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Looking good!! One thing I've not been able to figure out is the ratchet pawl when unlatched, still clicks against the gear. I'm trying to figure out how to get it to pull back just a bit further so it doesn't click. Does anyone else have that problem?

Yes, 5/8". That was one of the parts I documented pretty well. http://www.teqknow.com/Shop/Mery2.html about 1/2 way down. Just take your time. I've seen your work you got this one. It LOOKS much harder than it actually is.

Oh no... That sux! I've always done 1 piece cranks. I guess there are pluses and minuses to each. You may want to look into timing? The power stroke may be a bit too early and resulting in a more violent stroke. Since you aren't really powering anything, there's no need to fire too much...

LMAO!!! I recognize that cry at the end!!!! It will be like that for a bit. It will run for a bit then quit. You'll find something needs tweaking, then it will run a bit longer; rinse, lather, repeat. It does sound like it's firing a bit out of balance. I didn't slow the video down to...

Very well done Jack!!! Isn't it a great feeling when it comes alive!

Damn gremlins!! I'm glad I'm not the only one with those little rodents!!

VERY VERY nice job Jack!!! That purple engine is killer isn't it? I spoke with him. He almost ruined it. He left plain water in the jacket and plugged it up with rust. That was where I realized I will always use machine coolant. I think I would cry if I rusted mine.

For exhaust, I used the cast ones from the hardware store but I turned down what I could and tried to make them smaller. The intake side I did the same with the brass fittings.

Congrats Gramps!!

Like the explosion chambers, don't lose sleep over those slots. They're decoration at this point.

Sorry Jack, I zoned out for a bit and missed the last updates. You're on the right track for the .02 wire. .015 is in my mind for some reason but you have the right idea, minimal pressure to open.

Jack, Read the newsletters. They speak about the compression. If I recall, you'll need to cut the piston nearly 1/2 the thickness to reduce the compression. DON'T rely on leaks as a reduction method. PhilipinTexas, You said your flywheel key came loose. Did you use a tapered key? A...

Looking fantastic Jack.

Looking great Jack! "First one was piece of cake, the second one made me make a third" <--- I seriously laughed out loud at that!! But oh so true.

Absolutely no problem with a different plan. There's no right or wrong. It's what keeps us coming into places like this.

If I recall, I held it with a 4 jaw and some very imaginative blocking and a very light touch. I cut flats on the outside of the bolt ears that I could use to indicate the casting center that direction then I referenced the parting line of the 2 halves for the other direction. Once I had all...

Sounds like a solid plan.

The next gear is the small one. You made a different cutter for that right? Make a practice one out of aluminum or something.

Well hell... I can't believe my cheap @$$ spent $45 each for those cutters! What was I smoking? The cutters I have are TTC (Travers) 10-281-320 and 10-283-320. You'll need both the #1 and #3. I don't have any peperwork for where I got them.

Jack, If I may... Order the cutter from Ebay. You should find it for about $20. I'll find the spec when I get home. I'm affraid there are too many variables involved and there's no adjustment for mesh. You have to be 100% right the first time. The picture I saw above didn't look like the...