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  1. R

    Boll Aero - my first engine build

    Hi all, Neat to see some interest - it looks like photobucket have gone a bit nuts. I don't have time to move all the photos to a new hosting site and repost the links here at the moment, but I think if you visit my album on the photobucket site directly you should be able to see the images...
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    Setting up Shop Questions - from an NZ learner

    Very nice work James! You're motivating me to try and squeeze in a bit of shop time. If work would just ease of a touch...
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    Setting up Shop Questions - from an NZ learner

    Nice work James!
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    Setting up Shop Questions - from an NZ learner

    Very professional looking James!
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    Boll Aero - my first engine build

    Hi guys. Thanks for the ideas re fuel. I had read about people trying to make their own from starter fluid. Perhaps that might be worth a try to boost the ether content in the fuel I already have. I made a new contra piston today and got a really tight fit. It's no longer leaking past the...
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    Boll Aero - my first engine build

    Thanks for the encouragement Ed! I'm going to remake the contra piston today and see if I can't get a much tighter fit. I feel like that is probably the main contributing factor to the lack of compression. Once I have that done I will follow your steps to attempt the start. Unfortunately I...
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    Boll Aero - my first engine build

    Bit more detail on what I've tried so far: - tightened all the screws holding the block, main bearing and back plate up snug - made a paper gasket for the back plate as felt that it was leaking too much - screwed the compression screw all the way down to see if I could get a seal but no...
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    Boll Aero - my first engine build

    So, over the last month or so I've managed to grab an hour here and there and get the engine to a completed state. Here are some pics of the final parts collection and the assembled engine. The last remaining job before assembly was to finish lapping the piston to the cylinder. I did this by...
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    Setting up Shop Questions - from an NZ learner

    Nice work James!
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    New 2.5 cc Model Diesel design and build.

    Great looking engine and very informative build thread, thanks so much for sharing! Amazing how quickly you've built this. I'm hoping to get my Boll Aero finished in the next week or so. Cheers James Fitzsimons
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    Vertical I.C. Rupnow Engine

    Congrats David, looks and sounds fantastic! Cheers James Fitzsimons
  12. R

    Boll Aero - my first engine build

    Hi guys, So I got close to finishing and then life got in the way! Work has been absolutely manic, I'm in the midst of a bunch of home renovations, and my third child arrived safely a couple of weeks ago, so there hasn't been too much spare time to get out to the workshop! I did manage an...
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    Setting up Shop Questions - from an NZ learner

    Looking fantastic James! You'll be making swarf in no time! Cheers, James Fitzsimons
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    Vertical I.C. Rupnow Engine

    Hi Brian, am enjoying following your rapid progress on this build! What sort of loctite are you using for things like the crankshaft? I can't make it out in the photo. Cheers James
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    Remeber your first engine build--- Boll Aero----

    Looking fantastic! Love the integrated fuel tank. Is that an exhaust on the far side? Have you had one running yet? Cheers James
  16. R

    Boll Aero - my first engine build

    Well, my first attempt a lapping is done. I'm pretty sure this is a long way from perfect, but this whole engine is just a skills development / learning experience so if I can get it to start and the end that will be a win! Lap after lapping Inside of the cylinder bore now looks pretty...
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    Boll Aero - my first engine build

    Hi Jens, Thanks so much for your detailed reply! Unfortunately I'd already done the lapping by the time I saw this so I may have a bell in my cylinder. Oh well, it's all a learning experience so I'll see how this one goes and if it doesn't work out I can always make another one! Cheers, James
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    Boll Aero - my first engine build

    Hi Petertha, The removable section you have highlighted in blue is used to knock the lap sleeve back of the mandrel if you want to loosen the lap (or replace the sleeve). If you have over expanded the lap you can just back off the screw and loosen the chuck and tap the screw which will cause...
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    Boll Aero - my first engine build

    Over the last week I've managed to get a couple of nights out in the workshop to make the lap for lapping the cylinder. I decided to try my hand at drawing it up in CAD first. I've never really done any CAD before and so thought it about time I learn the basics. I used FreeCAD which seems a...
  20. R

    Boll Aero - my first engine build

    Hi all, I haven't given up or fallen of the face of the earth. I've been super busy with work family etc and haven't had much time out in the workshop for the last couple of months. After about four failed attempts at making the con-rod I probably needed a wee break anyway to recharge my...
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