1895 Mery Explosive engine from Gary Martin

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This is the 45 degree set up for the jig.... the engine body will be bolted to the jig not clamped and it will be then bolted to the mill table.
 

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Good day.... this was nerve racking. The thing is very spindly...... difficult not to get harmonic chatter, but I got it. Wanted to switch set ups and bore crank hole bit called it a day.and my numbers came out as perfect as can be.

Now I fully remember why this sat on the shelf for 26 years.... its very difficult and complicated. And probably why there aren't many around..... mine is number 155..... Gary told me recently he is on 290..... so not many in 26 years.
 

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Why didn't you mount the casting on its feet to the mill table and then tilt the mill's head 45°? I know it would take more math to work out the cut positions, but it would have saved making the fixture.
 
Why didn't you mount the casting on its feet to the mill table and then tilt the mill's head 45°? I know it would take more math to work out the cut positions, but it would have saved making the fixture.
The fixture does more than the 45. Plus this way its straight across the part...not stepping the angle down across the part. The cuts were small to keep ing harmonic to a minimum... took forever.
 
If they were easy to build, any fool could do it. Mine is#378 purchased Feb 2022,took about 6 months to build. I made a plywood holder similar to the fixture made by pamw to hold base while machining for crankshaft. Keep at it! A very satisfying engine when finished and running. Mine never fails to start and runs great. A crowd pleaser , one of the best engines I've got.(17) There is a short build log of mine in Engines from Castings Oct 2022.
Colin
 
If they were easy to build, any fool could do it. Mine is#378 purchased Feb 2022,took about 6 months to build. I made a plywood holder similar to the fixture made by pamw to hold base while machining for crankshaft. Keep at it! A very satisfying engine when finished and running. Mine never fails to start and runs great. A crowd pleaser , one of the best engines I've got.(17) There is a short build log of mine in Engines from Castings Oct 2022.
Colin
What do you use for fuel...id prefer NOT using propane due to the stink in these engines. Was hoping a lunkenheimer carb would work with a liquid fuel....
 
Start of the cam eccentrics..... next is the offset fixture. Tomorrow after the crank grease cups and anti rotation pins installed. And crank needs slight clearancing. Everything is very close and tight on this engine. He really kept to scale.....

Onward.....
 

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Lots done... eccentrics are turned... just need set screw holes done. changed the cam shaft design a bit... made it more secure.... cylinder mounting face done.. stuffing box bore and counter bore done... cylinder bolt holes done....cross head bore done..... couple dummy cooling line holes done... cross head oiler hole drilled and tapped.
 

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