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I completely agree. I would even add that in my cramped shop, there is something going on where the fallen part is most likely to end up hiding behind a bench leg or cabinet wheel. I am constantly astonished by how often that happens, way beyond the laws of chance. I suspect it has something...

Brian. Good to know and makes a lot of sense.

To be honest... on things like the general shape of the rod, especially the shaft, I didn't worry much about the plans specs. I just kind of winged it and used my Harbor Freight 1" belt sander to shape it. Part of the reason for that is I don't have a lot of specialized tools that would help...

Interesting: my plans show 4-40 screws for the connecting rod cap. You might want to consider those if it's not too late. I got the plans from the Upshur site about a year ago.

Yeah, that part I'm having trouble describing... Imagine the top surface of the rod if you lay it flat. Then, after cutting off the cap, lay the rod flat again, place the cap back where it was before cutting it off and flip the cap toward to wrist pin end of the rod so that the two, former top...

I have had good luck with this process on my Upshur. I did, however, add one step; after cutting off the cap, I "folded" it over and placed it on the larger piece of the rod so the two cutoff surfaces were on the same plane. Then I milled off a few thou so the surfaces became exactly...

I guess its like I said in my original post, maybe I'm overthinking this. Drill and ream sounds great and, from what I'm hearing it is fine for what I'm building. I had always heard from reading and YouTube that crankshaft alignment can be the source of a lot of problems in building small...

Fascinating, john_reese. I will remember this technique.

Lots of good advise here. Thanks much.

Bazmak. Good question. Answer is I don't have a collet the right size. Just have the 7/16 and next smallest size I have is 3/8. I'm told 3/8 would be too small for a 7/16 ream.

A newbie here and I have a question for all you experienced machinists out there. A question arose in my mind while I was working on a project. I needed a reamed 7/16 hole for a crankshaft on a little engine I'm starting out with. Work is 1/4" mild steel. I wanted the hole to be as accurate...