I built the crankshaft from 1/2" drill rod and 3/8" x 5/8" steel bar. Machined, 'glued' with red Loctite and pinned.
Started with the Crank webs. Rough cut, milled to length.
IMG_3084 by
Mark Savoca, on Flickr
IMG_3085 by
Mark Savoca, on Flickr
IMG_3086 by
Mark Savoca, on Flickr
After laying out the holes for the journal, I used the 4 jaw chuck, center drilled, step drilled and finally used a 1/2 reem. Repeated for the second web.
IMG_3102 by
Mark Savoca, on Flickr
IMG_3103 by
Mark Savoca, on Flickr
Next I cut the 1/2" drill rod to rough length. Here you can see all the rough parts.
IMG_3106 by
Mark Savoca, on Flickr
I put the webs back in the 4 jaw chuck to machine the shoulders. I used the dial indicator to reset the center.
IMG_3110 by
Mark Savoca, on Flickr
IMG_3115 by
Mark Savoca, on Flickr
Here you can see the shoulder.
IMG_3117 by
Mark Savoca, on Flickr
Back into the 4-jaw for the other side. Here you can see I used a parallel while mounting the web. This will ensure the surface if square with the turning plane. Make sure you remove the parallels Before you turn on the lathe!
IMG_3119 by
Mark Savoca, on Flickr
The completed webs:
IMG_3125 by
Mark Savoca, on Flickr
After test fitting the completed webs and journals I attempted to Loctite it all together. While I was assembling it, I started to struggle and felt like the Loctite was going to setup before I had everything positioned, so I pulled it apart and wiped off the Loctite. To give myself a little more control and time, I did one web at a time. First Loctite, let it setup, pinned it and then put on the second web. This way only one web could move and I could control the spacing better.
IMG_3144 by
Mark Savoca, on Flickr
Here is both sides Loctited and pinned. You can also see that I cleaned up / rounded the ends on the belt sander.
IMG_3156 by
Mark Savoca, on Flickr
Here you can see the assembled unit with the pins cut down.
IMG_3225 by
Mark Savoca, on Flickr
Cleaned up with the belt sander.
IMG_3227 by
Mark Savoca, on Flickr
Used the mill to remove the extra material
IMG_3230 by
Mark Savoca, on Flickr
IMG_3234 by
Mark Savoca, on Flickr
Next I got out the hacksaw and cut out the material between the webs.
IMG_3239 by
Mark Savoca, on Flickr
Into the Mill to clean it up
IMG_3241 by
Mark Savoca, on Flickr
Almost done, stick with me...
IMG_3243 by
Mark Savoca, on Flickr
Machined the keyway
IMG_3280 by
Mark Savoca, on Flickr
And with that we have a completed crankshaft