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Center drills don't help much when they're bigger than the drill bit. If you don't have a smaller center drill, try a nice fat punch mark or a split point drill bit without a center drill or punch mark

JB-Weld or other metal epoxies are always an option. Same with brazing.

You could use drill rod in a reamed hole for the piston.

Makes some "collets" for your drills. Turn some blanks to fit in a collet, drill a hole through it with the drill bit you are using it for, then cut some slots in the "collet". Stick the drill bit in the "collet", put it in an actual collet for your mill, and make some chips....

Thank you guys for all the help! I downloaded Draftsight and I really like it, even though it's a bit overkill for my needs. If I need anything "dumber" I'll use Sketchup or Open Office.

Thanks for the help, guys. Unfortunately getting a PC specifically for CAD work is not an option. For now I'll just stick to Sketchup or real drawings.

What software do you guys use to create technical drawings and plans? I've searched around on the internet, but I cannot find a free program for my Mac that will let me create technical drawings. I'm getting kinda tired of not being able to read my own handwriting and drawings. *club*

picclock, have you tried bumping up the RPM on the lathe? Carbide likes high speeds. I was wondering the same thing as you were until I found out that my indexable carbide tool bits really like high speeds on the lathe. With carbide I turn most things at my lathe's highest RPM, which is about...

Multi-flute high-helix end mills leave a very nice finish, but not completely perfect...

If you want something on the larger side, I suggest a Rotozip. The multitude of attachments make it very versatile and handy. Plus, different collet sizes let you use different burrs and dremel bits. If you don't want something as big, the tools you mentioned are great.

Thank you very much for the information, Pat. For now I think I will keep the engine "square".

My autoshop teacher commissioned me to build him a model stirling engine for him. I've never built an engine before, so this finally gave me an excuse. :) I've decided to design it myself, as opposed to following plans. I figure I'll learn much more this way. Plus, it'll look great on a...

Thanks for the welcome, guys. I have a Grizzly G1006 mill and a chinese import version of a Grizzly 10"x22" lathe. I managed to snag the mill on craigslist for $800 and the lathe for $675 So far I haven't built any engines, but I'm getting ready to build a stirling engine.

Hi guys, I'm a junior in high school and I've taken interest in machining while ago. I've already acquired my own machines and so far I've had a blast learning with them. I'm also on my high school's robotics team, so I have access to a plethora of engineers and a machinists who are mentors to...