I have built the Coles Corliss and sad to say I didn't keep a 'do's and don't' list but one thing comes to mind:
The drawings I have called for 8-32 machine screws in too many places, particularly the cylinder assembly.
I used 5-40's and certainly would not use anything larger than 6-40's.
I...
The blow by groove actually improves sealing. Any flow causes a turbulence, which acts somewhat as an air seal.
I used 12L14 precision stock from McMaster Carr.
Attached is photo of slitting saw operation and it looks like I used end mill for bevels, this was 4 years ago and my memory isn't serving me well. The third photo shows finished valves, note I cut a small groove in each end to serve as an air seal for blow by.
I have built a Coles Corliss, finished about two years ago and sorry to say, I didn't keep build notes although I have a U-tube of the engine running (link below), some of the machining setups in a .pdf file and a few up front comments.
First comment: the drawings mostly call for #8 screws...
Yes, O'Rings have too much friction.
There is a product called Grafoil! It's in the form of a tape and has no fiber base. I have used it very successfully. Make a 2 piece mold the size of the gland you need, pack the mold with Grafoil then pressing it. It makes a perfect gland that seals with...