Howell v-2 four stroke gas engine.

[gus]

Day Five, 6pm.

There is too liitle for the three jaw to to grip and secure job piece. Aluminum is too soft to get good grip. Make a plug to fit crankcase bore and apply tail stock centre to help secure. Deep cuts is ruled out.

 

[Davewild]

Great idea Gus, it's looking real nice, you and me suffer from the same impatience, take your time Gus it will get done, nice work.

 

[gus]

Great idea Gus, it's looking real nice, you and me suffer from the same impatience, take your time Gus it will get done, nice work.

Hi Dave,

Gus invested too much time on this crankcase and it would heartbreaking setback if I ruined same thru impatience and stupidity.

Was suppose to take a break and came back at 5 pm after a long walk and went on to finish facing the other side. Took ample t/p breaks to ensure no goofs.

Crankcase done less the small details. Will be done next week but again-------whats the hurry for??? Suppose to take our time to enjoy building engines and not to bulldoze thru. The timing gears,gear oil pump and gear casing will take at least a month to do. There are 12 module 0.8 gears to cut. Four rocker arms and 4 valves to make.

 

[Brian40]

Gus you are a hero with that open air workshop .
Don't forget to take some time to keep your lady happy. to much work makes Gus a dull boy.
Keeping a eye on you Brian.

 

[Swifty]

Doing a great job there Gus. Just take it steady to avoid goof ups.

Paul.

 

[gus]

Gus you are a hero with that open air workshop .
Don't forget to take some time to keep your lady happy. to much work makes Gus a dull boy.
Keeping a eye on you Brian.

Taking Nellie away to Nagoya,Japan, 14-------19 Feb ,Chinese New Year holidays. Deal is Gus pay for air fare and hotel and she buy Gus Breakfast,Lunch and Dinner. Good Deal???

 

[gbritnell]

Hi Gus,
It's coming along great. I'm sure it's much easier sitting here watching then what you have to do. I would think once you get the crankcase done things should go easier as far as size.
gbritnell

 

[gus]

Now setting up to align and profile mill crankcase side. My Digital Angle Level Meter went kaput and now gone back to mechanical stuffs.Bought this mechanical meter from TokyuHands last year. Sure came in handy.
Fine tune same to mill table before levelling crankcase side.
Still nail biting.Fear of ruining crankcase with one mis-cut. Taking my sweet time.

 

[gus]

Day Six.
Profile on both sides of crankcase done. No goofs.
Moving on the cutting the oil sump hole. Too much metal to remove on a mini mill. Took no chance and had the crankcase well secured.I have another 7 mm before break through.
Looks like will be Day 7. Again. No Hurry.

 

[Davewild]

Looking good Gus, take your time bro.

Dave

 

[gus]

Day 7
9am Break thru at last. Am only half done. Will try very hard not to rush.

Looks like Day 7 will be entirely taken up milling the crankcase bottom access hole.

 

[gus]

Day 8.
Rough bore pad face hole with 1'' Starret Hole Saw on the cheapy MIC Bench Drill. The Angle Plate was used to secure job piece safely. Finish bore with fly-cutter/boring tool. Finish bore both holes spot on to print dimension. Counterbore done with same tool. DIY Boring Head too big and cumbersome for this small bore. Setting up and centering of boring tool took sometime. With the crankcase done,I can start growing and plant cylinders and Outerheads. Took the entire morning.

 

[Swifty]

Looking great Gus, it's always nice to get a main part out of the way, especially as you were pushing your machines to their limits. Looking forward to the rest of the build.

Paul.

 

[digiex-chris]

Glad I saw your build, your fixture is exactly what I need to deal with some lather bits on my engine. Was trying to figure out how to hold it because I've got a cheesy vise. The angle plate setup looks like it's just the thing. I'll have to follow along for the rest of it!

 

[Davewild]

Well done Gus, it's looking great

 

[gus]

Day Nine.
I seem to have a habit to buy tools ahead of time. The Makita Bandsaw sure saved Gus from hard labour manually hacksawing a 70 mm C.I. Bar. Took only 5 minutes to cut CI Bar. Made good progress. Looks like the Cylinder will take at least 2 days to get done. Cutting the fins was another nail biting job.

 

[gus]

Glad I saw your build, your fixture is exactly what I need to deal with some lather bits on my engine. Was trying to figure out how to hold it because I've got a cheesy vise. The angle plate setup looks like it's just the thing. I'll have to follow along for the rest of it!

Hi Chris,

Like you,I took a good hard look at the awfully small milling vise and knew ,its a gamble,I would sure lose. Was not convince the vise was the best option.
Have no experience using angle iron plates for mill. After setting up and test cuts, I have the confidence and assurance it would be best option. Crankcase done except for some minor details which are too early to do.

Now working on the C.I. Cylinder. Taking my sweet time and plenty of tea/pee breaks plus some light classical music like Brahms.

All success on your engine.

 

[gus]

Day Ten.
With a mini lathe the drilling power is not good when you hit 15 mm twist drill. Using my arsenal of drills from 3mm--------13 mm and only 14 15 16 17 18 19 20 mm to rough bore before using boring bare. For rough boring ,used the fixed steady to support job. Due excessive hangout,boring bar did chatter. The last few cuts had the steady removed and nailing biting boring went on to finish bore I.D. Did hit 0.995'' and confirmed with a Holtest Inside Mike. To get to .998" the last three repeat cuts nearly killed the job. Final bored I.D. 1.002''.
Hole bored parallel and confirmed with Holtest Inside Mike at front and rear ends.

Cutting the bottom square flange was another brain bashing. The miiling vise would be another gamble. Went back to the Angle Plate. To prevent end snatch , used 8 mm endmill.

This first cylinder took Day Nine and Ten with Overtime to finish. Cylinder done but with one forgiveable goof-------cylinder bore 2 thou oversized. :hDe:

At last the crankcase did grow one cylinder. Remaining cylinder will be next fortnite.Cast Iron is not my preferred medium. Shirt stained very badly. Boss not happy. Bath Room has to be carefully flushed several times thoroughly to ensure no rust stains.:rant:

Next week taking darling boss to Nagoya,Japan to visit our Japanese daughter-in-law. Will be one week break.
Nagoya weather has warmed up for us. Forecast day temperatures 10--------14 C throughout our stay.

 

[gus]

Day Eleven & Twelve.
Machining the C.I. Cylinder is no fun,with the fine iron dust. Had to put on a mask to minimise inhaling the fine iron dust. After the two cylinders, I'ii have only two more C.I. pistons to cut.
Getting ample practice cutting the deep fins. I have two extra fins. Cylinder No. 2 done w/o mishap.Will take time and pleasure to make the drilling jig to drill cylinder footing.

 

[gus]

Day Thirteen.
Took 5 hours to make drilling jig and drill/tap the holes on the cylinder foot pads and crankcase. All in 16 holes to jig-drill and eight M4 holes to tap. Gus deviated from Jerry Howell's requirement to use 6-32 fasteners.The Drilling jig took two hours to invent,mark,drill and mill. Plan to DIY my own DRO to locate hole locations. Making drilling jig is mind and energy sapping but Gus is comfortable with WW-2 MachineShop Technology. Will have to catch up with new technology.
Results was good with all holes spot on.
Crankcase now have two cylinders mounted and bolted on.Incidentally I have exactly 8 socket head M4 fasteners.

The two Outerheads is next. And again drilling jigs is mandatory to all holes pin-point to mate with cylinder top and to receiver some sub-assemblies like valves, rocker arm supports and spark plug. Again plan to take my sweet time with no rush. Two drilling jigs required.