't matter...just cut the end off and start again. :doh:

The main point of this, or any, hobby is to enjoy yourself. If you have got Her Indoors into it as well then you have cracked it completely...I get complained at that she is a shed widow! :lol: :lol:

Good luck and keep moving onwards and upwards (as they say)

Andy
Waveney Valley, Suffolk/Norfolk Border

Offline -steves-

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Re: What I am working on
« Reply #20 on: October 30, 2011, 03:10:06 PM »
Well, first boo boo was made today......  :(

I had a go at the cylinder block, I was really struggling to try to work out what was level when it came to the top and bottom as neither was flat. After a bit of faffing around I "thought" I had managed to sort it out (mistake no. 1). So I faced up both ends and the steam block side. By the time I had finished milling both ends to try and and it flat I ended up a little short on the cylinder block, nothing major though a little disappointing (mistake no.2). Well, then it was time for the bore, never having done this before I took a "best guess" at the cetre of the hole, BIG mistake (mistake no.3). I took measurements from whe existing hole assuming it was central  :doh: It wasn't. I ended up with a near prefect bore of .750 through the clyinder block, the only thing is, not only is it offset from true centre, it also goes through the cylinder block at a slight angle  :doh: Looks like a new cylinder casting is in order.....though....I may continue onwards and see what happens as I "think" it will still go together and "may" even still run, Its just that the tops and bottom of the cylinders will be offset and the piston will be going up at a maginal angle. Oh well, we live and learn, certainly not put off and consider it a bit of a lesson in needing to take my time  :D
very new to all this....

Offline saw

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Re: What I am working on
« Reply #21 on: October 30, 2011, 04:25:20 PM »
Steves, that is happend to us all.  :Doh:
When you aree going to drill the cylinder, you can not expect from the hole, you must measuring from edges. I little tip is, piece of wood and fill the hole, then it's much easier to center the cylinderhole.
Good luck with the rest.  :thumbup:
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Offline doubleboost

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Re: What I am working on
« Reply #22 on: October 30, 2011, 04:31:37 PM »
Great shame that :Doh: :Doh: :Doh:
I think we have all messed things up
It is all part of the learning curve
John

Offline Pappy Frank

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Re: What I am working on
« Reply #23 on: October 30, 2011, 11:45:19 PM »
Your doing great. Do not worry about the lack of experience. My first experience with a metal lathe was in High School too, over 40 years ago. I worked as a machinist for a number of years before becoming a paramedic, at which I am retired from.

I still find myself wondering what went wrong with a project now and again, I am still learning, and I have made a few mistakes that make me look like my first day on a lathe.

Keep up the good work, and if you have questions, ask them. Someone can help. :mmr:

Pappy Frank

Offline -steves-

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Re: What I am working on
« Reply #24 on: October 31, 2011, 12:22:26 PM »
Well despite my little knock back yesterday, I had a day off today and did a little more between things.

I managed to do the tops and bottoms of the cylinder, the only bit left to do is tap the bottom one with an ME tap. Of course I need to drill them and then tap the cylinder liner as well.

You can see how far my cylinder bore is out on these, though it look worse in real life than on the pictures..





very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #25 on: November 01, 2011, 04:50:30 PM »
Tiny little update, got the cylinder tops and bottoms drilled and tapped etc, so that little job is now jobbed :)

Looks like some really difficult tasks on the way with the conrod, the eccentric, piston, etc on the way, not looking forward to those bits, lol



very new to all this....

Offline Stilldrillin

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Re: What I am working on
« Reply #26 on: November 01, 2011, 04:54:30 PM »
Looking good. Progressing nicely, Steve!  :clap: :clap: :thumbup:

David D
David.

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

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

Rob.Wilson

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Re: What I am working on
« Reply #27 on: November 01, 2011, 04:59:14 PM »
 :thumbup:  ,,,,, Nice going Steve  :headbang:





Rob

Offline -steves-

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Re: What I am working on
« Reply #28 on: November 01, 2011, 05:02:26 PM »
Looking good. Progressing nicely, Steve!  :clap: :clap: :thumbup:

David D

Thanks David & Rob :)

I will admit, its harder to do, harder to setup and takes far more setting up than I could have ever have imagined. At times like this, I see someones homemade engine, such as your one you did not so long agon David, and think, wow, that must have taken months of hard work to get to that, you just dont give it the credit its due till you have a go at a few of these smaller tasks.

For anyone thats tackled anything engine related, my hat off to you all,  :ddb:
very new to all this....

Offline saw

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Re: What I am working on
« Reply #29 on: November 01, 2011, 05:46:06 PM »
You are doing well, a bit of advice, just take one stepp and try to do that as good as you can. :D
We are not judging your project, the only one is mayby you  :lol:
To force too much can ruin your whole engine so take it easy :D
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Offline sbwhart

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Re: What I am working on
« Reply #30 on: November 01, 2011, 06:01:02 PM »
Looking very neat Steve  :thumbup:

Just carry on nice and steady has you have bin and you'll get their and produce a real great engine.

Stew
A little bit of clearance never got in the road
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Offline doubleboost

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Re: What I am working on
« Reply #31 on: November 01, 2011, 06:09:31 PM »
Hi
Steve
Coming along very nicely :thumbup: :thumbup: :thumbup:

Offline arnoldb

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Re: What I am working on
« Reply #32 on: November 02, 2011, 01:03:40 PM »
Looks very good so far Steve  :clap:

Like Stew & Benni said - take it one step at a time and work carefully. 

Good parts result from 50% positive attitude, 40% setup and 10% machining  :thumbup:

 :beer:, Arnold

Offline -steves-

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Re: What I am working on
« Reply #33 on: November 02, 2011, 04:48:15 PM »
Thanks very much everyone for the kind and helpful words :)

Took a bit of time out tonight from it and decided to see if I could make a new piston / conrod for one of my old mamod SE's.

All turned out reasonably well in the end, had it running and all is well. Deciced to make both ends brass and thread them, they are tight fits, so hopefully everything should be good. I am aware this is not the most exciting stuff to most people, but for me, its the first thing I have made that does something and works, lol  :)

Despite how they look in the pictures, they are actually the same length...

http://www.youtube.com/watch?v=7qbvzy_aezA






very new to all this....

Offline Stilldrillin

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Re: What I am working on
« Reply #34 on: November 02, 2011, 04:53:30 PM »
That thunders along nicely Steve!  :clap: :clap: :thumbup:

David D
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Offline -steves-

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Re: What I am working on
« Reply #35 on: November 02, 2011, 05:13:33 PM »
That thunders along nicely Steve!  :clap: :clap: :thumbup:

David D

 :thumbup: :D
very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #36 on: November 07, 2011, 02:29:09 AM »
Well, despite having my lathe working much better than ever before I made a couple of MAJOR BOO BOO's with the Stuart 10V :(

1) I went to mill the steam chest face, forgot to put the Z lock on and ended up with a lot more metal removed than anticipated, so much so that it has far more taken off one side than the other, not the end of the world I thought, a few modifications here and there and its not really a problem.

2) Much smaller, yet bigger and catastrophic mistake.... I drilled the steam chest for the eccentric guide rod, centre drilled it and all that and the first hole was no problem. however, that hole continues at the top of the steam chest dome. Now this was using a 2mm (ish) drill, having it quite a way out the chuck in the tail stock as I needed the length to reach the top of the steam chest, the drill was so flexible that it caught on the rough surface and put it off centre and continued to drill off centre, no problem I thought as the rod will still move ok. What I didn't take into account was the brass block which moves the steam from top and bottom on the eccentric, this needs to run flat at all times creating a steam tight seal, this now can not happen as the rod moves at an angle and is lower at the top than the bottom. Its a great shame as the outside of the chest was near on a days work and looked super by the end of it, but it just wont ever run like it.

My options now are to order a new steam chest and do it all again, remembering to file the inside of the steam chest before drilling it, and drill the eccentric rod hole first with the bigger drill it needs and then use that thicker drill to create a "dimple" in the top of the dome for the small drill to start from.

Very gutted at the moment and no sure what to do next, I think a call to Stuart may be needed to order a new chest.... :( I am more gutted about all the work that went into it, and now it has to be binned...

The other option is to have it as a decoration piece only as it would still turn by hand, and probably air/steam if it were under enough pressure, lol :)

Oh well, the saga continues, lol....
very new to all this....

Offline AndyB

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Re: What I am working on
« Reply #37 on: November 07, 2011, 04:34:30 PM »
Hi Steve,

We have all done it!!!!

Don't be disheartened; you may be able to rescue it by drilling oversize and plugging, then restart your proper holes. I did that with a broken tap in an aluminium casting.
And if you can't, don't bin it, there is a lump of metal there that is crying out to be made into something, even if it not part of this engine!

It is all a learning curve and you seem to be getting on much better than me! :clap: But! Take your time and work out what can go wrong before starting and that will give you loads of ideas about which way to go and what you have to check before you start.

Only my tuppence worth...

Andy
Waveney Valley, Suffolk/Norfolk Border

Offline doubleboost

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Re: What I am working on
« Reply #38 on: November 07, 2011, 04:57:39 PM »
Hi
Stive
Like andy says drill it out and put a plug in it
Or turn a fancy brass bit for it and screw it in
John

Offline saw

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Re: What I am working on
« Reply #39 on: November 07, 2011, 05:05:58 PM »
Hi Steves.
Sorry about your'e mess, but we have all been there.  :Doh:
The steam chess is a little tricke part of the casting to machine, but I belive that you can repare by follow the tips you have got here.  :headbang:
If you can't do it, you can always order a new one from Stuart.   :D
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Offline BK

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Re: What I am working on
« Reply #40 on: November 07, 2011, 05:45:40 PM »
That's a real bummer mate,  :Doh: but, as has been said, try the plug and redrill trick. :thumbup:
If it aint broke, don't fix it!

Offline mklotz

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Re: What I am working on
« Reply #41 on: November 07, 2011, 06:01:33 PM »
After you've plugged the existing hole, you might want to consider turning a steel rod the diameter of the required drill, putting a point on it, and using it as a center punch to mark the plug so the drill starts at that point.
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Offline -steves-

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Re: What I am working on
« Reply #42 on: November 08, 2011, 02:37:10 AM »
After you've plugged the existing hole, you might want to consider turning a steel rod the diameter of the required drill, putting a point on it, and using it as a center punch to mark the plug so the drill starts at that point.

 Now why didn't I think if that  :doh: I was thinking, well there is no way I can centre drill it, or use a centre punch as none will fit down the hole, I just never even considered doing that, this is just a total new way of thinking  :Doh:

Thank you  :)
very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #43 on: November 14, 2011, 03:05:09 PM »
Right, bit of an update...

Spent the weekend doing lots of things, but found little time for my engine, but time I did find...

I managed to make the piston and the connecting rod to the crosshead, so that bits done and seems tight yet smooth. I also managed to make the main "bearings" or at least drill them out and machine them down to the correct size and bolt them in place, the good news was a bit of 9/32 bar rotated nicely in them so thats more good news.

I had turn up in the post this morning my new valve chest and the new slide vavle, as I decided it was best to give it another go and see if I can make this right as I "think" I know what mistakes i made last time, I just hope I don't repeat any of them...lol.

I also "hashed up the crankshaft, and i have my step father seeing if he can supply more heat to it and fix it, he said he will have to strip it apart and have another go. if all else fails then another order to Stuart models for some 9/32 steel bar and 2" of 3/16 x 3/8, hey ho......I reckon i should have just bought a complete spare engine at this rate, lol. Yes I can buy the bar cheaper from Ebay, but cant get a small amount of the 3/16 x 3/8 anywhere other than Stuarts :(

very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #44 on: November 20, 2011, 03:13:04 PM »
Well bit of an update but without any pics tonight...

Progress so far....

Finished the cylinder off, I finally grew the necessary items to take on drilling the steam ways, and all went well, certainly better than expected. Also finished off the inlet and exhaust holes.

Started the con rod, got the top end fitted to the cross head, got the pin made to join those and all is good there. Just got to do the bottom end of the con rod to do as and when the necessary parts grow sizeably enough. Same goes for the eccentric rod and cam.

Still have the crank to finish off, though I have made all the parts, it just needs loctiting, drilling and pinning.

After that, see if the thing runs I guess, then if it does, lots of cleaning up and tidying up. All going well, should be done by the end of the year (ish, give or take)

Might post some pics up as and when I get the chance to.....
very new to all this....

Offline AdeV

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Re: What I am working on
« Reply #45 on: November 20, 2011, 04:19:43 PM »
Yes I can buy the bar cheaper from Ebay, but cant get a small amount of the 3/16 x 3/8 anywhere other than Stuarts :(

Couldn't you just buy some bigger (cheap from ebay) bar & turn it down to size? Surely cheaper than buying scrag ends from Stuarts? And good turning practice too...

If you don't already have a set of dial calipers (or digital - but dial is better, no batteries to go flat & you can read between the marks for extra accuracy) then a set is well worth getting; also, a 0-1" (or 0-25mm) micrometer would be a wise purchase too. I can't remember where you are, but if you're anywhere near Merseyside you're welcome to borrow mine in the interim.

Nice looking engine BTW... I've not dared try one yet - it's all very well doing a monster project like that sump, but there's no real "10th mm" or "thou" accuracy needed on that, not like a tiny little engine...
Cheers!
Ade.
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Occasionally: Zhengzhou, China. An even longer way from anywhere...

Offline -steves-

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Re: What I am working on
« Reply #46 on: November 20, 2011, 04:37:16 PM »
Yes I can buy the bar cheaper from Ebay, but cant get a small amount of the 3/16 x 3/8 anywhere other than Stuarts :(

Couldn't you just buy some bigger (cheap from ebay) bar & turn it down to size? Surely cheaper than buying scrag ends from Stuarts? And good turning practice too...

If you don't already have a set of dial calipers (or digital - but dial is better, no batteries to go flat & you can read between the marks for extra accuracy) then a set is well worth getting; also, a 0-1" (or 0-25mm) micrometer would be a wise purchase too. I can't remember where you are, but if you're anywhere near Merseyside you're welcome to borrow mine in the interim.

Nice looking engine BTW... I've not dared try one yet - it's all very well doing a monster project like that sump, but there's no real "10th mm" or "thou" accuracy needed on that, not like a tiny little engine...

In the end I bought a few pence bit of scrap cutoff for less than a pound from a local metal dealer and turned it down in the mill to the correct size, much easier than I expected. I have re-made the crank webs now am happy, more or less, with the result, as always, you look back and think, I could have dome that better, lol.

I have a set of digital verniers, as well as a set of metric and a set of imperial micrometers, but to be fair, I am not 100% sure on how tight to clamp them to get the correct readings, so tend to stick to the digital verniers for now. I am sure I will work things out as I go along....

That sump is an amazing bit of work, very very well thought out :)

If I can take on a set of castings as a first project then anyone can, though the running bit remains to be seen, lol, it just might need some tweaking, who knows  :thumbup: I truely believe this little 10V is a brilliant learning curve on so many things, even though at times, those learning curves can be very steep as a first step....all is good :)
very new to all this....

Offline AdeV

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Re: What I am working on
« Reply #47 on: November 20, 2011, 04:43:23 PM »
On the very end of your micrometer's twist handle, there should be a smaller twisty bit which, when the anvils touch the work, should start clicking like a ratchet handle. That gives you a constant pressure, and - in theory at least - constant readings. One of my mikes is a bit on the stiff side, so the ratchet doesn't work as it should do.

If you don't have the ratchet handle on yours, get 'em sold off on eBay & buy a set that do.... Calipers are great for rough & ready readings, but when you need to be certain down to that last 0.001" (or less), then you just can't beat a micrometer.

I'm sure you'll get a runner out of this project, just don't give up until it's going! Easier said than done, I know...

Cheers!
Ade.
Cheers!
Ade.
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Occasionally: Zhengzhou, China. An even longer way from anywhere...

Offline -steves-

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Re: What I am working on
« Reply #48 on: November 20, 2011, 04:54:47 PM »
Thanks Ade, they do indeed have those ratchet bis on, each set is a set of 4, roughly from 0 to 100mm and 0 to 4", I did wonder what they were for, they also came with some fixed length bits, which I guessed were for setting them up, but again, I had no idea how to do that or if they needed doing, I will have a play with them and see how I get on :)
very new to all this....

Offline ncollar

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Re: What I am working on
« Reply #49 on: November 24, 2011, 11:02:57 PM »
I think you are very good at following directions. Real nice build, love your write ups. :beer:
Nelson Collar

Offline -steves-

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Re: What I am working on
« Reply #50 on: November 25, 2011, 04:21:36 AM »
Well a bit of news today, been working hard on the engine for the last week or so and although it is NOT finished yet, and it has a few issues need sorting out, still needs the gaskets fitting, cleaning up, polishing, mounting on wood, parts still to be made, etc etc, I actually had the thing running on air today  :) :D

The noise is the compressor running and not the engine you will be pleased to hear,lol  :thumbup:

very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #51 on: November 25, 2011, 04:33:48 AM »
I managed to get a better video of it with the helping hand of someone else on the camera, much easier, also no compressor running this time, what a sweet little engine :) :)

very new to all this....

Offline andyf

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Re: What I am working on
« Reply #52 on: November 25, 2011, 05:08:07 AM »
IT LIVES!

Congratulations!

Andy
Sale, Cheshire
I've cut the end off it twice, but it's still too short

Offline spuddevans

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Re: What I am working on
« Reply #53 on: November 25, 2011, 05:43:13 AM »
Looking very nice there Steves :clap: :clap: Another one bursts into life  :thumbup: :thumbup:


Tim
Measure with a micrometer, mark with chalk, cut with an axe  -  MI0TME

Offline saw

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Re: What I am working on
« Reply #54 on: November 25, 2011, 06:18:04 AM »
Congrats it's looking very fine and running fine. Despite all of you're problems you have manage to solving it on a good way, that's a good MadModder  :thumbup: :thumbup: :thumbup:
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Offline Stilldrillin

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Re: What I am working on
« Reply #55 on: November 25, 2011, 06:35:45 AM »
YAY!!!    :ddb:   :ddb:   :ddb:    :ddb: 

Your first runner!!   :D   :D

Doesn't that feel great??   :thumbup:

Very pleased for you Steve!    Blummin well done:clap: :clap:

David D
David.

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

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

Offline arnoldb

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Re: What I am working on
« Reply #56 on: November 25, 2011, 07:00:57 AM »
 :clap: :clap: :clap: :clap:  :thumbup: :thumbup: :thumbup:

Well done Steve - I can just imagine the smile you're now walking around with  :D :D

 :beer:, Arnold

Offline -steves-

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Re: What I am working on
« Reply #57 on: November 25, 2011, 07:16:03 AM »
Thank you very much guys.  :thumbup: :thumbup:

 As you all guessed, yes I am chuffed to bits and very veyr pleased with it. I have a huge smile on my face today and it definately gives you an immense feeling of satisfaction, knowing that it lives because of you, and all that hard work has paid off and given you something back. As I said, it still needs many bits and bobs doing so it way fro mfinished, but knowing that I will have something working at the end of it is very very sweet.

As mentioned all the way through this post, I have encountered many issues, due to inexperience, lack of tools and lack of knowledge, but despite all of these it runs, even though I had no idea how to time it, I just kept trying different places until it ran, lol.

A special mention needs to go out to Stilldrillin and my step father, who without their guidence and experience, this engine would have not have come to life at all. Of course a thank you to Madmodder and all its members as its been a huge source of inspiration to me, and still is, seeing what can be done and what people can do with experience,  thank you  :thumbup:  :bow: :beer:
very new to all this....

Offline -steves-

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Re: What I am working on
« Reply #58 on: December 05, 2011, 09:50:21 AM »
OK, its finished apart from the wooden mount, which I am working on getting and making some form of brass pulley for the end of it so it can run a sprung belt through it, once thats on, I will cut the crankshaft down to size, and JD (job done)  :)

Here are some pictures and a video of it running on air, not on a compressor, but by me blowing into it, hence its a very short video as I do run out of breath quite quickly, lol  :)

Next project as a parellel clamp, but I finished that this moring too, lol, so on with the tail stock die holder. After all this work on the engine, its back to learning basics which is what I should have been doing in the first place, so some overdue turing practice is in order as well as making a very useful tool....













very new to all this....

Offline Stilldrillin

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Re: What I am working on
« Reply #59 on: December 05, 2011, 10:37:50 AM »
Steve.
As a first project, for a complete novice....... I really didn't think you'd produce  anything as good as that!!  :bugeye:

All I can say, is blummin well done:clap: :clap:  You'll go far....... :thumbup:


(Wish my lungs were as good as yours)........

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

Offline saw

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Re: What I am working on
« Reply #60 on: December 05, 2011, 11:06:54 AM »
Congrat, very nice  :thumbup: :thumbup:
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Offline doubleboost

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Re: What I am working on
« Reply #61 on: December 05, 2011, 04:51:21 PM »
Very nice
It is great when they come to life :thumbup: :thumbup: :thumbup:
John

Offline sbwhart

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Re: What I am working on
« Reply #62 on: December 05, 2011, 05:01:11 PM »
Well done that man  :thumbup: :thumbup: :thumbup:

  :clap: :clap: :clap: :clap: :clap: :clap: :clap:

Stew
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Offline Doc

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Re: What I am working on
« Reply #63 on: December 05, 2011, 08:26:31 PM »
Steve NICE job beautiful little engine!!!

Very Nice

Offline arnoldb

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Re: What I am working on
« Reply #64 on: December 06, 2011, 06:33:54 AM »
Great job Steve  :clap: :clap: :clap:
Especially for running on breath power  :bow: - that's not easy to do, and getting it on your first engine is really really good  :thumbup:

 :beer:, Arnold

Offline AndyB

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Re: What I am working on
« Reply #65 on: December 06, 2011, 01:43:50 PM »
Well done Steve,

Cracking job!

Andy
Waveney Valley, Suffolk/Norfolk Border