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The Craftmans Shop => Model Engineering => Topic started by: Brian Rupnow on August 01, 2014, 04:32:02 PM

Title: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 01, 2014, 04:32:02 PM
My current quest is to design and build a simple one cylinder, four cycle engine from barstock--(no castings). I am in the very early stages of design for this engine, and as it comes a bit clearer to me I will post my progress. The biggest stumbling block on an engine of this type is the complex machining required on the cylinder/valve body. I hope to simplify this by making the cylinder and valve body in two separate easy to machine pieces. This is where I am, so far.---Brian
Still thinking---
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX_zpscb020d1c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX_zpscb020d1c.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: dickda1 on August 01, 2014, 07:02:56 PM
Yes,  please keep us updated
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 01, 2014, 08:52:21 PM
My mind and computer take me to strange places----
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX_zps33118f20.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX_zps33118f20.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 02, 2014, 11:20:18 AM
Not there yet, but slowly getting all the parts in---
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX_zpse616eec5.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX_zpse616eec5.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 02, 2014, 04:13:56 PM
I think this could work---The cyan blue backplate would be 3/8" steel with 3 steel stub shafts welded into it. It would attach with 6 bolts and two locating dowels (not shown) to the dark green spacer bar, which is itself bolted and dowelled to the aluminum crankcase. The gears and cams might be machined from bronze or cast iron, something with enough lubricity that they can rotate on the fixed shafts without galling. The con rod has sealed needle bearings in both ends, the dark blue half of the split crankshaft has two sealed ball bearings supporting the end where the flywheel goes. The "follower half" of the split crankshaft would run in bronze bushings. The blue bridge which spans across the top of the aluminum crankcase is the tappet guide, and could be aluminum.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX_zpsb8354b49.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX_zpsb8354b49.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX-EXPLODED-2_zps61506224.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX-EXPLODED-2_zps61506224.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX-EXPLODED-1_zps7ee2c567.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX-EXPLODED-1_zps7ee2c567.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 02, 2014, 06:11:58 PM
Okay!!---I am happy with everything here, and know it will work. The only "grey" area is attaching the valve body to the cylinder and the cylinder to the crankcase.--I haven't spent any time thinking about the flywheel, and I am pretty certain that like the Jaguar/Canadian Cub engine that I just built, this one will need a built in fan for cooling. The exhaust will be simply a screw-in straight pipe, and the carburetor will either be a copy of the Jaguar carb or my version of the George Britnell carb clone.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: tom osselton on August 02, 2014, 07:56:35 PM
I would extend the tappet guide to mate with the stub/gear plate to stop any flex or vibration bolting it as a solid piece.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: vtsteam on August 02, 2014, 09:36:58 PM
Cool! I like the way you've done the cam gears.  :thumbup:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on August 03, 2014, 03:55:56 AM
Looking good Brian!  :thumbup:

Watching, quietly.....  :beer:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on August 03, 2014, 05:08:41 AM
Looking good Brian  :bow:

What CAD package are you using?  ('cos I like it  :wave:)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 03, 2014, 09:41:26 AM
Looking good Brian  :bow:

What CAD package are you using?  ('cos I like it  :wave:)
Solidworks
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 03, 2014, 01:40:45 PM
I gave up on the idea of having a steel backplate with welded in stubshafts. Last night I lay in bed thinking, and I had originally intended to solder the cams onto the face of the gears. This is always a somewhat "iffy" proposition, and as I have said all along, I want to be able to adjust the cam timing independent of the gear teeth. I decided I would be able to do that if I added a hub and set screws to one side of the gears and silver soldered the cams to the 3/8" shaft, while leaving the gears free to rotate into whatever position I wanted them to be in relation to the cam position, then lock them to the shaft with the set screws in the gear hub. This means of course, that the shafts must now be able to rotate. So---I changed the steel plate to an aluminum plate, with two 1" long oilite bronze bushings pressed into the thick part of the plate. The blue circles you see are the heads on the ends of the two cam shafts. They need shallow heads on them to keep then from trying to pull out of the bushings as they revolve. The other end of the camshafts which support the gears and the cams is still cantilevered, but it's only a 7/8" cantilever from the edge of the aluminum plate out to the centerline of the cams, so I don't anticipate any bending. The jockey gear is made from bronze and rotates on a 3/8" steel shoulder bolt which screws into the side of the crank case.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX_zpscfe28157.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX_zpscfe28157.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 03, 2014, 02:20:06 PM
We have to get a set of my favourite Chrysler product ignition points mounted somewhere, and since we are in the design phase, I might as well mount them on an adjustable plate so I can adjust the ignition timing while the engine is running. That is easy enough to do by extending the end of the outer crankshaft bushing and bumping up the extended diameter to 5/8". I can then clamp the ignition points mounting plate onto the head of the bushing.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX_zps7fcf2892.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX_zps7fcf2892.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: tom osselton on August 03, 2014, 03:34:58 PM
Shouldn't the points be on the cam you don't want them firing every revolution?
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on August 03, 2014, 03:58:20 PM
A timing chain and three sprockets would greatly simplify the gear set up
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 03, 2014, 06:09:43 PM
Shouldn't the points be on the cam you don't want them firing every revolution?
No, I quite often put the points on the crankshaft. You do get a "waste spark" but it does no harm, because the piston is at top dead center on the exhaust stroke, just getting ready to go down on intake stroke when this spark occurs. There is nothing in the cylinder to ignite.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 03, 2014, 06:13:49 PM
A timing chain and three sprockets would greatly simplify the gear set up

Andrew--We are talking some pretty miniature stuff here. The pitch diameter on the crankshaft gear is only 5/8"  (16mm). It's difficult to get roller chain that small, and then arrange for a take up system for when the chain stretches. I have seen no other engines in this size range with a roller chain drive.----Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on August 04, 2014, 02:34:27 AM
Perhaps a toothed timing belt then. They come pretty small
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 04, 2014, 12:42:00 PM
This is the point at which things begin to get a bit----goofy? The engine needs a flywheel. Past experience has proven to me beyond a doubt that the larger diameter a flywheel is, the better the engine will run and idle. Throttle response won't be as quick, because that's a lot of mass to move, but if fast throttle response isn't vitally important, then a large diameter flywheel is the way to go.
 The flywheel shown is 7" diameter, which is about 1" too much in my opinion, to keep the proportions reasonable.----So----Why make the flywheel so big?--Because a second factor I have proven to myself, is that without some kind of airflow over the fins, the engine will rapidly overheat. All you guys who build these small engines with a propeller, like for instance the Nemett series by Malcolm Stride will know how much the air from the prop will cool the engines. I don't like propellers.---Having once, in my jaded past, stuck a finger into a (thankfully small) propeller on a model gas airplane, I HATE propellers. So---What to do?--I need a flywheel anyways, it has to be made from steel (can't afford brass) and I can weld steel. ----By making the flywheel 1" larger in diameter, and drilling 5 holes through the web, I can then make up 5 blades of .125" thick steel and weld them into the holes at a 45 degree angle. This will create lots of air movement, yet the flywheel will have a smooth outer rim in case some poor fool like me inadvertantly touches it.  It will work. In fact, I think it will work very well. The only downside is that it makes the engine look "goofy".
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX-FLYWHEEL-1_zps07efdfc7.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX-FLYWHEEL-1_zps07efdfc7.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX-FLYWHEEL-2_zps8a129b7c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX-FLYWHEEL-2_zps8a129b7c.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/FLYWHEELWITHCOOLINGVANES_zps424716ec.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/FLYWHEELWITHCOOLINGVANES_zps424716ec.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 04, 2014, 01:12:33 PM
GOOFY???
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYDRAWING_zps612c3ed6.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYDRAWING_zps612c3ed6.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 04, 2014, 01:52:45 PM
This is a very good example of engine size comparisons. The engine on the left is patterned after the Nemett Jagauar, an engine having a 7/8" bore and a 3" diameter flywheel. The engine on the right is my new side valve engine with a 1" bore and a 7" diameter flywheel.  The basic engines are very close to the same size. The new engine with the large flywheel has to have the support angle feet extended a long ways so the bottom of the flywheel will clear the table. Of course, I had to add a belt driven fan to the Nemett engine to get it to run cool enough, so it was extra work to make the fan, fan housing, blade, shaft, bushings, etcetera. I like the proportions of the Nemett engine a lot better.--Decisions--decisions---
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/ENGINESIZECOMPARISON_zps4c6eb5e8.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/ENGINESIZECOMPARISON_zps4c6eb5e8.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: tom osselton on August 04, 2014, 03:46:11 PM
Somewhere on this site there is a pic of a flywheel offset and driven from a belt on the crank that would seperate the two making it look more pleasing.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 04, 2014, 04:59:51 PM
As I have said before, I plan on using "sealed" roller (not ball) bearings on both ends of the con rod and "sealed' ball bearings on the load bearing side of the crankshaft. That is why the crank is split into two halves. Since the bearings are filled with grease and "sealed" I shouldn't have to lubricate the rod nor the crankshaft bearings. The more I look at it, the uglier it gets with that big flywheel on it.--I'm not too concerned about the airflow---the airflow hitting against the side of the crankcase will be forced out to the sides and "up and over" the cooling fins. I think I will probably go with a 4" diameter flywheel and a separate fan setting above it. That simplifies the flywheel by an order of magnitude, and I can probably utilize the computer fan/propeller that I bought for the Jaguar and then didn't use, driving it with an o-ring drive belt.--That will also direct more of the air across the cylinder and head.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: vtsteam on August 04, 2014, 08:59:10 PM
Hmmm, I wouldn't want to get my finger caught in a flywheel either.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 04, 2014, 09:26:20 PM
I have a few minor logistics to figure out yet, but here is the engine with a 4" diameter flywheel and the 2 15/16" diameter computer fan I bought for a previous engine and then didn't use. As far as I'm concerned, this is a really big improvement over the 7" flywheel/fan.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYWITHFAN_zps9905dafe.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYWITHFAN_zps9905dafe.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 05, 2014, 11:03:18 AM
Okay Folks--It's opinion pole time!!! This morning as I was going through the model adding all of the bolt holes, I decided I didn't like those yellow angle end supports. A bit of quick modelling gave me the flat plate base as you see it here to support the engine instead of the angle plates.  Since the engine has a dry sump, I don't have to contain any oil in the crankcase. True, it exposes the spinning crankshaft and con rod, but any-one who sticks their finger in there would pretty well have to do it on purpose. I like this new base better. I want to know what you guys think. Do you like this plate base better or the yellow angles as in previous versions I have posted.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSYXX_zps5255c045.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSYXX_zps5255c045.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: philf on August 05, 2014, 11:18:47 AM
Brian,

This version looks much nicer.  :thumbup:

The base plate and the separate fan make all the difference.

Which version of Solidworks are you using?

Phil.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 05, 2014, 04:51:55 PM
philf---2012 basic
Title: Re: Side Valve i.c. engine from Bar stock
Post by: vtsteam on August 05, 2014, 05:00:48 PM
I like the base better, but personally tend to think enclosed engines look better -- admittedly less educational, though. A thin removable cover plate with small screws on the second version would be my preference.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 05, 2014, 05:02:21 PM
Okay--The plate gets it by a mile, from all 4 websites I post on.---A plate it will be!!!
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 06, 2014, 07:36:38 AM
For those of you who have been asking about how I will adjust the valve lash on this engine----This is it. The "tappets" will be of 3 piece construction, having an internally tapped bottom that will ride on the cam, an externally threaded top section which rides against the end of the valve, and a lock nut.  The bottom section of the tappet is 5/16" diameter, and is hardened "01" steel. the top portion will also be hardened "01" steel. The internal thread is a #10-24. I left the cylinder head off in this model so you can see that I plan on using pressed in valve cages.----Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSY-VALVELASHADJUSTERS_zpsf3f0674d.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSY-VALVELASHADJUSTERS_zpsf3f0674d.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 06, 2014, 08:49:44 AM
Well Sir!! I think that just about covers it!!! Oh, I've got to so something about a place for my started spud so I can use my variable speed drill as a starter, and probably add a few keyways and bolt holes, but I think the overall design is 99% done. everything on there I have built before on my previous 7 i.c. engines, except for perhaps the adjustable tappets----and that doesn't look like brain surgery. I think this will be a really neat project for a new engine this fall, and as usual I will be posting the engineering drawings fro anyone who wants to join in the fun. I guess my next step will be to make a list of all the bushings and bearings and go have a chat with my bearing supplier.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 06, 2014, 08:52:20 PM
I am going to "borrow" the crankshaft design from Malcolm  Stride's "Lynx" engine. The crankshaft will be made up from individual components which will be silver soldered together. However it will remain as two totally separate assemblies. The 1/2" shaft with keyway, the counterweight/web and the 1/2" diameter rod journal will be one assembly. The other end of the crankshaft will be 3/8" diameter and consist of only the shaft and the counterweight/web. This second counterweight/web will have a 1/2" hole reamed through it, which the rod journal will pass completely through, ending flush with the other side of the counterweight/web. The rod journal will be made from "01" water hardening steel, which will be quenched immediately after silver soldering to harden it. Both ends of the full crankshaft will be supported by two bearings, to prevent any potential misalignment. (The crankcase and outboard bearing support will be assembled, doweled, and all bored in one set-up.) This arrangement will allow me to use a sealed roller bearing on the big end of the con-rod. The width between the counterweight/webs when all is assembled is sufficient to allow a .015" thick spacer washer on each side of the con rod bearing.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/TWOPIECECRANKSHAFT_zps69ed4325.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/TWOPIECECRANKSHAFT_zps69ed4325.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 08, 2014, 12:16:34 PM
This morning I got bored!! Daughter is getting married next week---whole week will be crazy. Customer is squealing like a pig wanting me to come over to his factory and do some design on a new machine, but I can't because I'm waiting for a courier to bring me a new Solidworks disc. A friend wants me to machine some mounts for his new fishing downrigger but I'n waiting on material.---And yesterday I just bought a second house!!!--However, being stuck between all things and unable to do any of them, I decided to machine something this morning.----So---I rooted around in my scrap bin and found a piece of aluminum big enough to make the spacer bar that fits between the backplate and the crankase on my fall project engine.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SPACERBAR002_zps6e014bd7.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SPACERBAR002_zps6e014bd7.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 08, 2014, 12:25:19 PM
Sent out a list of bearings and bushings for the new engine to my bearing supplier.--Wouldn't you know it----Their system is down!!---I may just go upstairs and drink wine for the rest of the day!!!

REQUEST FOR PRICE AND DELIVERY
ONE—SEALED NEEDLE ROLLER BEARING .25” I.D. X 0.478” O.D. X 0.375” LONG #SCE46PP  INA
ONE--- SEALED NEEDLE ROLLER BEARING .375” I.D. X 0.563” O.D. X 0.5” LONG #SCE68PP   INA
TWO SEALED BALL BEARINGS  ½” I.D. X 1.125” O.D. X 0.5” LONG #R1616-2RS    RBI
ONE OILITE BRZ. BUSHING 3/8” I.D. X ½” O.D. X 1/2” LONG
ONE OILITE BRONZE BUSHING  3/8” I.D. X 5/8” O.D. X Ύ” LONG
TWO—OILITE BRONZE BUSHINGS 3/8” I.D. X ½” O.D. X 1” LONG
Title: Re: Side Valve i.c. engine from Bar stock
Post by: PekkaNF on August 08, 2014, 12:54:27 PM
Sent out a list of bearings and bushings for the new engine to my bearing supplier.--Wouldn't you know it----Their system is down!!---I may just go upstairs and drink wine for the rest of the day!!!

Bit like my day at the office. We need 6-7 systems to do the work. Each of them is can of worms, inherited, outsourced, offshored....uptime something like 90% - EACH. Meaning all is up and running about 50% of workday. MAX. Unless someone on HR ot IT has revoked all priviledges. And by 10:00 we had fire alarm and everyone had to leave the building. Half an hour later burnt light on the storage was found. Rest of the day went downhill....

Pekka
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 08, 2014, 01:19:25 PM
Damn!!!---And I mean that with all my heart!!! Three weeks ago I called Canadian Bearings and inquired about the sealed needle bearings, their sizes, and the fact that they could be sealed. Got the green light on everything, so went ahead and designed the engine based on that info. Today I sent out a request for quote for all bearings bushings, etcetera on the engine to Canadian Bearings. Just got an answer back----The 1/4" needle bearings I planned on using for the wrist pin  (gudgeon pin) are not available anywhere in North America. The 3/8" needle bearings for the big end are available, but they are no longer selling them as "sealed" bearings. This doesn't totally beat me, because I can still go to a 3/8" needle bearing at the wrist pin--(I do have sufficient room). The only pain in the arse is that now the rod bearings will have to be manually oiled. Oh well, none of this is a deal breaker, but it sure annoys me!!! (All the bearings and bushings including taxes came to about $40 Canadian, including taxes.)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 08, 2014, 06:39:10 PM
So here we have a pair of gears being born!! I had a 7" length of 1144 stress proof steel x 1 3/8" diameter left over from making the crankshaft for the Jaguar/Canadian Cub, and the o.d. of the timing gears for my side valve engine is 1.33 major diameter. I cut the 7" length in half, turned the short end to 5/8" diameter, turned the o.d. to 1.33" diameter, and drilled and reamed the 3/8" bore 2" deep all in one set-up. I then reversed the part in the 3 jaw chuck and turned the other end to 5/8" diameter. Next step will be to set it up in the chuck on my rotary table and make one long gear, then saw it in half in the bandsaw and turn the face of each remaining gear half to the correct length, then cut off the long hub to leave a .343 long hub. Then I will add the set screw holes.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/timinggears-1001_zps88138f84.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/timinggears-1001_zps88138f84.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 10, 2014, 09:06:19 AM
I got thinking about how I was going to loosen off the gears on the cam-shafts to adjust the cams, and realized that there would be no portion of the shaft (which has the cam fixed to the end of it) available to grab hold of and turn. So---I extended the shafts to extend through the backplate 3/8", and made up a couple of knurled caps to fit over the ends of the shaft and bolt on with a #8 shcs. This will act as a retainer washer to keep the shaft and cam from sliding out of the bushing, and will give me something I can grip to turn the cam and shaft manually when the set screws holding the gear are loosened off. There is no danger of getting my finger sucked down between the knurled rollers, because they both turn the same direction---they don't roll in towards each other.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CAMADJUSTMENT_zps099a54d5.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CAMADJUSTMENT_zps099a54d5.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 10, 2014, 02:31:17 PM
Last night I lay in bed thinking about the crankcase for this engine. It looks kinda neat with that rectangular hole all the way through it.--But I am beginning to think that perhaps it doesn't need that big rectangular hole through it. That big rectangular hole, which would be a bit of a pig to machine, doesn't serve any real purpose that I can see. (except to give access for oiling the big end of the rod with a squirt can)The crankshaft is two piece, and can be inserted through the big round hole in the side for the bearing housing.(I designed the hole to be 0.030" greater in diameter than the largest diameter on the crankshaft.) So, for assembly, the driven side of the crankshaft that eventually has the cam gear mounted on it would be inserted first. Then the con-rod (with piston attached) would have the big end lowered down through the hole in the top of the crankcase, then the main (dark blue) section of crankshaft would be inserted,with the rod journal going through the rod big end bearing and passing on through the reamed hole in the web of the first piece of crankcase--(that hole is just a sliding fit, not an interference fit). Then the bearing housing and bearings would be slid on over the end of the dark blue crankshaft and bolted up to the side of the crankcase. Of course all of this depends on whether or not I can find a sealed needle bearing or not.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKCASEFORSIDEVALVEENGINE_zpsf3370390.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKCASEFORSIDEVALVEENGINE_zpsf3370390.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 11, 2014, 07:48:48 AM
Unless somebody can convince me otherwise, I am going to build the crankcase as shown, with no rectangular hole running through it. The hole does nothing in terms of running the engine, and the crankcase becomes so incredibly much easier to machine, since all of the material from inside the crankcase can be removed with a boring tool in the lathe, using the 4 jaw chuck. I am still chasing down "sealed fro life needle roller bearings", but even if I can't find them and have to run an oil sump, this should still work.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSY-SOLIDCRANKCASE_zps6a902fe8.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSY-SOLIDCRANKCASE_zps6a902fe8.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: DMIOM on August 11, 2014, 11:21:46 AM
Brian,

You may not be getting much feedback but I'm sure there are many like me who, whilst never likely to build an engine, are enjoying watching the evolutionary process and appreciating the design skills.

Dave
Title: Re: Side Valve i.c. engine from Bar stock
Post by: philf on August 11, 2014, 12:21:39 PM
Brian,
You may not be getting much feedback but I'm sure there are many like me who, whilst never likely to build an engine, are enjoying watching the evolutionary process and appreciating the design skills.
Dave

Brian,

I second Dave's comment.

Keep the posts coming.

Phil.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 11, 2014, 12:34:43 PM
I went back to Canadian Bearings today and chewed on the salesman for a while about these damned sealed needle bearings. Now it seems that I can get a 1/4" sealed needle bearing x 7/16" long. This will work fine for the wrist pin, because my piston is 1" diameter. I had previously asked for a 3/8" long bearing, and it is NOT available. The 3/8" needle bearing for the con rod big end is only available in an unsealed version, but I can probably find a work-around for that.---One word about needle roller bearings---When I built my Kerzel hit and miss engine, I put a set of needle roller bearings on the crankshaft to make it spin easier. It worked, but they are very noisy little devils. I didn't pack them with grease, just oiled them which may have been a mistake. What I am thinking now is that if I go to the solid crankcase without the rectangular hole all the way through it, the engine might be a lot quieter, in terns of bearing noise.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on August 11, 2014, 12:42:54 PM
What I am thinking now is that if I go to the solid crankcase without the rectangular hole all the way through it, the engine might be a lot quieter, in terns of bearing noise.

It'll still be just as noisy - only you won't hear it   :nrocks:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 11, 2014, 03:43:00 PM
My small mill did not enjoy cutting this 1144 stress proof at all -at all.  This stuff cuts much harder than mild steel or brass. Poor mill was shaking and quivering, and I could tell that I was hurting it. I did cut all the way round, and I did get the right number of teeth, but I think all the shaking and shuddering may have thrown the 3 jaw chuck out of center, as the teeth on one side are deeper than the other, and the tooth form is off. I will center up the 3 jaw on the rotary table and see if I can re-cut this gear and save it. So---A lesson learned here. If you have a small mill and not a full size Bridgeport or equal, you probably shouldn't use 1144 stress proof for gears.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/camgearsfirstcut003_zps72cf5000.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/camgearsfirstcut003_zps72cf5000.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/camgearsfirstcut005_zpsce637f12.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/camgearsfirstcut005_zpsce637f12.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 11, 2014, 07:21:51 PM
It seems the day is saved!!! I tore everything down re-centered the chuck on the rotary table (it was about .008" total runout), then set everything up again, eyeballed to make sure I was cutting in a space, not on a tooth, and went around again--all 30 spaces. Gear now looks good, all teeth are the same height and same shape. I will know better when I get all the gears made and mounted, but I think it's going to be okay.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/camgearxxx001_zps83b2adaa.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/camgearxxx001_zps83b2adaa.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on August 12, 2014, 02:12:20 AM
It seems the day is saved!!! Gear now looks good, all teeth are the same height and same shape. I will know better when I get all the gears made and mounted, but I think it's going to be okay.

It's a good feeling. When a wonky component can be easily salvaged.  (http://freesmileyface.net/smiley/respect/woohoo-022.gif) (http://freesmileyface.net/free-respect-smileys.html)

Especially, when only you know.......  :thumbup:

David D

Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 12, 2014, 08:47:10 AM
David--That's why I keep all my failures a secret and never let anyone know about them :doh: :doh:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 12, 2014, 01:49:14 PM
Old age and treachery triumph once again!!! The gear has now been split and finished and mounted on two 3/8" diameter dowels mounted in two reamed holes exactly 1.25" apart (The pitch diameter of the gears)---They mesh perfectly. Hurray for my side!!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CAMGEARTSMESHING-2001_zpse4ddb737.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CAMGEARTSMESHING-2001_zpse4ddb737.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 12, 2014, 05:23:21 PM
This afternoon I cut the 15 tooth crankshaft gear from 3/4" diameter cold rolled steel. The mill liked that!! No quivering and shuddering like when I cut the stress proof 1144. I found a left over piece of grey cast iron and bored it 3/8" through, then press fitted and Loctited  a cold rolled steel arbor tuned to 0.376" diameter into it. It can set in the lathe until tomorrow sometime when I find the time to turn it down to 0.708" diameter, and then I will cut teeth into it on the mill. The crankshaft gear is steel, and will be pinned to the crankshaft with a 0.093" diameter hardened steel pin. The cast iron jockey gear will ride on a 3/8" diameter shoulder bolt.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTGEARFINISHED002_zpscc1bf6d6.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTGEARFINISHED002_zpscc1bf6d6.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTGEARFINISHED001_zps3dfb8b2a.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTGEARFINISHED001_zps3dfb8b2a.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 17, 2014, 12:21:18 PM
Here is a post from yesterday morning, when I was in Hamilton, Ontario. I couldn't get on the forum from there, as I couldn't remember my password---
So---No machining lately. I started a new contract for an old customer this week, and it's one of those deals where I have to be "On site" to do it. It's kind of fun to go back to work for a while, but it doesn't leave me much energy at the end of the day for machining in my own home shop. My life has been exciting lately, and not in a particularly good way. After setting in the old computer chair at my customers for two days, my back has "gone out" and so I'm living in 4 hour stretches, from pain pill to pain pill. I have had an allergic reaction to a steroid nasal spray, and have tonsilitis as a result. Life sucks when ya get old!!! I m setting on a computer in the Comfort Inn in Hamilton this morning, waiting to walk my daughter down the aisle at one o'clock today at her wedding. Then a reception tonight, where I will have to be cheerful and happy and dance with my dear wife, while secretly hurting like heck and grumpier than a bear with a sore a$$ !!! Ah well, enough whining for now. I am getting really excited about this new engine, and even though the project is slated as "A new engine for fall", fall is fast approaching. I ordered all of the bearings last week, and also purchased all of the aluminum bar stock I will use, along with the cold rolled steel flatbar for the crankshaft webs. I took my gigantic lump of bronze over to the place I buy my aluminum and they are going to saw of a couple of slices for me, one to make a flywheel from and a thinner one to cut "odds and sods" from for accent pieces on the rest of the engine. My 3D cad models are 99% finished, and also most of the mechanical detail drawings. I see someone else standing around the lobby watching me, so they probably want to use this computer. So---wish me luck guys. I will post more when this grand event is over and life returns to normal.----Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 17, 2014, 12:27:28 PM
Back home today. Wedding went off without a hitch. The bride was beautiful and I have gained a handsome young son in law. I am looking forward to sleeping in my own bed tonight. The older I get, the less I sleep in Hotel rooms. I am going to get back to the engine this week and get the jockey gear cut. Once all of the gears are finished I will decide what to make next.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on August 17, 2014, 02:04:30 PM
Brian,

I empathise greatly with your back 'going out' when away. I well remember once incident when I was doing some consultancy work in Poland. I woke up in the morning with what turned out to be a slipped disk. I couldn't move - couldn't get my socks on - and I had to catch the only flight out of Wroclaw that day  :bugeye:

Ended up rolling all over the floor making all sorts of contortions rather than ask a maid to put my socks on in a language I only knew a couple of words of  :lol:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 17, 2014, 02:20:01 PM
Awemawson--When rolling around on the floor in a foreign country, you have to be VERY careful of what you ask the maid to do!!!---It might be something other than what you expected---Thankfully my back isn't feeling quite as "ouchy" today. I have taken my $500 ergonomic chair and my heating pad strapped to the back over to my customers office. This isn't quite as weird as it sounds, since it's a very small company and I am the only design engineer there. I may look a bit foolish, bet there aren't many people to see it, and I would gladly suffer looking foolish if it makes my back stop hurting.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on August 17, 2014, 02:46:40 PM
I suffered for a long time, and eventually was persuaded by the wife of a friend to have the operation. Made a huge difference and now just get the odd twinge. That was perhaps 10 years ago now. Poor old surgeon has popped his clogs so no going back!
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 18, 2014, 07:31:04 PM
This new contract I'm working at has cut deeply into the time I have for working on this engine. However, I think about it as I lay waiting for sleep at night. On previous engines I have built, the spur gears which run the camshaft are quite noticeably noisy when running with the gear case removed. I'm not concerned with the danger of getting my fingers caught in the gear teeth (I've learned not to stick my fingers into gears---don't ask how). However, with only a minor change to the backplate, I can machine a filler piece to fit into the gap between the backplate and the crankcase which can be easily removed for adjusting the valve timing, but can be easily reinstalled to keep the noise of the gears down to acceptable levels and to retain a bit of grease. I have shown it in the assembly, and pulled out to one side by itself to show what it looks like.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVEASSY-SOLIDCRANKCASE-ENCLOSEDGEARS_zps52535ff2.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVEASSY-SOLIDCRANKCASE-ENCLOSEDGEARS_zps52535ff2.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 20, 2014, 06:30:54 PM
Today was bearing day. All of the bearings I had ordered for my side valve engine came today---with a surprise!!! The bearings in the foreground are two 1/2" sealed ball bearings for the main crankshaft side, the needle bearings for both ends of the con rod, two oilite bronze bushings 3/8" i.d. x 1" long for the camshafts, and  one 3/8" i.d. oilite bushing x 1/2" long and one 3/8" i.d. x 5/8"  for the follower half of the crankshaft. So----what are all those bushings in the background?? Well, what I didn't know was that Canadian Bearings have changed their policy and many of these bushings are available in minimum lots of 5 or 10 pieces!!!  I didn't squeal too loudly, because everything only cost a total of $45.32, and there are probably enough left over bushings to last me for the rest of my life!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/BEARINGSFORSIDEVALVEENGINE001_zpsaa9c1a6d.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/BEARINGSFORSIDEVALVEENGINE001_zpsaa9c1a6d.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 21, 2014, 07:18:28 PM
Tonight I finished the last gear for this engine. It is the jockey gear, the one which fits between the crankshaft gear and the two large camshaft gears. The two large camshaft gears do not mesh with each other, only with the jockey gear. The jockey gear is not driven by a shaft, but sets free to rotate on a 3/8" diameter shoulder bolt. I chose to make it from cast iron, as that will have self lubricating capabilities, and I have read that cast iron spur gears running on steel gears are quieter than steel gears running on each other. I'm not sure if that is true, but if it is, that will be a bonus. The gentleman who supplied the aluminum material for this job is supposed to be finished slicing off two lengths of bronze from my 50 pound bronze weight tomorrow---a thick one for the flywheel, and a thinner one to make various trim pieces from (I'm thinking the tappet guide bar, at least.) I have not torn down my rotary table set-up in the mill yet, as I want to put in a piece of plain mild steel and cut a gear tooth in it with my #4 cutter.---That's the one that gave me so much trouble cutting the 1144 stress proof material for the cam gears.  If the cutter is dull or damaged, I would rather know now so I can order a replacement, rather than find out the cutter is bad the next time I go to use it.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/GEARSFINISHED002_zps9734b867.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/GEARSFINISHED002_zps9734b867.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: tom osselton on August 21, 2014, 10:34:36 PM
nice looking gears.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 22, 2014, 02:43:28 PM
So here we have it, gentlemen- The material (or at least most of it) for my new engine. The thick slab of bronze is destined to become a flywheel. The thin piece will become trim pieces such as the tappet guide. The steel flatbar in two different thicknesses will become crankshaft webs. the large aluminum block will become the crankcase, the two smaller blocks will become combustion chamber immediately below the cylinder head and the backplate. I have enough round steel stock on hand to make the crankshaft from. I have yet to purchase the cast iron for the cylinder and the piece of aluminum which will become the baseplate. My supplier with the giant size self feeding bandsaw charges me $10 per slice through the bronze, so I think the total price came to around $35.00 for material.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/MATERIAL001_zps555d52ac.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/MATERIAL001_zps555d52ac.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 22, 2014, 03:42:37 PM
Mystery Solved----Kind of---I chucked up a piece of cold rolled round stock in my rotary table/3 jaw chuck, put the #4 gearcutter back in the mill, and took a full depth 0.090" cut. The gearcutter was shrieking at a "normal" speed for this kind of work, and I was again getting sparks off the cutter. ---And that was WITH cutting oil.  A close examination of the cut cold rolled shows material being "extruded" around the sides and end of the cutter path. I have concluded that the gear cutter was duller than a hoe!!! It probably wasn't the fault of the 1144 stress proof material after all. Some ham-handed bugger who uses my mill MAY have run the cutter up against a hardened jaw on the 3 jaw chuck the last time the cutter was used and put away. I don't recall doing it, but I am the only person who ever works in my little home machine shop. Anyways, a quick phone call to Travers in South Carolina, and I am $60 poorer and a new cutter is coming UPS.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/DULLCUTTER002_zps0a6ec509.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/DULLCUTTER002_zps0a6ec509.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 23, 2014, 09:26:11 AM
One burning question remained--On the cast iron cylinder, due to very close clearances and constraints, I ended up with a #5-40 tapped hole 0.079" off the side of the cast iron part. I wasn't sure if I could do that or not without the thread breaking out thru the face. This set-up answers my question, and it's an answer I didn't want to hear. There is still enough thread in the cast iron to hold sufficiently, but it looks crappy. My next stunt will be to drill and tap the hole .188 back from the edge, and then machine material away until I have my .079" edge to center distance and see what that looks like.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/TAPPEDHOLENEAREDGE001_zps78f1f3f4.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/TAPPEDHOLENEAREDGE001_zps78f1f3f4.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 23, 2014, 09:42:18 AM
And the short answer is---that doesn't work either!! The thread still breaks thru. This is going to call for a small design change on the affected drawings :doh: :doh:.--Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/threadatedge-2001_zpsfc45450b.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/threadatedge-2001_zpsfc45450b.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 23, 2014, 09:57:45 AM
Okay!!! At 0.095" edge distance, we are golden!!! No break out of the threads thru the side at that edge distance. I will write that on my wall of "things to remember" and make the slight design change to my drawings.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/095edgedistance001_zps327382d0.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/095edgedistance001_zps327382d0.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 24, 2014, 05:32:16 PM
And so it begins---Once I had the outsides of the block milled to size, I set it up in the 4 jaw chuck and drilled a hole all the way through, and reamed it to 7/16" diameter. I then proceeded to use a series of drills to go part way through the block, until I topped out a at my 1" Silver and Demmings drill. Then it was boring to the proper depth and diameter. That finished hole that goes all the way thru will eventually be reamed to 0.5" for a bushing, but since I want to "align-bore" all of the plates together to get the bores all in exact alignment, that 7/16" reamed hole will act as a set-up hole when I get to that point.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANK-CASEBORE001_zps6dbd22b7.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANK-CASEBORE001_zps6dbd22b7.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 25, 2014, 05:37:14 PM
I just about got caught!!! I finished up the two main bores in the crankcase, and just as I was finishing the hole thru the top for the con rod and cylinder base, I began wondering if I had checked for side clearance on the rod where it comes thru the hole in the top of the crankcase. I opened up the 3D cad model to take a look, and it's a good thing I did. What I had forgotten was that the big end of the con rod actually extends beyond the crankshaft web/counterweight, and there would have been a big time interference. I had to set the crank case back up in the 4 jaw (I hate that) and relieve a center path all around to clear the con rod big end. I took a couple of pictures while things were still set up to try and show the additional path I had to create. The original bore I had put in would have cleared the crankshaft web/counterweights with .030" radial clearance, but not the con rod big end.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COUNTERBORETOCLEARRODBIGEND005_zpsfd7cd510.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COUNTERBORETOCLEARRODBIGEND005_zpsfd7cd510.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COUNTERBORETOCLEARRODBIGEND001_zpsc5e447f0.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COUNTERBORETOCLEARRODBIGEND001_zpsc5e447f0.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/BIGENDINTERFERANCE_zps1064b691.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/BIGENDINTERFERANCE_zps1064b691.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on August 25, 2014, 05:43:45 PM
Brian.
It's good to have afterthoughts. Before it's too late......  :palm:

Well spotted!  :thumbup:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 25, 2014, 07:12:02 PM
David--I will post a download to all of the drawings for this engine as .pdf files for  those who would like to build it. I used to post the drawings as I was building the parts, but experience has shown me that I "tweak" the drawings so much as I go along to show what actually is made in metal, that I would have to repost the same drawing 3 or even 4 times. This drives everyone a bit mad, and there is too much chance of people not saving the newest "revision" and making bad parts. I am always thrilled when people build one of my engines, but it is a much safer thing to wait until I have a running engine with all of the drawings up to date before I post the link.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 26, 2014, 05:08:25 PM
Well, if you squint your eyes real hard, and look at it just the right way, it's beginning to look like an engine.At least all the big parts bolt together.---That's a good start.!!!---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/ENGINE-FIRSTASSEMBLY001_zps94c8e562.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/ENGINE-FIRSTASSEMBLY001_zps94c8e562.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/ENGINE-FIRSTASSEMBLY002_zpscf33966c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/ENGINE-FIRSTASSEMBLY002_zpscf33966c.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 27, 2014, 11:53:58 AM
Things are going together remarkably well, so far. I had a bit of problem with gear mesh between the crank gear and the jockey gear, but I am sure its something that a bit of a run in with carborundum paste will fix quickly.Probably the next thing I build will be the large bearing support which registers and bolts to the large hole in the side of the crank case.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/ENGINEASSEMBLY-2001_zps291a5fe5.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/ENGINEASSEMBLY-2001_zps291a5fe5.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/ENGINEASSEMBLY-2003_zpsa843ab1d.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/ENGINEASSEMBLY-2003_zpsa843ab1d.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 27, 2014, 06:29:46 PM
So---what do you do with sticky gears??---Well, if you live at my house you find a way to "unsticky" them. There are a host of different reasons that gear trains can be sticky---some can be fixed without setting the gears back up in the rotary table/mill and recutting them, and some can't. If the shaft centers for the shafts supporting the gears are not drilled the correct distance apart, well, you're toast. Nothing can fix that except maybe, if you are very very lucky you can SOMETIMES take a very small cut off the o.d. of the gears, to prevent the tip of the tooth on one gear from bottoming out on the root of the other gear, if the holes are drilled a few thou too close together. If the holes are too far apart, the gears will work, but will be noisy. If ya don't believe me, you can ask Chuck Fellows about that one. Sometimes gears are sticky even when the shaft centers are drilled "Right on". That can be put down to the tooth form being off a little bit, or a bit of spring in the arbor when the gears are being cut. Sometimes it seems to be just plain orneryness (if that's a word). About half the time, the gears I cut run together perfectly. The other half the time---well---If I can get the gears to turn at all (meaning they aren't locked up solid with each other). I cover the faces with a bit of 300 to 400 grit carborundum paste and put some power to them. Not for long, and not too fast, because that stuff cuts fast, and we don't want gears with pointy teeth!!! I recommend a rotating speed of about 300 rpm, and a time of about 15 minutes. If they aren't "unstickied" by then, run them in reverse for the same amount of time. The carborundum paste works very well, and once you can turn the gears freely by hand, take everything apart and wash everything really well with Varsol or a similar solvent. If you are still not 100% happy with the way they mesh, then cover everything with a good slather of grease, set them up with a power source, and let them run for an hour or two. The set-up in my attached picture shows the engine I am building with all 4 gears in place, covered with grease, and running in my milling machine. They turn very freely now, and should give trouble free service when I get the engine finished. The crankshaft gear is cut from cold rolled steel, the jockey gear is cut from cast iron, and the two large gears for the cams are cut from 1144 stress proof material. As I said in an earlier post, spur gears can be very noisy when running on a small engine with no gear cover. The gear cover serves two functions, one being to keep a good supply of grease around the gears, and another equally important reason is to keep the sound of the gears meshing contained.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/RUNNINGINGEARS001_zps13e08e47.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/RUNNINGINGEARS001_zps13e08e47.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on August 28, 2014, 03:19:26 AM
Back when I was cutting gears with involute gear cutters (rather than hobs) the usual reason for them not running correctly was not getting the cutter bang on the centre height of the blank. You could cut a pair of identical gears that would mesh beautifully, but if you flipped one gear over and tried, they'd bind.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 28, 2014, 07:19:03 AM
Today I'm going to start out making this part. If all goes well, I may even get to the base plate.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/5DIABEARINGSLEEVE--_zps7211eb5e.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/5DIABEARINGSLEEVE--_zps7211eb5e.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 28, 2014, 09:05:22 AM
After initially turning one end of the 2 1/2" diameter aluminum to size, I tried to cut the 6" length down in my little 14" bandsaw, but it kept grabbing and wanting to rotate in my hands. So---I walked it out to the main garage, where I keep my old monster power hacksaw that I built almost 40 years ago. It is self feeding and will saw anything up to a 5" diameter billet. It seldom gets used anymore, but on a job like this it earns it's keep!!!

(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/MONSTERSAW001_zpsd51e8350.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/MONSTERSAW001_zpsd51e8350.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 28, 2014, 11:31:43 AM
Well, that's my good (machining) deed for this morning. Now on to more mundane things like mowing the lawn. We've had so much rain this summer the damn lawn is growing like it was still June!!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/BALLBEARINGHOUSING002_zpsdebea8d0.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/BALLBEARINGHOUSING002_zpsdebea8d0.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 28, 2014, 05:36:56 PM
And yes, I do occasionally resort to "crude lashups"----Especially when my main Kurt clone vice lacks just that tiny little bit of opening wide enough to hold the part I want to work on. Why all the layout dye?---I just felt like painting for a change!!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/enginewithbase001_zpsdc4e1d60.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/enginewithbase001_zpsdc4e1d60.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 28, 2014, 06:21:11 PM
And here we have it with the "poll approved' baseplate. In the rear view you can see the two 3/16" diameter alignment pins which fit into holes reamed thru all 3 pieces which bolt together to maintain alignment. You can also see the rear crankshaft bushing which extends 3/8" out past the backplate for my ignition point mounting plate to register on, to give me variable timing while the engine is running. The 3/8" shaft setting in the bushing is just a long piece of 3/8" rod used for a temporary alignment rod for the bushings.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/enginewithbase003_zps9e624500.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/enginewithbase003_zps9e624500.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/enginewithbase004_zps7bd16f8c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/enginewithbase004_zps7bd16f8c.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 29, 2014, 07:29:20 PM
So far, on this build, I have been making great speed machining the comparatively "easy" parts. I consider the hardest parts will probably be the cylinder and the combustion chamber, so I'm shying away from them so far. I guess that before I go much farther, I better have a crankshaft. It is a two piece crankshaft, which I haven't made before, with a primary half and a follower half. The fact that it is two piece lets me run a con rod with a needle bearing in the big end, which is not split.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTFORSIDEVALVEENGINE_zpsdf4ab47c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTFORSIDEVALVEENGINE_zpsdf4ab47c.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFT-FOLLOWERHALF-SIDEVALVE_zps70f6f595.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFT-FOLLOWERHALF-SIDEVALVE_zps70f6f595.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 30, 2014, 06:07:53 PM
Nothing of real importance machined in the last two days. I moved my son and his family from a rented townhouse into the house I bought two weeks ago. My Gawd!!! I never realized you could collect so much junk after living in a townhouse for ten years. He only had to move about 1/4 mile, so I moved him with my little Ford Ranger, and he had a friend to help with the heavy lifting. I think it took about 16 trips, but we got everything moved between 8 in the morning and four in the afternoon, except the barbecue, which we forgot. Went back and got it this morning. The new house currently looks like a disaster area, but him and his wife can sort that out this week coming. The kids will be able to start in their new schools on Tuesday. I had good intentions of starting work on the crankshaft, but this afternoon I'm too pooped to participate.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: tom osselton on August 30, 2014, 08:29:11 PM
I hear you! I bought my house in 82 so my butt is staying where it is  I've acumulated too much stuff mind you the basement shop is nice the double car garage is full!   :doh:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 07:27:16 AM
This type of crankshaft, where only one half bears the load from the connecting rod, and the other half simply follows the arc of the first half to drive the ignition points is something entirely new to me. I think that as suggested, the entire crankshaft will be press fit together with no pins or welds. I have found by experimentation that a .002" interference gives a really hard press fit, as hard a fit as I am capable of achieving with my equipment. The only "slip fit" will be where the con rod journal enters the web of the "follower half" of the crankshaft. The con rod journal itself will be hardened to 50-55 Rockwell c so the con rod needle bearings running directly on it will not chew up the surface. In order to get the holes in exactly the same locations in both crankshaft webs, I plan on mig welding the two bars from which the webs will be cut together, then drilling and reaming the holes with undersize reamers while they are clamped to the milling machine table with toe clamps (with a 1/2" piece of sacrificial aluminum between them and the mill table) to ensure that the axis of the holes are 100% square to the face of the bars. I don't trust my vice for this rather critical operation. I will have the thinner of the two bars, which forms the web of the follower crankshaft on top of the stack, so that I can run the undersize rod journal reamer thru both bars, then without changing my set-up run the clearance reamer thru the topmost bar only.--(Picture to follow). I think that in order to ensure that the pushed in shaft sets square to the plates, I will push the shafts thru the flatbar about 1/2", then trim the excess shaft sticking out the far side with my lathe.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 07:37:14 AM
I seem to get more reactions to my posts when I post the actual in progress drawings of the pieces I am making even though these drawings may change somewhat as the pieces are actually made. For that reason I am going to post the drawings marked as "preliminary" purely for interest sake for the remainder of this project. I do not recommend that anyone save these drawings, but instead wait until the end of the project when I will post a download link to all of the corrected drawings.--I will begin by posting drawings of the parts which have already been made.-Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKCASE-SOLIDFORSIDEVALVEENGINE_zpse9ba46c6.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKCASE-SOLIDFORSIDEVALVEENGINE_zpse9ba46c6.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/BASEPLATE-SIDEVALVEENGINE_zps73482a0f.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/BASEPLATE-SIDEVALVEENGINE_zps73482a0f.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/BRZBUSHING_zps51b14778.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/BRZBUSHING_zps51b14778.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 07:39:53 AM
The gears---
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/RushGears_2010_1036-6985_zps07720499.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/RushGears_2010_1036-6985_zps07720499.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/RushGears_2010_1036-7235-20-jan-2013_zps06b38c77.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/RushGears_2010_1036-7235-20-jan-2013_zps06b38c77.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 08:11:46 AM
Here you can see my crankshaft web layout on one of the cold rolled steel bars. (There is one extra arc on there that shouldn't be---I had the compass set wrong) I won't be machining from that layout. It is only a visual reference. I will use the edge finder and the dials on the mill table to locate and drill/ream all the holes. You can also see a short bit of mig weld holding the two bars together. There is another weld the same size on the far side. I will drill both bars at the same time, then separate them and trim them, then press them onto their respective shafts and finish the o.d. in the lathe. It will be an interrupted cut, but i don't see any good way to avoid that.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTWEBS003_zpsa481702c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTWEBS003_zpsa481702c.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTWEBS004_zps118423b4.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTWEBS004_zps118423b4.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 12:26:48 PM
I found a mistake in the reamed hole size in the "crankshaft for side valve engine" and I have corrected it, but there doesn't seem to be any way to modify my previous post on this forum, so here is the same post with the error corrected.
So far, on this build, I have been making great speed machining the comparatively "easy" parts. I consider the hardest parts will probably be the cylinder and the combustion chamber, so I'm shying away from them so far. I guess that before I go much farther, I better have a crankshaft. It is a two piece crankshaft, which I haven't made before, with a primary half and a follower half. The fact that it is two piece lets me run a con rod with a needle bearing in the big end, which is not split.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTFORSIDEVALVEENGINE_zps710fa173.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTFORSIDEVALVEENGINE_zps710fa173.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFT-FOLLOWERHALF-SIDEVALVE_zps70f6f595.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFT-FOLLOWERHALF-SIDEVALVE_zps70f6f595.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 02:46:45 PM
Hmmmmmmm---The best laid plans of mice and men----I reamed the holes in my web plates with my 0.4985"  reamer. I then went to press the 5.0005 drill rod into place. It was su7pposed to be a .002" interference fit. It didn't exactly fall through, but it sure as heck didn't press. So much for my "all press fitted" crankshaft. That will now be amended to "My silver soldered crankshaft!!!"
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 06:11:56 PM
Just as I was all set up to start silver soldering, my wife called about some emergency connected with the new house. Seems that 3 year old grandson had managed to lock and close a bunch of doors that there were apparently no keys to unlock!!!--After dashing across town and applying my dormant burglary skills (which mostly involved beating on the locksets with my 3 pound hammer till the guts all fell out of the locksets) I got to thinking-----I really didn't want to solder the crankshaft. I wanted it all pressed together. Then I got to thinking, I have a lot of 5/8" cold rolled shaft ends about 10" long that some kind soul from Toronto or Orangeville brought me a couple of years ago. The simplest thing in the world would be to turn new crankshaft ends (They are only about 3" long) and bump up the end diameter to whatever size will be a hard press fit in the holes I reamed in the webs. I THINK I know why the reamed holes are larger than they were supposed to be.---Hindsight being 20/20, I think I was running the reamer too fast and that made it cut oversize. I know that the drill rod I have just re-measured is exactly 0.500, not the .5005 that I was expecting it to be, and it is a somewhat loose sliding fit in the reamed holes. This leads me to believe that if I make up a new crankshaft end that is 0.500 diameter for all of its length except the last 3/8" which I hold at .503" diameter, I should ultimately end up with what I wanted---all press fitted together. The follower end will be turned to 3/8" over its full length, again, except for the last 5/16" where I will hold the 0.503" diameter.  This is holding things to closer tolerances than I am used to working to, but it will give me what I wanted.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 06:25:55 PM
It has been a rather upside down afternoon for me, and in all the excitement I forgot to post a couple of "in process" shots of the crankshaft webs. The shot where the two bars are clamped on the milling machine bed show the shaft holes being drilled and reamed, and the holes drilled which will give the 1/4" radius in the inside corners. The second shot shows where the  excess material has been milled away, and both parts are almost completely separated from the parent stock. The next step, if I ever get there, is to press the webs onto the crankshaft ends, set them up in the lathe, and turn the outer diameter of the plates to the finished dimension.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKWEBINPROCESS001_zpsd7ef6548.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKWEBINPROCESS001_zpsd7ef6548.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKWEBINPROCESS004_zpsbd18ff7b.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKWEBINPROCESS004_zpsbd18ff7b.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on August 31, 2014, 07:43:58 PM
IT WORKED!!!!!  0.503" was just the ticket. It was all I could do with my big nasty old mechanics vice to bring the shaft all the way thru the web, and then with a hollow socket backing the web up, about 3/8" more. Then I set it up in the lathe, cut the stub end off that was sticking thru, and finish machined the outer diameter of the web. Tomorrow will do the same to the follower half of the crankshaft.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/bigendcrankshaft001_zps038173e5.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/bigendcrankshaft001_zps038173e5.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 01, 2014, 10:56:07 AM
So--Ladies and Gentlemen--Here we have it!! My very first, two piece pressed together crankshaft. One picture shows the two pieces separated with the needle bearing for the big end of the con rod laying between them. The second picture shows the two piece crankshaft assembled with the needle roller bearing setting in its place. Each end of the crankshaft is supported by two bearings or bushings. The force from the con rod is totally transmitted through the 3/8" thick web plate to the large side of the crankshaft. The"free" end of the con rod journal engages with a slip fit hole in the other web and drives the smaller diameter side of the crankshaft, which operates the timing gears and the ignition points.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTFINISHED001_zpsd9143e82.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTFINISHED001_zpsd9143e82.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTFINISHED002_zps6f932e19.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTFINISHED002_zps6f932e19.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 01, 2014, 02:08:11 PM
So, here's a view "Down the hole" as it were. The crankshaft fits in nicely, nothing rubs or scrapes when rotated through 360 degrees. There is one tight spot in the rotation, but it's only a minor tight spot which I'm sure will wear away once the engine is ran for a few minutes. There are supposed to be spacer rings incorporated into the crankshaft, just behind each web, but I'm going to wait until I have the cylinder, piston, and rod in place to determine their final thickness.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VIEWDOWNTHEHOLE002_zps65b5c292.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VIEWDOWNTHEHOLE002_zps65b5c292.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 01, 2014, 02:36:48 PM
And now, since I have the material setting right here on the corner of my desk, I think I will machine some bronze.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/TAPPETGUIDE_zps3ee15b71.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/TAPPETGUIDE_zps3ee15b71.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/FLYWHEEL_zpse79ac217.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/FLYWHEEL_zpse79ac217.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on September 01, 2014, 05:55:05 PM
Looking good, Brian!  :thumbup:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 02, 2014, 08:32:13 PM
No machining today. I did however work 8 hours in a design office across town, rush home, gobble supper, drive to new house, install 3 smoke/carbon monoxide detectors, put new locksets (without keyholes) on two doors, measured up the partially rotten deck for new planks as required, and remove one door and bring it home to trim the top so it will close properly and install a cat door. Now I'm going to drink my herbal tea and go to bed!!!
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 04, 2014, 09:35:16 AM
Had time for a "quicky" before I left the house this morning.---No, not that kind of "Quicky" ya dirty buggers!!! I finished and installed the tappet guide, in bronze. The corners aren't mitered yet, as I thought it best to bolt all the mating pieces together and miter them all at the same time so the corners line up nice.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/TAPPETGUIDE001_zps0de31fea.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/TAPPETGUIDE001_zps0de31fea.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 04, 2014, 05:56:34 PM
Making a 4" diameter flywheel from a 6" diameter slab of bronze x 1 3/8" thick may be cheap---(I got the bronze for nothing), but it sure isn't easy!!! That's a lot of cutting on my old "push as you go" 14" jet bandsaw!! I have a good center punch mark  where I anchored one leg of the compass that drew the 4 1/8" circle, and I will use that center punch mark for setting up in my 4 jaw chuck in the lathe to turn the  flywheel.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/FLYWHEEL-1001_zps61618140.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/FLYWHEEL-1001_zps61618140.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 06, 2014, 07:54:17 AM
Slowly the flywheel is taking shape. I centered it in my lathe 4 jaw chuck around the center punch hole that I mentioned in a previous post, then turned most of the outer diameter (except the part held by the jaws) and drilled and reamed the center hole and the two large counterbores and faced the exposed side. My 3 jaw chuck will hold up to a 4 1/8" diameter piece with the reversed jaws in it, and the flywheel was now 4" diameter on the machined outer diameter, so I changed chucks, flipped the flywheel around, and carved away the material to leave the 2" diameter spigot as shown in the picture. I still have to take my evil trepanning tool and put the recessed annulus in the exposed side, and then add the 3 tapped holes to hold the starter ring and put in a keyway and set screws. I an very busy with other things right now, so I just do a bit of machining whenever I can fit it in.(And if I have any energy left!!!!)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/FLYWHEEL-2001_zps17f8f93c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/FLYWHEEL-2001_zps17f8f93c.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 07, 2014, 02:15:06 PM
Cowabunga!!! I like that!! And that is the last easy part finished for a while. I want to see what this thing looks like with a cylinder on it.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/FLYWHEELFINISHED001_zpsd4d73397.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/FLYWHEELFINISHED001_zpsd4d73397.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 07, 2014, 02:50:49 PM
I just had to share this, because I know all you old grandpa types like me will love it. This shot was taken last week as the girls were heading back to school for 2014. Brennen is too young for school, but he wanted to be in the picture. Wife and I just got back from our first "overnighter" with all 3 grandkids. Drove 185 Km up to Bancroft to see my 94 year old mother and wish her a happy birthday. There is always a certain amount of trepidation when taking a grandkid away overnight for his/her very first time, but Brennen was a trooper and probably slept better than I did. "Little Grandma" was happy to see Bren, as the last time she seen him he was a new born.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/backtoschool-2014_zps1430faac.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/backtoschool-2014_zps1430faac.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 07, 2014, 06:12:56 PM
This is going to be---well--tricky. There is no great science in the cylinder itself, other than having to hold my breath for minutes at a time while I plunge cut the 3/8" deep grooves with my .093" wide HSS parting off tool. The tricky bit will be in machining the three different levels of "flat" without breaking any fins in the process. I am told not to use cutting fluid when machining cast iron. Any good advice would be well appreciated before I get too deeply into this.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVECYLINDERSPERATE-NEW_zps98df798f.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVECYLINDERSPERATE-NEW_zps98df798f.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on September 07, 2014, 06:13:24 PM
That's a great pic, Brian!  :thumbup:

Tomorrow's the big day, for our Little One, to start, "big school".......   (http://serve.mysmiley.net/love/love0001.gif) (http://www.blueislandsdiving.com)

David d
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 07, 2014, 08:34:15 PM
As I understand it, grey pearlitic cast iron has a high graphite content, and as a consequence it is self lubricating. That is why it is popular for use in engine blocks and cylinder liners. Of course, this explains why you don't NEED coolant/lubrication when machining it, but it doesn't explain WHY you shouldn't use lubrication/coolant when machining it. I just googled it, and the Sandvic website confirmed what I thought about not needing lubricant, but it didn't say anything about not being supposed to use lubricant. On a deep plunge cut like the fins require, I would think that the use of lubricant would help flush out chips and keep the tool from grabbing and/or binding, but I don't know for sure.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: chipenter on September 08, 2014, 02:47:34 AM
Cutting cast iron prduces dust wich clumps up with coolant and just forms a paste , air will blow the swarf away and with a slow speed won't get to hot , or use a rear tool post .
Title: Re: Side Valve i.c. engine from Bar stock
Post by: philf on September 08, 2014, 03:05:33 AM
Brian,

Just a thought.

Have you considered using a slitting saw to machine the fins? You could machine the flats first and then set the cylinder up on a rotary table.

I am hoping that my grandson shows some interest in the workshop -  I've a long wait as he's only 21 months old!

Cheers.

Phil
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 08, 2014, 07:17:17 AM
Gentlemen--Thank you for your replies. I was looking at my engine collection this morning, and it seems that my Atkinson engine has .093 slots between the fins and the slots are 3/8" deep. I don't remember having any particular problems with that cylinder, and I machined it dry. I will machine this new cylinder dry and hope for the best. Philf--I did buy a .093" slitting saw, in case I ran into any problem with the cylinder machining, and because the part directly above the cylinder along with the cylinder head have a number of the same size slot, and they can not be turned. I couldn't imagine the time it would take to do these with a 3/32" endmill, so I have the slitting saw in reserve.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 09, 2014, 06:44:49 PM
Made a mistake. Kissed a snake. How many cooling fins did I make??--Well okay, maybe you're not into skipping rhymes!!! However, if you are paying attention, you will see that I have one more cooling fin on there than the drawing calls for. To make it even worse, the top 3 cooling fins are skinny little devils, while the bottom 3 are full size. I have absolutely no excuse for it, other than encroaching old age and gross incompetence. By the time I noticed that the first cooling fin down from the top was too skinny, I had already advanced the tool .040" into the work, and there was no good way to hide it or cover it up. I'm still a bit baffled as to exactly what happened, but somewhere in there, the math let me down. At any rate, I have convinced myself that since this is a prototype, it really doesn't matter that much. The cylinder will still function just as well with one extra cooling fin. Everything seems to bolt together okay, although I did have to use a ball end hex wrench to tighten up the bolts holding the cylinder to the crankcase.---Probably would have had to do that even without the extra cooling fin. And for my next amazing stunt---I will be making the combustion chamber that mounts on top of the cylinder.---And, Oh yeah---I machined the cylinder dry, and there was absolutely no binding, galling, or "scare the crap out of me cut off tool breaking".
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CYLINDERFINISHED001_zps8f91aa83.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CYLINDERFINISHED001_zps8f91aa83.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CYLINDERFINISHED002_zps1d284ba2.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CYLINDERFINISHED002_zps1d284ba2.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 09, 2014, 07:07:13 PM
This is the part I will build next. I will probably mess with the cooling fin spacing a bit so it matches my miss-machined cylinder cooling fins.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVECOMBUSTIONCHAMBER_zpsfafc6f2a.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVECOMBUSTIONCHAMBER_zpsfafc6f2a.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: tekfab on September 09, 2014, 08:31:35 PM
Hi Brian, I'm too late getting here but if you have to do any similar fin cutting in cast iron we always used a compressed air jet to keep the cut clear and also cool the tool down always assuming you have access to a compressed air source.
Keep up the good work  !

Mike Young
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 09, 2014, 08:58:22 PM
Tekfab--Thanks for having a look and posting a comment. I do have compressed air in my shop, and as I said on one of the other forums I post on, it is a good solution but makes an awful mess of a small home shop. Another good solution is to rig a holder for the shop vac nozzle so it follows the cutting tool. Accomplishes the same thing but without the mess of cast iron dust blown all around the shop. Actually, I cut that cylinder dry with no compressed air or vacuum and didn't experience any problems.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: PekkaNF on September 10, 2014, 05:20:01 AM
Hi Brian,

did you first turn all fins round and then milled flat on them or other way round? I have some cat iron offcuts but ita allways machines beutiful, althoug pretty messy. I use shop vack pretty much all the time, specially if I am boring. I really don't like that mess on my chuck, backplate, spindle and all the way down to change gear.

Pekka
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 10, 2014, 07:36:42 AM
PeckaNF--I turned everything round first, then machined the flats. Experienced no trouble whatsoever. I machined it dry, no coolant. only trouble I encountered was the different sized fins, and that was my fault.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 10, 2014, 08:49:36 PM
I don't post a lot of "in process" shots anymore, but tonight I thought I would put up a shot of the beginning of the aluminum combustion chamber. I have marked out the outer profile, bored the 1" through hole, and the 1.160" diameter counterbore. You can see the cylinder setting on the end of the work. When I bore holes to a critical fit, I do a lot of "try it and see if it fits yet" with the mating pieces. After a summer of engineering work avoidance, some of my customers are calling me up and asking to have their projects worked on "Right Now", and if I ignore these folks they find someone else and I never hear from them again. Between the engineering work and work fixing up the house I bought, I am sometimes hard pressed to find a bit of time to machine my own stuff.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COMBUSTIONCHAMBER-1002_zpsc3767aa7.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COMBUSTIONCHAMBER-1002_zpsc3767aa7.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Manxmodder on September 11, 2014, 07:33:40 AM
Interesting project you're doing here Brian. I wondered what you plan to do for a spark ignition system,create something from scratch or use a flywheel magneto type from a petrol strimmer or chainsaw maybe?

Just a little thought on the error with machining the cylinder fins,if you machine a chamfer on the outer edges of the 3 thick fins at the bottom of the cylinder it would improve their proportional appearance to the thinner ones at the top.....OZ.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 11, 2014, 08:01:16 AM
Hello Manxmodder.--glad you stopped by to say hi. I am going to use a set of 1980`s Chrysler ignition points and condenser. I have about about 9 engines, so have made up a separate ``power box``containing a 12 volt coil and the appropriate wire leads that let me move it from engine to engine. That way it becomes inexpensive (less than $20) to buy a set of points and a condenser for each engine.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 11, 2014, 02:36:32 PM
I still have some fin cutting and finessing to do, but this is getting quite exciting!!! I have to buy some material to make a fixture to mount this combustion chamber in the 3 jaw chuck on my rotary table to let me cut the cooling slot that runs around the perimeter. There is a lot of work in this part, but I am pleased with how it is turning out.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COMBSTIONCHAMBER-2003_zpseb5db03b.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COMBSTIONCHAMBER-2003_zpseb5db03b.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: philf on September 11, 2014, 03:53:42 PM
Brian,

It's looking good!

Are the valve seats just aluminium or is there a steel or iron insert?

I agree with Manxmodder's suggestion that you could chamfer the thicker webs to camouflage your error.

Cheers.

Phil.

Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 11, 2014, 05:08:41 PM
If you look way back to post #30 you will see the answer to your question. I will be installing pressed in valve cages, made of brass. That way, if a valve seat goes funky, I don't have to replace the entire complex combustion chamber. I will post a drawing of the valve cages sometime in the next 2 or 3 days.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 12, 2014, 08:49:06 AM
For those of you who wondered about the fixture I would make to cut the groove in the combustion chamber and to round the curved side of it, here is how I am going to do it. I found a suitable piece of 2" round aluminum and bored it for a hard press fit of a 3/4" crs shaft. I then set it up in the lath and turned a spigot on the face to be a precision fit into the 1" bore side of the combustion chamber. I then drilled and tapped five #5-40 holes in it and bolted the combustion chamber to it, using bolt holes which were already in the combustion chamber. The third picture shows it set up in my milling machine with a 0.093" slitting saw mounted in the spindle arbor. In order to take a quick picture, I put the slitting saw arbor in my 3 jaw chuck. In reality, it will be mounted in a collet held in the mill spindle by the drawbar.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COMBUSTIONCHAMBER-3003_zps3c9a0f5c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COMBUSTIONCHAMBER-3003_zps3c9a0f5c.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COMBUSTIONCHAMBER-3001_zps62772c8c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COMBUSTIONCHAMBER-3001_zps62772c8c.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COMBUSTIONCHAMBER-3004_zps67bcb61c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COMBUSTIONCHAMBER-3004_zps67bcb61c.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 12, 2014, 03:52:11 PM
I get a great sense of accomplishment (and sometimes astonishment) when everything actually bolts together, and all of those random lumps of steel and aluminum begin to look like an engine. Today I have reached that point. The combustion chamber turned out great, and my experience with the .093 slitting saw was a success. The two yellow pencils indicate where the valves and tappets are going to be.Although there are many different directions I could jump in right now, I am anxious to see what the "overall" engine is going to look like, so I think I will machine the cylinder head next.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COMBUSTIONCHAMBER-3003_zps436adeef.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COMBUSTIONCHAMBER-3003_zps436adeef.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/COMBUSTIONCHAMBER-3001_zps8156e74e.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/COMBUSTIONCHAMBER-3001_zps8156e74e.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 12, 2014, 04:08:56 PM
This will be my weekend chore----
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/SIDEVALVECYLINDERHEAD_zps944c77f3.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/SIDEVALVECYLINDERHEAD_zps944c77f3.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 13, 2014, 04:08:11 PM
Now I know what I DON'T want to be when I grow up!!!---A cooling fin slot cutter!! The .093" slitting saw works amazingly well, but at 0.100" depth of cut, thats 4 passes per fin-slot x 11 slots = One heck of a lot of cranking on a manual mill. The sparkplug is a 1/4"-32 Rimfire plug from Roy Sholl. I didn't get too crazy finishing the bit of combustion chamber inside the head. It will work just as well the way I have it as it would polished.--In fact, it might work even better. I am really pleased with the way the engine is looking.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CYLINDERHEADFINISHED002_zpsbefcc292.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CYLINDERHEADFINISHED002_zpsbefcc292.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CYLINDERHEADFINISHED003_zps7e1499be.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CYLINDERHEADFINISHED003_zps7e1499be.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CYLINDERHEADFINISHED004_zpsa234b487.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CYLINDERHEADFINISHED004_zpsa234b487.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on September 13, 2014, 04:56:34 PM
Taking shape, and looking good Brian!  :thumbup: :clap: :clap:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 13, 2014, 07:18:14 PM
It's a bit late in the game to be figuring this out, but just for the heck of it I  ran a quick calculation to see what the compression ratio on this engine was going to be. Without taking the heads of the valves into consideration, the compression ratio is a whopping 4.8:1----------That is about what I had figured it would be, but it's nice when the math confirms it.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Manxmodder on September 14, 2014, 06:28:34 AM
 :clap: :clap: Looking really good now Brian,keep the updates coming......OZ.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 14, 2014, 08:54:54 AM
Todays offering to the machining Gods is a piston. Granted, its a rather strange looking piston, and I have never built one like this before, but remember, we are in the wonderful world of prototype here. The top section of the piston extends up beyond the split between the combustion chamber and the cylinder, so we don't want it to contact the wall of the combustion chamber in that area. Additionally, there is more "hogging out" of material in the rod end of the cylinder than is usual. That is to accommodate the 1/4" sealed needle roller bearing, which is the smallest size I was able to buy. I'm not even certain a needle roller bearing is going to give us any great benefit there in terms of reducing friction, because the rod only swings in a small arc, not a full rotation.
I have to contact the manufacturers of the needle bearings on Monday, as I remember reading somewhere that needle bearings are made deliberately oversize, both on the outer diameter and on the inner diameter. They are intended to be press fitted into a housing, with a hard enough press fit to reduce the bore to the correct size.--That could be quite a trick, when they are going into an aluminum rod with only a thin band of material enclosing the bearings.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/1INCHPISTON-RUPNOWENGINE-2_zps86161cf8.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/1INCHPISTON-RUPNOWENGINE-2_zps86161cf8.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 15, 2014, 09:07:35 AM
I was getting ahead of myself!! Before I make the piston I have to lap the cylinder bore. Before I lap the cylinder bore I have to figure out a gasket to go between the cylinder and the combustion chamber and permanently lock them together. Before I do that I might as well make the valve cages and install them. So---These are the valve cages, which act not only as a seat for the valve to close against, but also as a guide for the valve stem. People have made these valve cages from many different materials, but I find that brass seems to work well, and an added advantage is that the brass cage, being softer than the steel valve, will "conform" to the shape of the valve face after the engine has been run for a short period of time, providing an excellent seal for compression.--And--If you do happen to screw up a valve seat, then you only have to replace this small item, not an entire cylinder head or whatever it is pressed into.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VALVECAGE-RUPNOW-2_zps39de80f0.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VALVECAGE-RUPNOW-2_zps39de80f0.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 15, 2014, 12:00:03 PM
Hmmmm---Everything I do has consequences--- I had to go out this morning to buy some brass to make valve cages out of. While I was out and about, I got thinking about the 0.197" diameter on the cages. Started thinking, that if I found out after the fact that the .197" diameter was too large to fit into a spring comfortably, there was no way to change it after it was pressed and Loctited into place. So---I stopped at the tool shop and bought a .197" diameter drill. Then I stopped at my fastener supplier and dug around in his spring collection. I ended up buying a pair of springs "INDUS0615125" They are a tight fit onto a .197" drill. Consequently, I will reduce that diameter on the cage drawing to .193" diameter. In the picture that is a .193" diameter drill setting inside the spring, and it fits well with no binding. The spring is wound from .023" diameter wire, has a pitch of .090 between the coils, and each spring is approximately 2" long, free length, but they will be cut down to a shorter length when I install them.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VALVESPRINGS001_zpsa68448bc.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VALVESPRINGS001_zpsa68448bc.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 15, 2014, 03:05:53 PM
So now we have a pair of valve cages installed. The first picture shows one of the semi-completed valve cages laying beside the cylinder, with the "pusher tool' that I use in my mechanics vice for pushing the cages into place. The valve seat is not cut yet in that picture, and the hole which lets fuel or exhaust enter/exit from the cages are not yet drilled.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VALVESEATSINSTALLED001_zps3613fa43.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VALVESEATSINSTALLED001_zps3613fa43.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 15, 2014, 03:11:35 PM
In these two pictures you can see the underside of the valve cages in one shot, and the top of the cylinder and valve cages in the other. In the shot showing the top of the cylinder, you can see my "George Britnell valve seat cutting tool". The seats are cut in that picture, but are hard to see because they are very small. They are cut by hand---no power tool involved.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VALVESEATSINSTALLED-2001_zpsf301ee16.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VALVESEATSINSTALLED-2001_zpsf301ee16.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VALVESEATSINSTALLED-2002_zps33f73531.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VALVESEATSINSTALLED-2002_zps33f73531.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 15, 2014, 06:37:57 PM
After letting the Loctite set up for a couple of hours on the pressed in valve cages (.0015" interference fit) I drilled the connecting holes thru from the carburetor and exhaust mounting surface to the center of the valve cages. Now my engine will be able to breath in and breath out-----------
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/INTAKEANDEXHAUSTPASSAGES003_zpsf8fb3863.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/INTAKEANDEXHAUSTPASSAGES003_zpsf8fb3863.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Manxmodder on September 15, 2014, 08:31:36 PM
 :clap: :clap: Looking better as every post you put up appears. I'm really looking forward to seeing you fire her up for the first time......OZ.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on September 16, 2014, 02:12:45 AM
I thought that loctite required a small clearance fit not an interference fit?
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Manxmodder on September 16, 2014, 07:01:13 AM
Andrew, that depends on the surface finish on the component faces treated with loctite.

Years back when I was frequently involved in fitting press fit cylinder liners it was recommended practice to produce a honed crosshatch finish inside the cylinder block or barrel that the liner was being pressed into and use a low viscosity loctite retainer compound.

The loctite film occupied the small troughs in the honed surface......OZ.

 
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 16, 2014, 07:56:14 AM
Sometime to day I hope to visit one of my suppliers and pick up some suitable head gasket material and some high temp sealing compound for the two bolts that have their heads exposed in the combustion chamber. I don't want to hone/lap the cylinder until after I have permanently locked the cast iron cylinder and the valve body (which I have been mistakenly been referring too as the "combustion chamber") together. In the meantime, I have just rattled off a quick detail of the valve. I see some people make valves out of stainless steel and other exotic materials, however I have always used just plain old garden variety cold rolled steel and never has a valve fail.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/INTAKE-EXHAUSTVALVERUPNOWENGINE-2_zpsee5ace33.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/INTAKE-EXHAUSTVALVERUPNOWENGINE-2_zpsee5ace33.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 16, 2014, 08:05:03 AM
And in case you are a bit confused about how this valve business goes together, here is a cross section thru the valves, cages, tappets, cams, etcetera.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/crosssectionshowingvalves_zps3ec0e4f5.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/crosssectionshowingvalves_zps3ec0e4f5.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 16, 2014, 08:55:41 AM
Oh Heck--While I'm setting here waiting for a call back about gasket material, I may as well put up a drawing of the valve keeper.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VALVEKEEPERRUPNOWENGINE-2_zpsd08aeb58.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VALVEKEEPERRUPNOWENGINE-2_zpsd08aeb58.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 16, 2014, 02:32:00 PM
We have valves and valve keepers!!! I had to order some gasket material and some extreme high temperature sealant and it won't be in until tomorrow, so in the interest of keeping things moving, I machined the valves and the keepers today. The valve on the right is open .080" which is the rise on the cam shaft, and the valve on the left is completely closed. Unlike an automobile engine, these valves set up a bit from the flat surface, even when they are closed.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/VALVESANDKEEPERS002_zps02460613.jpg)[/U (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/VALVESANDKEEPERS002_zps02460613.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 17, 2014, 08:33:58 AM
If you guys remember back to when I made the crankshaft, there is a .563" diameter spacer ring on the back side of the web on each half of the crankshaft. This web is in there to maintain some clearance between the revolving crank web and the inside of the crankcase, as well as to locate the crankshaft so it doesn't float back and forth in the crankcase as the engine is running, making a clatter. Due to accumulated tolerances when machining, the thickness of this spacer ring invariably ends up either too thick or too thin. I have made it a separate piece Loctited into place on the crankshaft and here is why. Since my crankshaft is a two piece and comes apart in the center, I can make up this "setting master" fixture, insert the large end into the cylinder, and let the small end hang down into the crankcase and put the crankshaft "throw" through the 3/8" reamed hole. The small end at 0.531" is exactly the width I want between the webs of the crankshafts. Then a bit of careful measuring done by sliding each end of the crankshaft to its extreme travel in both directions should let me know exactly how thick these spacer rings should be made.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSHAFTFORSIDEVALVEENGINE_zps7f6aa22d.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSHAFTFORSIDEVALVEENGINE_zps7f6aa22d.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CRANKSETTINGJIG_zpsd36c7da1.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CRANKSETTINGJIG_zpsd36c7da1.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 17, 2014, 09:52:32 AM
Here is a picture of the Setting Tool in place. The cylinder fits over it and locates into the counterbore in top of the crankcase. I have made it and installed it and the results are about what I expected. Although the design calls for a 1/16" thick spacer on each side of the crankshaft to prevent endplay, in reality there is virtually no endplay in the driving side of the crankshaft, but it is still free to rotate. The other end of the crankshaft, the "follower" end will require a 1/32" spacer. Why the big difference from the design.--Well, mainly because of "stack up" of tolerances. There are a lot of pieces fitting together to give this theoretical 1/16" spacer on each side. Although I could have held all of my tolerances much closer when machining the parts, I doubt that I could ever had everything come out as a perfect match for the drawing. The 0.531" wide setting master will allow for a 1/2" wide connecting rod and a 1/64" brass or teflon spacer on each side of it between the webs.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/crankendplaysettingtool002_zps6c790a84.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/crankendplaysettingtool002_zps6c790a84.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 17, 2014, 01:20:42 PM
Today I'm just tidying up loose ends, so decided to machine the starter collar. This bolts onto the brass flywheel and lets me use my variable speed drill as a starter.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/STARTERCOLLAR_zps8d672213.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/STARTERCOLLAR_zps8d672213.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 17, 2014, 05:46:41 PM
So now the engine has a starter ring. If I ever get finished to the point where I want to start it, the ring will be waiting for me.---On to more interesting things like pistons tomorrow. (I hope!!)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/STARTERRING2002_zps6ed67295.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/STARTERRING2002_zps6ed67295.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 19, 2014, 05:59:43 PM
Somebody messed up, and my gasket material never got ordered. Now it's ordered and won't be here until Monday or Tuesday. This doesn't cause a huge problem, because I'm up to my armpits in "real" work right now and have no time to play machinist. This drawing is an  interesting part. I have made it before. It mounts a set of my favorite Chrysler product ignition points, and clamps onto the extended head of a crankshaft support bushing. By loosening off the clamp bolt, I can manually adjust the ignition timing while the engine is running. This is no big thing once the engine is all set up and running at its optimum timing, but it sure is a nice thing to have when first starting the engine and "setting up". I used this when I built the Odds and Ends hit and miss engine designed by Philip Duclos, and it really is a handy thing to have on the engine.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/POINTSMTGBLOCK-RUPNOWENGINE-2_zpsf0d73d01.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/POINTSMTGBLOCK-RUPNOWENGINE-2_zpsf0d73d01.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 19, 2014, 06:16:37 PM
Now I have enough work to keep me going until the gasket material arrives. There is a big chain of consequence attached to the lack of gasket material. I can not permanently attach what I have been calling the "combustion chamber" to the cast iron cylinder until I have a ring of gasket material to insert between them to prevent loss of compression. I can't hone nor lap the cylinder/combustion chamber until they are permanently attached to each other. I can't make the piston until I am finished the lapping and honing. I'm sure there will be enough work in this con rod and the points mounting bracket to keep me going until the gasket arrives next week.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CONROD-SIDEVALVE_zps5b124679.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CONROD-SIDEVALVE_zps5b124679.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 19, 2014, 08:02:30 PM
Here we have the con-rod layout. I don't work to the layout lines, but they let me know if I have turned the dials on my mill one too many times when I am actually machining it. I don't trust my mill vice to hold this perfectly flat while working on it. I will put a sacrificial plate underneath it and use hold down bolts in the tee slots to hold it flat on my mill table while drilling and boring all the holes. Two critical holes for the bearings at each end which will have to be bored, and 4 drilled holes to form the radii where the straight sides blend into the round ends.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CONRODLAYOUT004_zps7db3bc96.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CONRODLAYOUT004_zps7db3bc96.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 20, 2014, 08:30:53 PM
That went well!! The machining was pretty straightforward stuff. I did learn one new thing today. When you order this type of bearing, the outer diameter comes in at .0005" to .001" oversize so that they can be pressed into a hole made by a standard reamer. For 49 years now I have been putting a note on machining drawings "Bore for light press fit of .562" nominal o.d. bearing (or bushing).--I never actually realized that there wasn't some magic formulae or set of undersized reamers involved to do this. As you can see in the picture, the 1/4"small end bearing is sealed with rubber seal lips. I was unable to buy a sealed 3/8" i.d. needle bearing----anywhere, for the big end. I guess this means that I will be running some oil in the crankcase after all.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/CONRODFINISHED003_zps3dc41d81.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/CONRODFINISHED003_zps3dc41d81.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 21, 2014, 03:51:26 PM
By Golly, Miss Molly---I must be doing something right!!! Along with all the other things I had to do this weekend, I managed to carve out enough time to make the con rod AND the ignition points mounting block. I decided at the last minute not to put the raised boss on that is shown on the drawing. The head of the bushing it clamps to only extends 3/8" past the aluminum backplate, so that is the thickness I finished the points mounting block at. I used a scrap of bronze, just to balance the bronze flywheel aesthetically. The points mount up perfectly, and all it need there now is an ignition cam to finish that bit off. The #5 capscrew sticking out horizontally is where the handle will screw into, to adjust the timing.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/POINTSMOUNTINGBLOCKINPLACE001_zps87b27d4f.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/POINTSMOUNTINGBLOCKINPLACE001_zps87b27d4f.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/POINTSMOUNTINGBLOCKINPLACE002_zps514c0bb0.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/POINTSMOUNTINGBLOCKINPLACE002_zps514c0bb0.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 21, 2014, 06:36:53 PM
Time for one last "Quicky" before I shut down for the day. The all important ignition cam. This cam serves a dual role in life. It opens/closes the ignition points, but also acts as a shaft collar to prevent any axial movement of the driven crankshaft in its bushings. :ddb:
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/IGNITIONCAM-RUPNOW-2_zps7774d1db.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/IGNITIONCAM-RUPNOW-2_zps7774d1db.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 22, 2014, 07:37:13 AM
The ignition cam is machined and installed. For any newbees following these posts, this kind of ignition cam holds the points open most of the time. They only close when the flat, which is about 3/8" long pass under the rubbing block on the ignition points. This gives enough time to charge the primary windings on the ignition coil, and when the points open again as the cam revolves, that is when the spark occurs.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow016/ignitioncaminstalled001_zpsbd3b9101.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow016/ignitioncaminstalled001_zpsbd3b9101.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 23, 2014, 07:55:40 PM
The cast iron cylinder and the aluminum valve body (which I have been mistakenly calling the combustion chamber) are now permanently and forever locked together with a ring of super duper heat resistant gasket material and some high temperature gasket goo.--That's not to say I couldn't take them apart, but I don't want to. I want to treat the two items as a single component now, hone them together, lap them together, and then make my piston to suit the bore.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CYLINDERANDVLAVEBODYLOCKEDTOGEHTE001_zpsa9a1b24d.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CYLINDERANDVLAVEBODYLOCKEDTOGEHTE001_zpsa9a1b24d.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 24, 2014, 08:41:01 PM
Not much machining accomplished today. I'm a bit overwhelmed by 'real' work right now, plus making a wooden cabinet to hide an ugly wall mounted 100 amp electrical service at my son's house. I did manage to steal 20 minutes out of the day to hone the cylinder/valve chamber with my 3 stone brake hone, and to lap it using a piece of 1" aluminum round bar and first #400, then #600 carborundum paste.  Sometime in the next few days, I will use the other end of the 1" aluminum round stock which is not polluted with embedded carborundum paste to make a piston. Good Heavens!!! If I get a piston made, then I am getting awfully close to a finished engine. Oh yeah, I forgot---I still have tappets to make.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: DavidA on September 25, 2014, 05:40:58 AM
It's coming together nicely.
Makes me feel guilty every time I look at my part finished Jan Ridders engine.
When the weather turns bad again I will have to make some progress on that front. And the Fowler 4F loco.

Dave.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 27, 2014, 06:51:03 AM
I haven't had a very "machiney" week due to other obligations. I hope to make a piston sometime today, and I have realized that due to adding the 1/32" gasket between the valve chamber and the cylinder body, I will have to make the piston 1/32" taller between the gudgeon pin and the top surface, in order for it to come even with top of the "deck" when at top dead center.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/GASKETSFORSIDEVALVEENGINE_zps4ff9b4f6.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/GASKETSFORSIDEVALVEENGINE_zps4ff9b4f6.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 27, 2014, 01:48:46 PM
Hey Hey!!! we got a piston!!! That's two things accomplished today. Machined a piston and got a haircut. Damn, I'm a good looking fellow when I get a haircut.--Look just like Elvis---sorta---
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/pistonfinished003_zpsc4f863e6.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/pistonfinished003_zpsc4f863e6.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 27, 2014, 05:34:50 PM
I'm very pleased to announce that with rod and piston installed and all gaskets in place, the crankshaft does indeed go "round and round". No matter how much fancy 3D cad modelling I do and how many calculations I make, this is always the moment of truth for me. I actually had one little heart stopper---the crankshaft wouldn't make a full 360 degree rotation when I first assembled everything. I took out the bolts that hold the cylinder to the crankcase one by one, but it wasn't that. Then I pulled the head off----and discovered that the top of the piston actually comes up about .013" higher than the top of the deck. That would have been okay, I have .060" clearance milled into the head.---But--I had cut the gasket hole a bit small, and the piston was hanging up on the gasket material. A bit of very careful exacto knife work to trim the gasket, and that fixed things. A big sigh of relief----Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on September 27, 2014, 05:41:40 PM
Well done, Brian!  :clap:   :clap:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on September 28, 2014, 02:26:07 AM
 Looking good Brian

Is that con rod the finished article or are you planning to slim it down a bit? It's certainly chunky as is.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 07:07:19 AM
I'm going to leave it chunky. This is not a high speed engine, so the mass of an aluminum connecting rod is not really a big issue. On higher speed engines, where the weight of a a connecting rod can cause balance problems, slimming the rod down has advantages. It also has advantages for the manufactureres, where cast rods are used, because it saves material.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 07:55:34 AM
Jeez, we're really coming down to the wire here folks.The two knurled items in this post will be what allows me to grip the ends of the camshafts and rotate them by hand after loosening of the set-screws in the timing gears to adjust the cam timing. They also limit the axial movement of the camshafts in their bushings. They will be bolted and Loctited to the ends of the camshafts.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMSHAFTRETAINERWASHER_zps868b2667.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAMSHAFTRETAINERWASHER_zps868b2667.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 08:03:48 AM
These are the parts I've been saving until last, for two reasons. First reason is that 95% of the engine has to be built before their is a place for them to go, and the second reason (the real reason) is that I'm not sure how I am going to make them. The method outlined by Malcolm Stride in his Bobcat/jaguar/Lynx series works very well, but involves an awful lot of mill cranking. The second method which I believe Chuck Fellows made a video of and involves doing them in a rotary table on the mil looks a lot simpler, but I'm not certain about being able to hold the accuracy with the Chuck Fellows method.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAM-RUPNOWENGINE-2-_zps68282791.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAM-RUPNOWENGINE-2-_zps68282791.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 06:15:25 PM
So--What did I do wrong? I just used the cam-calc program http://modelenginenews.org/design/CamTable.html to create this cam profile. My inputs were --cam angle=120 degrees--valve lift 0.080"--flank radius =.640" --base radius =0.240" --engine rpm 3000, and 2 degree angular increments. It created a profile that dishes in rather than out like it is supposed to be. I am not sure I have laid it out correctly but I think I have.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMCUTTRYOUT_zpsf935d789.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAMCUTTRYOUT_zpsf935d789.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 06:27:29 PM
And just for interests sake, that generates a nose radius of a whopping great .1815" . I'm sure I must be doing something wrong. Maybe the calculator doesn't like such a slow engine speed. The only really major difference between the inputs for this cam and the one Malcolm Stride generated for his Bobcat and Jaguar engines was that he used an engine speed of 5000 rpm for his inputs, and his cam profile turned out like one would expect a cam to look like.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMCUTTRYOUT_zps2a881194.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAMCUTTRYOUT_zps2a881194.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 06:42:03 PM
I must be doing something wrong in my layout. I just reran the cam-calc program using a 5000 rpm input and it spit out exactly the same numbers as for a 3000 rpm input. The output for both 3000 rpm and 5000 rpm inputs  is also telling me that the nose radius will be .080" which I expected it to be. I'm doing something wrong in my layout. I just have to figure out what it is.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 08:04:07 PM
Okay--I'm sorted out. I have figured out that my layout was incorrect. I am currently working on a 3D cad model which will give me the proper profile when finished, but it's not quick nor easy. I have to create a solid, then rotate it and machine away portions of it exactly as I would in the machining process. I will post the profile when I get it finished.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 09:25:12 PM
This was a battle royal, but I got it sussed out. The end result is happy!!! The cam profile generated by using all of the inputs for machining from CamCalc is a VERY VERY close match to what I had originally designed. I feel confident that if I use the generated numbers when actually machining my cams, I will end up with the result I was after.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMPROFILECOMPARISONS_zps7d446518.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAMPROFILECOMPARISONS_zps7d446518.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 28, 2014, 09:28:43 PM
Yowzahhhhhhhhhhhhhh!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMPROFILECOMPARISONS-models_zps061f0cf1.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAMPROFILECOMPARISONS-models_zps061f0cf1.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: philf on September 29, 2014, 01:40:53 PM
Hi Brian,

I thought I'd replied last night but it must be stuck in the ether somewhere. (We're on holiday in our touring caravan and the wireless broadband connection has been very dodgy until 2 BT OpenReach engineers turned up this morning.)

I drew out your cam on Autocad using your figures of 0.24 base radius, 0.08 lift and 0.64 flank radius and it comes out with 0.08 nose radius. So, how the program generated a profile with such a huge nose rad I don't know. (It wouldn't display anything on my PC complaining of a Java Security issue.)

By the way - the speed has nothing to do with the profile the program generates. It's only used if you need to know accelerations.

For your 3d model why couldn't you just extrude the profile?

A very simple machining job for a CNC mill!

Phil.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on September 29, 2014, 04:50:36 PM
Philf--I did exactly that (extruded the profile) on the green cam. On the grey cam, I used the machining sequence generated by CamCalc to create the profile. That is why you see the side facets in the grey cam. It is a rotary table job with a cut taken every two degrees of rotation.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 04, 2014, 07:34:43 AM
I have had a crazy busy week, and haven't had a chance to play machinist very much. I did come home last night from the factory where I've been consulting for a couple of weeks, and got a good start on the tappets. I figure that if I have to set the rotary table up on the mill to do the cam anyways, I might as well cut the hex shapes on the tappets, which are being made from 1/2" 01 drill-rod. I hope to get the cams done this weekend as well. You are probably right about the shape of the cams not being all that critical. They are very "not critical" if using a follower wheel on the tappet, but for a flat bottomed tappet, if you don't get the curve right on the cam flank, they will 'slap' the bottom of the tappet on every revolution.----At least that's what the books say.-----Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 04, 2014, 12:21:27 PM
This morning I made the tappets from drill rod, which is a "water hardening steel". The machining went reasonably well, until I realized that I had tapped the wrong end of the larger diameter which rides on the cam!!! After remaking the large ends and getting it right the second time around, I carefully fit everything, then took the pieces out to my big garage for hardening. I heated the pieces one at a time with my oxy acetylene torch until they were bright orange, then tipped them into a can of water. I hoped that I wouldn't get much heat distortion which would have buggered up either the internal or external threads, but I must have lived right this week, because everything went back together fine. The outer diameter of one of the large parts may have grown a little, as it was a tight fit into the bronze guide block and I had to set it up in the lathe and polish it a tiny bit with some 280 grit paper. I decided at the last moment to use mild steel #10-24 locknuts, because it was less work, and I figured when used as a jam nut the mild steel would grip better and not back off while the engine was running. In the picture, one valve is open and one is closed, but the cams are still not made. That will be tomorrows job. The blob of stuff on top of the left hand tappet is some oil I had used when assembling things and then forgot to wipe off before taking the picture.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/TAPPETS003_zps25dce9df.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/TAPPETS003_zps25dce9df.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/ASSEMBLEDTAPPET_zpsaa70540f.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/ASSEMBLEDTAPPET_zpsaa70540f.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 04, 2014, 07:34:05 PM
We have a cam!!! Actually, we have two cams, once I get them parted off. Everything went very well, and the profile looks perfect. I took a cut every two degrees of rotation in the rotary table. This leaves only microscopic ridging, which will clean up very easily with a fine diamond file. However, no matter how you do the math, that is 180 trips back and forth with the manual table. My right shoulder will be sore tomorrow from crank turning. Old dogs do learn new tricks---this time after the profile was cut, I left the cam in the rotary table set-up and continued taking cuts every two degrees until I had completed the full 360 degrees. This is an excellent method of making cams, but it is tedious. Tomorrow I will dress things a bit with the fine diamond file and part the cams of from the parent stock. Then they will be flame hardened and quenched, then silver soldered to their individual camshafts.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMASCUT002_zps4187506e.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAMASCUT002_zps4187506e.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMONTABLE001_zps9194a609.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/CAMONTABLE001_zps9194a609.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: lordedmond on October 05, 2014, 04:14:45 AM
Hardened and quenched then silver soldered

Bit odd there Brian surly the SS unles you quench it again will soften them ?

Stuart
Title: Re: Side Valve i.c. engine from Bar stock
Post by: chipenter on October 05, 2014, 05:22:19 AM
Hardened and quenched then silver soldered

Bit odd there Brian surly the SS unles you quench it again will soften them ?

Stuart
Even soft solder will soften to spring steel , will requenching crack the joint ?
Title: Re: Side Valve i.c. engine from Bar stock
Post by: lordedmond on October 05, 2014, 05:45:12 AM
Not sure

But I wonld not SS them but pin them and fix with Loctite ,put the pin in from the large rad portion where the Tappit has its clearance so that it will not affect the cam profile .

Just my 2pence worth

I think G Meek put this method forward when he did his cams made easy write up

Stuart
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 05, 2014, 07:56:15 AM
The outside diameter of the cam, in the non lift area is only .480"  (12.2 mm).  The bore is 3/8" (9.5  mm).That means that the wall of the cam is only .052" (1.3 mm). not much room for a pin in that. I will be a doing a bit of experimenting with this and let you know the results.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: lordedmond on October 05, 2014, 11:18:55 AM
The pin is not to fix but to locate it the glue that fixes the cam, the position I mentioned for the pin is the non working area and will not cause any problems.

With this method you can harden the cams right out and then put them on the shaft , pin hole drilled before hardening as you know

Stuart
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 05, 2014, 12:38:05 PM
Okay--Experiment completed. I had a bit of left over 1/2" drill rod. It cuts very easily with a file. I flame hardened and quenched one end, put it in the lathe to hold it, and tried to cut it with a file. Couldn't cut it at all. Harder than the devil's horn!!! I set it up in a vice and silver soldered a small bit of 3/16 mild steel shaft to the end of it, let it air cool, and again set it up in the lathe. The file now once again cuts the drill rod very easily. The heat of silver soldering "unhardens" the hardened drill rod. Looks like I will be using Stuart's suggested method.---Something worth remembering!!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/EXPERIMENT001_zpsc85925d8.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/EXPERIMENT001_zpsc85925d8.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/EXPERIMENT003_zps3d41c2cb.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/EXPERIMENT003_zps3d41c2cb.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/EXPERIMENT005_zpsaedcd31c.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/EXPERIMENT005_zpsaedcd31c.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 05, 2014, 06:54:06 PM
AAARRRRGGHHHHH!!!!!!!!!!---Giant headslap for me!!! I cross drilled the cams, hardened the cams, cross drilled the cold rolled camshafts, made up .093" cold rolled cross pins----and trial fitted everything. Was being REALLY careful with the cams. Slathered everything with Loctite, dropped the cam into place, aligned the cross drilled holes, and as I pushed the .093 pin into place by hand, encountered some resistance. Took it out to the anvil and CAREFULLY tapped the pin all the way thru.--And then---just as I thought I had won---I heard a little "crack"!!! OH POOP!!!!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/brokencam001_zpsb8362dce.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/brokencam001_zpsb8362dce.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 05, 2014, 07:28:51 PM
They were supposed to BOTH look like the one on the left----Honest!!! The cross pin is mild steel and will get filed down until the surface is an exact match for the hardened cam surface. And everything is coated with #638 Loctite.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/GOODCAM-BADCAM001_zps9b2d0290.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/GOODCAM-BADCAM001_zps9b2d0290.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 10, 2014, 08:26:42 AM
I have been so overwhelmed with "busy" in the rest of my life, that I haven't had time to devote to this engine lately. I did manage to steal two hours yesterday evening to remake and harden the cam which was broken and assemble the cams, camshaft, gears, and tappets and tappet guide. This engine is getting very close to being a runner. During the rush leading up to having the top end of the engine finished, I forgot to lap the valves into their seats. Fortunately, I can easily access the valve stems to grip them with a finger chuck when the cylinder is removed from the engine, so that shouldn't be a problem. I am very pleased at how well the gear/cam/tappet train seems to work, so have attached a short video of them in operation.

     


(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/th_CAMMOVIE_zps583420f7.mp4) (http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/CAMMOVIE_zps583420f7.mp4)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Manxmodder on October 10, 2014, 09:40:37 AM
That's great progress,Brian.

Nice to see the scale of the motor compared to your hand,I look forward to more of your posts in the near future......OZ.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 11, 2014, 06:31:52 PM
I haven't abandoned ship--Just been very busy. This afternoon I made up the knurled adjuster knobs that fit on the ends of the camshafts, but then found out I was out of #8 socket head capscrews of the correct length. I stuck two in the place that the much shorter ones will go in when I get them. On the right you can see the true meaning of "Make it up as you go." I forgot to lap the valves, and cut the long piece of parent metal off that I generally use for a handle when lapping the valves and seats together. So---I made up a pair of extended 1/4" "handles", counterbored them 1/8" to suit the valve stems, and cross drilled them together with a 1mm (.039") drill for a drive pin to connect them. The valves needed to be cross drilled anyways, so it kills two birds with one stone. I will lap the valves tomorrow and start the final assembly of everything.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/KNURLEDADJUSTERS002_zps7d9bc820.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/KNURLEDADJUSTERS002_zps7d9bc820.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 12, 2014, 11:01:00 AM
This morning I got up early and lapped both of the valves into the seats. I first lapped them with 400 grit carborundum paste, then after a good cleaning, lapped them again with 600 grit. Everybody seems to do this a different way. In an earlier post you will see the "handles" that I attached to the valve stems. (Normally I leave the parent material from which the valves are cut long enough to be a "handle" and then cut it off after lapping is completed). The valve seat and valve face are coated with the carborundum paste (it doesn't take very much) and then the "handle" is gripped between my thumb and finger and revolved back and forth while pulling the valve into the seat. I do this ten times back and forth, then lift the valve off the seat,rotate it a quarter turn, and then repeat. I do this a total of ten times.  Never use a power tool to do this. This is a job for "finger twiddling" only. After a thorough cleaning of both valves and seat areas, the valve springs and brass keepers were installed and the .039" cross pins installed. This as a job that always makes me wish for a third arm and hand, but I manage with the two I have. I am now at the point where I can't really go any further until I can buy a tube of Molycote grease tomorrow for the big end needle bearing. (Do you suppose turkey grease would work?--It's thanksgiving here today.) The valves open and close very nicely, which is always pleasing to see. I hear my wife up now preparing a feast for hoards of children and grand children, so being a firm believer in self preservation I had better get upstairs out of my machine shop and help her.--All you other Canadians following this thread---Happy Thanksgiving!!!---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/VALVESPRINGSIN005_zpse4a24d6e.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/VALVESPRINGSIN005_zpse4a24d6e.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: dsquire on October 12, 2014, 12:36:11 PM
Hi Brian

Looks like your getting close to the end on this one and it's looking good.

;Have a good Thanksgiving with family and friends.  :D :D

Cheers  :beer:

Don
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 12, 2014, 01:17:00 PM
Thanks Don---
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 12, 2014, 08:37:21 PM
I've heard it said that "Close only counts in horse-shoes and hand grenades." There is one other place that it counts, and that is clearance where the con rod exits a round hole in the bottom of the cylinder. I showed lots of clearance in my 3D cad model when I took a section view thru the center of the engine, but in the case of a rectangular cross section rod exiting thru a round hole in the bottom of the cylinder, it doesn't tell the whole story. If you look at the edge of the con rod, about at the center, you will see how much clearance I DIDN'T have. I thought I felt some resistance when I first rotated the assembled engine by hand, but it was stiff and I was able to get a full rotation after working the crankshaft back and forth a bit rotationaly.  I will file a radius on the corners of the con rod, and that will take care of things. There is no moral to this story, other than the fact that building one of these small engines always has a few surprises in the process. Laying in the picture with the con rod and piston is the newly machined and hardened wrist pin.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/WRISTPIN003_zpsb14648f3.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/WRISTPIN003_zpsb14648f3.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on October 13, 2014, 02:50:28 AM
Bad luck. Presumably there will be witness marks on the rod where the interference is? Can you perhaps mount it in the 4 jaw and turn the corners off ?
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 13, 2014, 09:12:36 AM
  I will file a radius on the corners of the con rod, and that will take care of things.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 13, 2014, 02:24:36 PM
I am down to the point in my parts making where all that is left is the carburetor, exhaust pipe, and the cooling fan system. I still have a lot of bronze laying around, so decided to make this part today, just because it's do different. Alas, it is not going to happen. Whatever it is about bronze, if the bandsaw blade has any wear on it at all, it simply won't cut bronze. A new blade, it cuts fine.  A slightly used blade, and it just isn't going to happen. The blade still cuts aluminum and steel with no problem but not the bronze. My metal supplier who has a big industrial size self feeding bandsaw and cuts the slices of the 5 or 6" diameter " bronze billet" I have says the same thing about his saw. I would switch to aluminum for the part, but I have to be able to silver solder the fan shroud to it.---Darn!!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/FANSUPPORT-RUPNOW-2_zps9a8aaae1.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/FANSUPPORT-RUPNOW-2_zps9a8aaae1.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: lordedmond on October 14, 2014, 09:45:52 AM
Brian

You will have to do what I do keep a blade for bronze/brass when it wears then use it for steel same for milling cutters new ones for the two B,s the down to steel

Both things once they have cut steel are NBG for brass

Build is coming along just fine soon be time for some bangs


Stuart
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 14, 2014, 05:44:58 PM
Now here is something a little different. I really didn't like the look of the exhaust pipe running out of the engine on an angle, and the carb being mounted on an angle, but I had to design it that way so the exhaust wouldn't interfere with the carburetor. Today I was down at Partsource, an automotive supply store, and seen a rack of steel 90 degree and 180 degree bend steel tubes for automatic transmission repairs. For a couple of bucks, I thought "Hey---If that worked out, I could run the exhaust straight out from the engine and mount the carburetor at 90 degrees." I can't bend anything on that sharp a radius without kinking it badly. That tube measures 3/8" o.d. and has a .028" thick wall. I will keep you posted on this and let you know if it works out.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/90DEGREEBEND002_zps167524aa.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/90DEGREEBEND002_zps167524aa.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 14, 2014, 08:56:06 PM
For reasons far more complex than I want to go into (but mainly involving how little material was left beside the counterbored bolt holes), I have went to a total redesign of this part. I don't do this terribly often, but since it is almost the last major part, and because it will be made of brass now instead of bronze, I have redesigned it. I finished the last of my "drop in" engineering design contracts this morning, so hope to complete this part and possibly the fan tomorrow.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow017/FANSUPPORT-RUPNOW-2_zps039fdd22.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow017/FANSUPPORT-RUPNOW-2_zps039fdd22.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 15, 2014, 02:32:08 PM
If the engine runs, I can guarantee that it will run cool. The white plastic fan is out of  some computer hardware. I am not crazy about the color of it, (I may paint it) but at least the pitch on the blades is correct. I realize that the curvature of the blades would make it more efficient if it was going to turn counterclockwise, but it still puts out a good column of air if turned clockwise (I set all my engines up to turn clockwise.) That is because I use my variable speed drill as a starter, and if I run it counterclockwise the chuck loosens off. I still have to find some thin wall tubing of the correct diameter to solder onto my fan support to act as a fan shroud as per the 3D cad model seen at the early stages of this thread.--those little fans will really chop up fingers.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/COOLINGFAN001_zpsbe4929ba.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/COOLINGFAN001_zpsbe4929ba.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/COOLINGFAN002_zps07aa8b33.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/COOLINGFAN002_zps07aa8b33.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 15, 2014, 07:11:10 PM
I think I may try my Chuck Fellows carburetor on this engine. It works great on the Webster. I will make a more complicated larger carburetor if I have to, but I already have the Chuck Fellows carb, and if I use it I can come straight out of the engine ports with both exhaust and carb and not have any interference.--Speaking of exhaust---I kind of like this. You can do nifty things with a piece of 1/2" diameter brass and a 1/16" slitting saw!!!---
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/ALTERNATEEXHAUSTASSEMBLY_zpsece52964.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/ALTERNATEEXHAUSTASSEMBLY_zpsece52964.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 16, 2014, 04:23:07 PM
Cross your fingers for me guys. It's pretty well all over but the final assembly. I am pleased with the way my intake and exhaust manifold turned out, and my Chuck Fellows carburetor looks real proud setting up there. Yes, I will be bevelling the corners on the tappet guide, gear backplate and fan support just like the solid model, but I thought I would wait until I had everything assembled and do it "in place". All I have left to fabricate is the fan shroud, and I MIGHT do that before I try to start the engine---but I am just as anxious to see this thing run as you are!!!---
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/INTAKEANDEXHAUSTFINISHED001_zpsb94b0e96.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/INTAKEANDEXHAUSTFINISHED001_zpsb94b0e96.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/INTAKEANDEXHAUSTFINISHED002_zps8d9940b5.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/INTAKEANDEXHAUSTFINISHED002_zps8d9940b5.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/INTAKEANDEXHAUSTFINISHED003_zps4dd53959.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/INTAKEANDEXHAUSTFINISHED003_zps4dd53959.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on October 16, 2014, 05:40:32 PM
Good luck, Brian!  :thumbup:

Waiting, with bated breath........   

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on October 16, 2014, 05:55:47 PM
But you forgot to mount a starter motor !

Best of luck, I hope that it runs smoothly
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 16, 2014, 09:16:12 PM
As I began my final assembly of the engine, a thought occurred to me. The displacement of this engine is quite large in relation to the volume inside the crankcase. I am breaking new ground here (for me anyways) and I thought it MIGHT need a crankcase vent. It might not, too, but now is the time to put one in, while I can still pull the engine all apart and flush it out before I put the rod and piston back in. If I don't need one, that's fine, it won't do any harm and didn't cost any money. If it does need one, at least it's in there.----Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/CRANKCASEVENT001_zps159f7b58.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/CRANKCASEVENT001_zps159f7b58.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 17, 2014, 03:55:12 PM
After a full day of final assembly, individual cam timing, ignition timing, adding a new set of points and condenser, adjusting valve lash, and making a starter spud to fit this particular engine, I am just about ready to Rock and Roll. Has it got compression?--Hard to tell. It's a brand new engine, and it's too stiff to tell if I have compression or not when turning it over by hand. Tomorrow should tell me more---
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on October 17, 2014, 04:27:20 PM
Still holding me breath........

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on October 17, 2014, 04:31:18 PM
Still holding me breath........

David D


... and I'm holding the spray can of Easystart  :lol:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on October 17, 2014, 04:49:54 PM
Still holding me breath........

David D

... and I'm holding the spray can of Easystart  :lol:

 :thumbup: :clap: :clap:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 17, 2014, 06:45:30 PM
Engine does have reasonable compression for a new engine that has never yet fired. I hooked it up with a v-belt to my 1800 rpm electric motor with a 1:2 ratio so it was turning at 900 rpm+/- for about 10 minutes without the sparkplug in it, to loosen it up a bit. I then put the sparkplug back in and turned the engine over with my variable speed drill. I had coated everything with oil, and as I turned it over, I seen ripples in the oil racing away from the sparkplug. Closer investigation shows that I need to machine the counterbore that the sparkplug sets in about .020" deeper to get below a cooling fin groove. That will be my first chore in the morning---Pull the head and machine the sparkplug seat a tiny bit to get a good seal at the plug. I will borrow a gas tank from one of my other engines.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 18, 2014, 09:56:50 AM
It's been a GREAT morning here. I got up and borrowed the gas tank off my Odds and Ends hit and miss engine, did a little machining on the cylinder head sparkplug seat, hooked up the battery, and AWAY WE WENT!! I have lots of clean up and finessing to do, but we have a runner!!!!--Brian

     


(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/FIRST%20RUN--RUPNOW%202%20ENGINE_zpsya3y89ph.mp4) (http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/FIRST%20RUN--RUPNOW%202%20ENGINE_zpsya3y89ph.mp4)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on October 18, 2014, 10:16:03 AM
 :thumbup: :thumbup: Excellent Brian  :thumbup: :thumbup:

(and no sign of using ether  :ddb: )
Title: Re: Side Valve i.c. engine from Bar stock
Post by: DavidA on October 18, 2014, 10:21:59 AM
Another success story;  well done.

Dave. :thumbup:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 18, 2014, 10:23:16 AM
As a matter of interest, I took my new laser aimed temperature sensing gun out to the garage after the engine had been running for 15 minutes at a mid range speed. The top of the cylinder head was 180 degrees F at the base of the cooling fins, and 150 degrees F at the tip of the fins. The exhaust pipe at 150 degrees half way down its length, but 195 degrees F right where it exits the engine.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: dsquire on October 18, 2014, 10:41:19 AM
Nice to see that you have a runner right off this time, makes you feel so much better. I fixed the video link so that it would have the picture embedded.

Now you will have to build something fancy for it too power.  :D :D

Cheers  :beer:

Don
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 18, 2014, 11:00:45 AM
Here is a video taken from the other side of the engine, and a video in which the Chuck Fellows carburetor gets an honourable mention. The crankcase vent doesn't seem to have any effect on the way the engine runs, whether it is open or blocked.

     


     


Title: Re: Side Valve i.c. engine from Bar stock
Post by: RussellT on October 18, 2014, 01:52:21 PM
Hi Brian

I've been following this all the way through and I've been very impressed by your whole approach to it.

Great job.

Russell :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap:
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on October 18, 2014, 03:36:39 PM
Great result, Brian!  :thumbup:

Well done.....  :clap: :clap: :clap:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: millwright on October 18, 2014, 04:16:26 PM
Excellent result Brian,  i have followed your design and build all the way. its been a very popular read on here by the number of views registerd. You must be very pleased now its running.
 :beer: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap:

John
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 18, 2014, 05:34:02 PM
Thank you guys. Sometime within the week, I will be posting a link to a download of all the updated drawings as .pdf files. Nothing would give me greater pleasure than to see someone else build my engine.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 19, 2014, 05:57:38 AM
After I went to bed last night, I realized that during the excitement of the first run, I had forgotten to put gaskets between the intake/exhaust flanges and the valve body. The exhaust gasket is not terribly important, but without an intake gasket it's a wonder that the engine run at all. I will start today getting all of the drawings ready for download.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 19, 2014, 08:53:51 AM
I have uploaded about 40 drawings to filefactory.com. If you click on the attached link, you should be able to download then free. They are in pdf format, so you won't need any engineering software to open them. Somebody please let me know if this works okay and lets you download them with no hassle. If anybody finds errors in the drawings, let me know about that please.---Brian
http://www.filefactory.com/file/1dkn3uxr9xbx/RUPNOW%20ENGINE-2.zip
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 19, 2014, 12:50:29 PM
I made up gaskets for the intake and exhaust flanges (I had forgotten to make them) and after a bit of tuning this morning, I got out my spanking new digital tachometer. This gave me pause, because at first it wouldn't work. Then I tested the batteries that came with it from the factory, and two of them were stone dead. After replacing two of the batteries and warming the engine up, I found that its lowest consistent idle was at about 800 rpm. It would idle lower, but then it faltered and threatened to stall. On the high speed end, it topped out at a whopping 1950 rpm. This is really about what I expected from the cam I designed. This is more of an "industrial" engine that likes a steady speed without wide rpm range fluctuations. It is really happy at about 1200 rpm, and would run all day at that speed without faltering. The heavy flywheel gives a good steady run, with a slow throttle response due to its mass. This engine is almost the exact opposite of the Canadian Cub (Malcolm Stride's Jaguar engine wearing Canadian clothes). I went to separate camshafts so I could set the cam timing of exhaust and intake totally independent of each other.--You simply can not do that with a one piece camshaft. On the question of cooling fans---I wanted a fan with a pitch which would push air over the cooling fins, rather than pull it, when rotated clockwise. (All of my engines are set up to turn clockwise). Unfortunately, the only fan I could find in the correct size range was designed to rotate counter-clockwise, thus the curvature (dished shape) of the blades. However---That doesn't mean they won't blow in the opposite direction if rotated clockwise. They just won't blow as efficiently. I don't need a whole lot of airflow---just enough to keep a steady flow of air over the cooling fins, to move the heat away. As for writing a book---I have had two of my engines published in "The Home Shop Machinist" magazine. I may see about publishing this one, because it is a very unique engine and seems to run very well.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Joules on October 19, 2014, 01:02:04 PM
Zip file downloads fine, all looks OK Brian, big  :thumbup: for publishing the plans.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: krv3000 on October 19, 2014, 01:29:55 PM
well dun
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 20, 2014, 08:36:27 AM
The engine runs well, but the gears are---ahh----noisy. I knew that they would be. They mesh well, and operate very smoothly now that I have an hours running on the engine. However, experience with other engines I have built sort of forewarned me that the open gearing would make a fairly noticeable "whirring" noise as the machine ran. That is why I made provision for an enclosure to go around the gears. An enclosure will cut down the noise quite a bit,  will act as a containment for grease around the gears, and will provide some measure of safety (although I doubt I would have stuck my fingers in there anyways.)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/TIMINGGEARENCLOSURE_zps5f4cfd84.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/TIMINGGEARENCLOSURE_zps5f4cfd84.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: awemawson on October 20, 2014, 08:42:32 AM
Harder to make, but helical gears would be the elegant solution if the straight gears cannot be given an oil bath?
Title: Re: Side Valve i.c. engine from Bar stock
Post by: philf on October 20, 2014, 09:07:10 AM
Brian,

A superb project.

Thank you so much for sharing it with us.

How about fibre gears to mesh with the steel crankshaft gear. They should run much quieter and are no more difficult to make.

Cheers

Phil
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 20, 2014, 12:37:59 PM
Philf--If I can avoid remaking parts, I will be much happier. I will try this solution first. -Fabrication of the timing gear enclosure went very quickly with no problems. I did have to split it to get it on, as I had indicated on the drawing. The only problem I ran into is that I don't have any bolts long enough to bolt things together. I had to order a minimum quantity of one hundred #5-40 socket head cap screws x 1 1/4" long to get the 6 I need. That will probably last me for the rest of my natural life!!!
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GEARCOVERS002_zpsa4794228.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GEARCOVERS002_zpsa4794228.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 20, 2014, 06:13:25 PM
When Ringo sang the song "It don't come easy" I'm sure he must have been thinking about something like this fan shroud!!! The only tube/pipe I could find slightly larger than my 3" diameter fan was a piece of schedule #40  3" nominal diameter steel pipe. It has a 3 1/16" inside diameter. I don't like working with pipe in the lathe.--It's nasty stuff to hold if you don't have a bull nose live center for the tailstock (I don't) and it has a propensity for jumping out of a 3 jaw chuck and rocketing around the room. This forced me to take .002" deep  very light cuts until I had things close to the outside diameter that I wanted to end up with. The wall is still a little thicker than I would have liked, but it was just getting too scary.  I have had a slight change of plan----I was going to silver solder it to the fan support bracket but that would have given me no adjustability at all. I have come up with a rather novel solution for bolting it to the fan bracket instead, giving me a bit of wiggle room if it ends up interfering with the tips of the fan blade anywhere.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/FANSHROUD-1002_zpsed93b70f.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/FANSHROUD-1002_zpsed93b70f.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 21, 2014, 12:36:41 PM
Going boldly where no man has gone be----Well, you get the idea.--Fan shroud is coming together nicely. At the last minute I decided to make the small pieces silver soldered to the steel hoop from brass. My reasoning--If I have to slot the holes with an end mill to move things around for fan clearance, the brass cuts easier. As you can see in the picture, the soldering job called for a couple of strange little "fixtures" to ensure that everything ended up where I wanted it to be. Now to ensure that the steel hoop will be concentric and clear the tips of the fan blades, I wrapped the fan with masking tape until I had .030" thickness of masking tape. Slid the hoop over that (snug fit) and will mark thru the brass ferrules welded to the hoop with a transfer punch to locate the holes I will tap in the fan stand.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/MOREFANSHROUS001_zps41aa5910.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/MOREFANSHROUS001_zps41aa5910.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/ASSEMBLYOFFANSHROUD_zps9c9f1451.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/ASSEMBLYOFFANSHROUD_zps9c9f1451.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 21, 2014, 02:04:31 PM
So, there we are!! Painted up pretty and done like dinner!! Nothing rubs nor scrubs, nor interferes, but a business card won't fit into the gap between the flywheel and the bottom of the fan shroud.--But it does clear. And that, my friends, was the very last part I had to build for this engine. I have to wait a couple of days for my long bolts to come in that hold the timing gear covers in place, but that's it. I will post one more video before I'm done, showing the engine running at its slowest and fastest speeds because someone has requested it, but other than that, I'm finished. This has been a long thread, as I knew it would become when I started it in July, but it's been fun and interesting. I encourage anyone out there who has at least a couple of i.c. engines "under their belt" to build this engine. ---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/FANSHROUDFINISHED002_zps37f3ada9.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/FANSHROUDFINISHED002_zps37f3ada9.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/FANSHROUDFINISHED003_zpsa69aa7b0.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/FANSHROUDFINISHED003_zpsa69aa7b0.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 22, 2014, 03:10:04 PM
Liar Liar--Pants on fire---I said I wasn't going to post anymore but---I have never really liked the base I made for this engine. Oh, it was a lot better than the long angles that I had first proposed, but somehow it never looked--uhh---industrial enough for me. so--Today being free time, and having a bit of 3/4" aluminum left over, I made a new base. I like it much better.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/BASEPLATE-2-SIDEVALVEENGINE_zps22ce5717.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/BASEPLATE-2-SIDEVALVEENGINE_zps22ce5717.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/NEWENGINEBASE001_zps18d6eee6.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/NEWENGINEBASE001_zps18d6eee6.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 23, 2014, 11:38:56 AM
As Bugs Bunny would have said----That's all folks. Thanks for following.---Brian

     



Title: Re: Side Valve i.c. engine from Bar stock
Post by: dawesy on October 23, 2014, 11:45:32 AM
That's awesome. Runs really well. A credit to your skills :)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: tom osselton on October 23, 2014, 05:04:18 PM
Thanks for showing thats a well thought out engine!
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on October 24, 2014, 08:14:24 AM
It certainly is. "A great success"!  :thumbup:

Very well done, Brian.....  :clap: :clap:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: sbwhart on October 24, 2014, 01:52:30 PM
A real smooth runner Brian  :ddb:

Great job  :thumbup: :headbang:

Stew
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 26, 2014, 09:25:03 AM
Judging by the number of downloads I have had for the plans of this engine, someone, somewhere , is going to build it. I am going ahead with a gas tank bracket and gas tank for it, so will post them as "supplementary drawings" to the main download package. The bracket is located right in the center of the engine block, and the underside of the bracket is 1" below the top of the block. This will place the top of the tank about 1/8" below the center of the carburetor.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/SIDEVALVEASSY-GASTANKBRKT_zps990ddc98.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/SIDEVALVEASSY-GASTANKBRKT_zps990ddc98.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GASTANKBRACKET_zps0924ed8f.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GASTANKBRACKET_zps0924ed8f.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 28, 2014, 08:12:30 AM
I spent all of yesterday fighting "gas tank wars". What should have been a very simple and straightforeward silver soldering job left me frustrated. All of the joints looked good, but when I put a rubber tube on the outlet spigot, then put the tank underwater and blew into the tube, I got a stream of bubbles coming out of the one end. I resoldered it twice, with the same result each time. Finally I set the whole tank up in the lathe and drilled/bored the leaking end completely away, made a new brass end  insert and silver soldered it again before I went to bed. As of right now it doesn't leak, as per the "blow test" but I haven't filed away the excess silver solder either. I am waiting for my wife to get up before I start any power equipment in my shop, but I sincerely hope that when I get my last solder joint "cosmeticized" that I don't see any more bubbles!!
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 28, 2014, 09:56:44 AM
I used a piece of my bronze stockpile to carve out a gas tank mount. I set it up to have a 1 1/4" i.d. and chose a 6" long 1" pipe nipple which has an o.d. of 1 5/16" to make the tank from. The pipe is galvanized, but that doesn't matter, because when I turn the o.d. down to 1 1/4", the galvanized will be all machined away. I also picked up a brass 1/2" pipe nipple to become the gas tank filler spout. I could have bought the 6" long pipe nipple in brass, but it would have cost $21 as opposed to the $3 I paid for the galvanized steel one.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GASTANK-1001_zps7381e6d5.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GASTANK-1001_zps7381e6d5.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 28, 2014, 10:05:55 AM
Here we are machining the o.d. of the pipe in my lathe, after cutting the threaded ends off. I don't like machining with something sticking out of the jaws that far, but the "thru the spindle" hole in my lathe is only 1 3/16" and the o.d. of the pipe was 1 5/16". So---Take light cuts and hold your breath a lot, being ready at all times to "Duck and cover". Once I got the o.d. turned to a finished diameter, I pulled out my seldom used steady rest and set it up to counterbore the ends of the pipe for brass end caps.
I used a piece of my bronze stockpile to carve out a gas tank mount. I set it up to have a 1 1/4" i.d. and chose a 6" long 1" pipe nipple which has an o.d. of 1 5/16" to make the tank from. The pipe is galvanized, but that doesn't matter, because when I turn the o.d. down to 1 1/4", the galvanized will be all machined away. I also picked up a brass 1/2" pipe nipple to become the gas tank filler spout. I could have bought the 6" long pipe nipple in brass, but it would have cost $21 as opposed to the $3 I paid for the galvanized steel one.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GASTANKFINISHED001_zps03f09c32.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GASTANKFINISHED001_zps03f09c32.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GASTANKFINISHED002_zps72af36b4.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GASTANKFINISHED002_zps72af36b4.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 28, 2014, 10:10:18 AM
And finally, after an absolute bear of a time getting one of the soldered in ends to be leak-tight, we have a custom fitted gas tank.
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GASTANKFINISHED001_zps4a68ebd2.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GASTANKFINISHED001_zps4a68ebd2.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GASTANKFINISHED002_zpsa88d3593.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GASTANKFINISHED002_zpsa88d3593.jpg.html)
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/GASTANKFINISHED003_zps80952564.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/GASTANKFINISHED003_zps80952564.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on October 28, 2014, 06:19:53 PM
And finally, after an absolute bear of a time getting one of the soldered in ends to be leak-tight, we have a custom fitted gas tank.

And. Very good it looks too, Brian!  :thumbup:

Well done.....    :clap: :clap:

David D
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on October 30, 2014, 10:57:34 AM
I have been asked by a  machining magazine to present an article on this engine for publication. As a consequence of this, I have had to put together an "overview" drawing of the engine with the maximum envelope dimensions and information about bore, stroke, etcetera. This morning I took the time to add the gas tank and a couple of minor components that were not shown previously. The build of this engine is finished, but since I have never actually posted this final information, I am attaching it to the end of the build thread.---Brian
(http://i307.photobucket.com/albums/nn294/BrianRupnow/BrianRupnow018/SIDEVALVEENGINE-OVERVIEW_zps33c35d4a.jpg) (http://s307.photobucket.com/user/BrianRupnow/media/BrianRupnow018/SIDEVALVEENGINE-OVERVIEW_zps33c35d4a.jpg.html)
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Manxmodder on November 02, 2014, 08:34:56 AM
Brian, the finished engine with all the ancillaries looks wonderful and is a credit to your skills and problem solving. I would also like to say a very big thanks to you for this very detailed and interesting documentary of the planning and building of this project. :bow: 

And thanks for making detailed plans freely available and hope you will share some future projects with us other madmodders........Cheers, OZ.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on November 03, 2014, 01:59:52 PM
-I am going to have to find a different site to upload my drawings to --there is just too much horse #### involved with the site I am currently using. The reason I don't upload them here is that I post on four different machining/modelling sites, and I want the downloads to be available to all of them. I don't make any money from posting these plans, so I try to use free sites, but it seems to be becoming more and more difficult to find a free site that is not over-ran by spam-ware and misleading advertisements.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on November 13, 2014, 11:18:24 AM
Hooray for my side!!! Just as I was about to go bonkers from terminal boredom, I got a call ten minutes ago for some design engineering work starting tomorrow. I have been thinking about using my new engine to run a lighting plant, using an old bicycle generator, the kind with the friction wheel that ran off the front or rear tire. Dearie me!!!---Time has moved on in the last 55 years since I had a bicycle. I went into 3 bike shops and Canadian tire asking about generators for bicycles, and they all looked at me as if I had two heads. Apparently now, if you want a light on your bicycle, you use batteries and LED's. I see many of these generators (also called dynamos) on ebay but I don't totally trust buying used electrical things from people I don't know in places I have never been to. I will pursue this a bit more though, because I would like to have my new engine power something.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: philf on November 13, 2014, 11:54:52 AM
 Hi Brian,

As you have found out LEDs have revolutionised bike lighting but there are still those who use dynamos. The tyre driven dynamo seems to have disappeared in favour of hub dynamos. I guess the hub type are designed to run at too slow a speed to drive from your engine without a wheel size pulley.

How about just using a permanent magnet motor as a generator.

Phil.
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Brian Rupnow on November 13, 2014, 02:47:10 PM
A very kind gentleman from Michigan who built my Muley style Sawmill and exhibits it at shows around USA has just "volunteered" me a bicycle generator. It will be sent here by snail mail (I assume) and then we will go about building a "lighting plant" for my newest engine to run.---Brian
Title: Re: Side Valve i.c. engine from Bar stock
Post by: Stilldrillin on November 13, 2014, 03:14:33 PM
Brian.
Back when I tinkered with motorcycles. A pal fitted a bicycle hub dynamo, onto the crankshaft of his trails bike. To provide, "bobby dodger" lighting. (ie. no battery)......

It worked!  :thumbup:

David D