Mill Engine

[doubleboost]

Hi
I seem to have gotten bogged down with my v twin marine engine 
 So i have started another project.

Going to build a big mill engine
I made a start on a pattern for the cylinder
I want it to have a 4 inch stroke and a bore of at least 2 1/2 inch no bolts smaller than 5 mill 
It will be double acting with a slide valve , nice and big and simple 
Once i have my cylinder i will be able plan things out
Glued some magic wood together last nite


Started to square up the ends for the driving dog

Poor boxford is contaminated again 

[saw]

What happend with your'e v twin marine engine ?     

[doubleboost]

It is about 80 % done just seem to have lost interest 
It will come back and i will finish it
Just needed a change from fixing machines and making tooling 

[saw]

Ok I missundersud you, I thought som shocking hade happend (dropped on the floor ore something
). I can understand that you need something else to do. 

[Bernd]

Neat idea of using the spindle for a clamp. 

Bernd

[doubleboost]

Got a bit more done on the cylinder pattern


MDF needs to run fast with a heavy cut 

[saw]

Looking good. 

[doubleboost]

More sanding and filling






getting there

[doubleboost]

Today i managed to turn the wood in to bronze
TWICE 

Pattern all ready to go

Core mould and cores

Top half of mould showing feeder and riser

Core in place

Top half of mould showing "gate "

Smoking core

Looking good


The finished casting
You can see how the metal has not filled the port face fully
Rob Wilson came over for an inspection
We re cast it with the same result.
Some mods to the pattern and moulding method and the job should be a good one

[saw]

Good luck with redone the job. 

[doubleboost]

Took Rob Wilsons advice and split the patern the other way.
This also gave the opertunity to add the exhaust port flange and cylinder drains.
After much sanding and filling the finished patern
Hopefully this will be cast this week 

[Rob.Wilson]

  Looking great john


Rob

[doubleboost]

Today the plan was to turn the nice red patterns into bronze
I have been looking forward to this all week
Yesterday i baked the cores and rammed up the moulds
These were carefully assembled ready to cast today
Extended risers were used to make sure the mould would fill completly


Rob Wilson called in to oversee the pour

Cylinder we cast last time ready to melt
Fired up the furnace soon had a nice crucible of liquid bronze
The pour went ok but i seemed to be short on metal
The pattern is biger than last time



Not looking to bad



Not enough metal
On closer inspection the core had collapsed

Rob examined the miserable looking casting his verdict

The damp casting sand had softend the core ccausing it to break up during the pour
Wont be making up any more moulds the night before
Going to cast it in aluminium tomorrow nite just to make sure the crucible holds enough metal
If it was easy every one would be doing it

[Bogstandard]

John,

If it was easy every one would be doing it

And most probably walking on water as well.

I find you learn more from making mistakes than doing it right first time, and thanks for showing that we all have problems sometimes.

I'm sure you will have a Cheshire Cat grin soon.


John