Author Topic: Potty Popcorn Engine  (Read 89664 times)

Offline arnoldb

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Re: Potty Popcorn Engine
« Reply #50 on: September 29, 2011, 03:08:58 PM »
Looks Great Stew  :thumbup:

 :beer:, Arnold

Offline NickG

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Re: Potty Popcorn Engine
« Reply #51 on: September 29, 2011, 10:43:42 PM »
Stew, very nice ... a lot of work in that part there. I've often wondered how people did that, nice method ... guess it's one of those that although taking more time to remove metal, it's actually easier done from stock than casting.

Nick
Location: County Durham (North East England)

Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #52 on: September 30, 2011, 01:14:45 AM »
Thanks Nick/Arnold/Dave/Saw

Stew, very nice ... a lot of work in that part there. I've often wondered how people did that, nice method ... guess it's one of those that although taking more time to remove metal, it's actually easier done from stock than casting.

Nick

Thats a very good point Nick, I had been wondering myself how you would machine it up if it had bin made as a casting, and i just couldn't see how you would hold it. Had a good natter with John the other night about making this part and he suggested that you could make it in two parts and silver solder it together, which I think would be very veasable also.

Stew
A little bit of clearance never got in the road
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Location:- Crewe Cheshire

Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #53 on: September 30, 2011, 04:35:12 AM »
On with the connecting Rod:-

Cut a length of mild steel to length and put a sacrificial centre in each end.

Then with the compound set over at 2.5 deg for the barrel shape



Then onto the mill and mill flats on the ends had to use thin parallels for the barrel to fit in.



Drill holes for the bearings



This is what you get



Cut the centers off then using filing buttons shape the eye at one end to fit in cross head.



It's coming on next job crank shaft bearing supports.



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

Location:- Crewe Cheshire

Offline saw

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Re: Potty Popcorn Engine
« Reply #54 on: September 30, 2011, 05:07:48 AM »
Looking good  :D
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Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #55 on: September 30, 2011, 01:34:08 PM »
Cheers Saw

Well it bin a bit of a frustrating day, made a good start on the bearing stands, then my DRO jammed up the read out was just saying the same numbers switched it off and on fiddled with it went and had a cupa, came back switched it on and it was OK 1/2 hr later same thing, had a fiddle left it alone for at bit switched it on all OK 1/2 hr later same thing.

Decided to leave it until the morning when its cooler, its bin darn hot her in the UK, but you would have thought it could handle a hot UK day, any of you guys experienced similar problems  :scratch:

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

Location:- Crewe Cheshire

Offline doubleboost

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Re: Potty Popcorn Engine
« Reply #56 on: September 30, 2011, 02:02:31 PM »
Hi
Stew engine is looking great  :thumbup: :thumbup:
The taperd con rod is a nice touch :clap: :clap:
I have a newall dro on my mill (suposidley propper gear) :doh: :doh:
I have had nothing but problems with it , at the minute its brain is scrambled
I have been told it needs reprograming
Problem is postage back and forward to newall is a fortune
John

Rob.Wilson

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Re: Potty Popcorn Engine
« Reply #57 on: September 30, 2011, 04:27:20 PM »
You have way way too much time on your hands Stew  :coffee:

Cool rod  :thumbup:

Rob

Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #58 on: October 01, 2011, 01:49:47 AM »
I thought you guys would like to see this Brian Rupnow over on HMEN as drawn the engine up in 3D, this is the link to his thread

http://www.homemodelenginemachinist.com/index.php?topic=15975.msg163279;topicseen#new









How cool is that  :bugeye: :bugeye: :bugeye: :bugeye: :bugeye: :bugeye:

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

Location:- Crewe Cheshire

Offline Stilldrillin

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Re: Potty Popcorn Engine
« Reply #59 on: October 01, 2011, 01:57:33 AM »

How cool is that  :bugeye: :bugeye: :bugeye: :bugeye: :bugeye: :bugeye:

Stew

That's,  cool.......  :bugeye:   :thumbup:

David D
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: Potty Popcorn Engine
« Reply #60 on: October 01, 2011, 05:59:52 AM »
Got up this morning bright and early nice and cool in the shed and the DRO work without a hitch, I think the problem must be temperature related, but the UK is not known for its high temperatures, you would have thought it would work at temperatures greater than 30 C.

The bearing support is a tail of a cleaver idea coming apart.

Squared up A piece of jig plate and fly cut it to the correct thickness.



My idea was to make both out of the same part as mirror images, first thing I realized was that my co-ordinates on the drawing were all to cock, I seemed to have snapped onto the wrong point when doing the dimensions and they are a mile out so I had to go back on the computer and correct the drawing.

Drilling the corner holes out went fine.



Spot the deliberate mistake:-the two supports are not identical one has an extension for the cross head guide to fasten to, I went and put a 20mm drill right through it.  :doh:

I out cleavered my self with that one.  :hammer:

Ok make another one, just a single this time and leave the support untouched.



Her they are waiting to have the rest of the unwanted bits chewed away.




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

Location:- Crewe Cheshire

lordedmond

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Re: Potty Popcorn Engine
« Reply #61 on: October 01, 2011, 07:12:02 AM »
On with the connecting Rod:-

Cut a length of mild steel to length and put a sacrificial centre in each end.

Then with the compound set over at 2.5 deg for the barrel shape



Then onto the mill and mill flats on the ends had to use thin parallels for the barrel to fit in.



Drill holes for the bearings



This is what you get



Cut the centers off then using filing buttons shape the eye at one end to fit in cross head.



It's coming on next job crank shaft bearing supports.



Stew


is that a small live centre in your TS ?  if it is then where are they sold


Stuart

Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #62 on: October 01, 2011, 07:50:31 AM »
Hi Stuart I made it myselve using a CO running centre and a blank M3 morse taper.

http://madmodder.net/index.php?topic=1208.0

Arceuro now sell them as a kit  http://www.arceurotrade.co.uk/Catalogue/Centres.

Stew

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

Location:- Crewe Cheshire

lordedmond

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Re: Potty Popcorn Engine
« Reply #63 on: October 01, 2011, 07:54:03 AM »
Thanks for the info


good build BTW

Offline madjackghengis

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Re: Potty Popcorn Engine
« Reply #64 on: October 01, 2011, 10:37:06 AM »
Hi Stew, I have to say the machining of the guide was very interesting, and very well done, particularly considering its complexity, and the percentage of it which remained when the machining was done.  As a side note, should you need a boring bar for something that deep, a piece of steel tube or pipe, filled with lead or solder, with a solid end to hold a cutter will do very well at great depths with a sharp edge and light cuts.  I also wanted to say how cunning and beautiful the con rod has turned out, very well done, both mechanically, for strength, and esthetically, looking like architechture.  I am a big fan of simplicity, and of parts holding each other in place by the nature of their fitment.  The inclusion of the CAD picture also helps put your work in better perspective and shows it off better as well. :drool:  I think perhaps I need to quit working so I have more time to build engines and such for pleasure, but then I couldn't afford the tooling.  I could sit and go through your log many times, over and again, seeing different details each time.  I'm really looking forward to watching her run, I hope you do her on steam for the video :poke:  I've got a small "boiler" from a carpet machine which I intend to use for a test boiler, as a proper engine should have a proper boiler, but I can't throw away a perfectly good boiler, when it could be used for test purposes.  It is hard to say too many times, just how nicely she is coming along. :jaw: :bugeye: :bow: :beer:  Cheers, mad jack

Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #65 on: October 01, 2011, 10:51:42 AM »
Thanks for your comments and interest Jack.

And thanks you're boring bar tip I guess the lead adds weight and deadens the vibration.

I can remember visiting one of our subcontractors, one job he had on the go were large hydraulic cylinders about 6 ft long with an ID of about 9" he had it mounted on a large long lathe with fixed steadies, and was using a long boring bar that overhung the back of the tool post by a significant amount and he had a big three jaw chuck fastened on the end of it, I asked him about the set up and he said it was to counteract the bend and natural vibration frequency in the bar.

As for putting her on steam, I don't have a boiler for that, I guess I'll have to build one someday.

Stew



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

Location:- Crewe Cheshire

Offline raynerd

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Re: Potty Popcorn Engine
« Reply #66 on: October 01, 2011, 12:55:01 PM »
Hi Stew, I`ve not been keeping on track with this and just caught up. Amazing work as always!

Chris

Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #67 on: October 02, 2011, 10:32:54 AM »
Cheers Chris

Finished of the supports.

I stuck the two supports together with two way tape, and made a couple of plugs to go in the holes to stop things moving around, I also made a filing button, for the top eye.

It was then a matter of nibbling material away from where its wasn't wanted.

In the mill



And with files.



And used a slitting saw to cut through the base, and cleaned across the base with a fly cutter, I'd plugged the bearing hole together, so the crank shaft will sit perfectly level.



A bit more work with files and they are looking something near, I'll tidy them up a bit more but has they are going to be painted they won't need polishing.



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

Location:- Crewe Cheshire

Offline Stilldrillin

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Re: Potty Popcorn Engine
« Reply #68 on: October 02, 2011, 03:35:46 PM »
They're very nicely done Stew!  :clap: :clap: :thumbup:

David D
David.

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

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

Offline raynerd

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Re: Potty Popcorn Engine
« Reply #69 on: October 02, 2011, 03:39:34 PM »
Stew, could you explain how to use a button to file a round? It is apparently a simple process but I`ve not tried it yet. I think you showed it me in passing a year or so again when I visited but it was in passing and taking everything else onboard, I`ve forgot!  :doh:

Offline saw

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Re: Potty Popcorn Engine
« Reply #70 on: October 02, 2011, 04:39:27 PM »
Very nice build  :nrocks: :nrocks: :nrocks:
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Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #71 on: October 02, 2011, 05:07:32 PM »
Cheers Saw

Chris

Its just a nut and bolt but with round head the size you want to file the radius, you make the bolt a close fit in the hole, you just use it to guide where to machine/file too.

You can see it her with the screwdriver slot across it.



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

Location:- Crewe Cheshire

Offline doubleboost

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Re: Potty Popcorn Engine
« Reply #72 on: October 02, 2011, 05:12:55 PM »
Hi
Stew
You are making this look to easy :bow: :bow: :bow:
It is nice to see files being used as they were intended :thumbup: :thumbup: :thumbup:
When you get this finished a triple expansion engine should slow you down a bit  :bugeye: :bugeye: :bugeye:
John

Offline sbwhart

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Re: Potty Popcorn Engine
« Reply #73 on: October 02, 2011, 05:29:48 PM »

Thanks John,

Quote
It is nice to see files being used as they were intended


I think files tend to get overlooked, you can do a lot with them, the first job we had as an apprentice was to file  a block of steel square and flat then drill a hole in it and file this so a square block fitted in it, after four week I hated the site of that bloody block.  :D

Quote
When you get this finished a triple expansion engine should slow you down a bit

Something like this



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

Location:- Crewe Cheshire

Offline doubleboost

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Re: Potty Popcorn Engine
« Reply #74 on: October 02, 2011, 05:37:19 PM »
Stew
Been there done the same thing :doh: :doh: :doh:
Did us no harm though
I got a clip round the ear for taking the thick off on a grinder :dremel: :dremel: :dremel:
Happy days
John