Another PeeWee

Discussion in 'Engines From Castings' started by e.picler, Aug 25, 2018.

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  1. Nov 13, 2018 #21

    michael-au

    michael-au

    michael-au

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    Nice work on the castings, will be watching the progress of this engine
     
  2. Nov 24, 2018 #22

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    hello to all!
    Little more progress.
    I have worked on the Cylinder heads, Timing Cover and Water Pump.
    After machining the head to the finish dimentions, I remade the grooves to get a better appearance.
    IMG_20180825_163121957.jpg

    IMG_20180825_182948912.jpg
    Locating the edge
    IMG_20180902_152547794.jpg

    I used a 16mm flat end mill to make the recess for the combustion chamber
    IMG_20180827_210128791.jpg

    IMG_20180827_214157092.jpg

    IMG_20180827_220743449.jpg

    IMG_20180827_220807676.jpg

    Locating the intake runner
    IMG_20180902_164930701.jpg

    Exaust runner
    IMG_20180902_174620197.jpg

    Valve cages
    IMG_20181020_204738422.jpg
    More pictures on the way.

    Tks

    Edi
     
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  3. Nov 26, 2018 #23

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Hello!
    Here are some more photos of my progress.
    The heads are almost finished. It is only missing to drill the running holes on the valve cages.

    Valve cages are finished
    IMG_20181021_195607712.jpg IMG_20181021_200152128_BURST002.jpg

    Pressing in the valve cages into the holes
    IMG_20181021_200822343.jpg
    IMG_20181030_204300072_HDR.jpg

    I decided to advance on those parts that demand milling machining so, I got a touch on the Pump and the Timing Cover

    Raw material/blanks prepared for the Pump Body and Back plate and the Timing Cover
    IMG_20181102_152713256.jpg

    In order to get a more visual attractive, I have added a fillet on the inner border of the Timing Cover it have 1mm high.
    I have used the Fusion 360 to do that once I need 3D drawing to use the SprutCam.
    I hope it do not interfere with the crankshaft pulley otherwise I will need to chage it to clear the space between them

    Programing the G-Code on SprutCam
    IMG_20181108_120354029.jpg

    I have machined it on the CNC milling machine
    IMG_20181106_194908192.jpg

    IMG_20181106_210020803.jpg


    To be continued.

    Edi
     

    Attached Files:

  4. Nov 26, 2018 #24

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Hi again! Continuing with Timing Cover progress.

    Almost finished,
    IMG_20181107_081424520.jpg

    Here I'm using a 4mm ball end end mill to add a radious on the botton of epigot
    IMG_20181107_203126582.jpg

    Drilling the patern holes
    IMG_20181107_204219752.jpg

    Timing Cover finished on milling. It still need the bearing sitting hole on the back, it will be done on the lathe
    IMG_20181107_212050310.jpg

    Next will be the Waer Pump

    Tks,

    Edi
     
  5. Nov 26, 2018 #25

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Water Pump machining
    It was also machined on the CNC. I started on the Back Plate

    Contour and holes drilled. The fixing holes were done with a regular drill bit however, the gear shaft holes and the plug thread were machined (circle mill)
    IMG_20181110_112005057.jpg

    Finished the first side
    IMG_20181110_195034430.jpg

    The botton holding extra hight material (3.5mm) was removed
    IMG_20181110_200448211.jpg

    I gave a light cleaning pass on the top surface to guarantee a very flat surface for good sealing against the body surface
    IMG_20181110_113841457.jpg

    Water Pump body is the next.

    Edi
     

    Attached Files:

  6. Nov 26, 2018 #26

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Water Pump.
    It was also machined on the CNC

    IMG_20181111_120025842.jpg

    Finished
    IMG_20181111_162959482.jpg


    We have a saying here in Brazil that says that the happiness of the poor one does not last for long. MISTAKE DONE!!!!

    As always, I screw something that was going nice with the part. Brurrrr!!!!!

    An error was done when relocating the center of the bearing sitting on the bottom side when programing the second side
    IMG_20181112_120241736.jpg

    More than two hours of work LOST!

    Had to do it all over again. That's OK, in the end it came out nice GOOD ONE!

    Here is where I am so far
    IMG_20181112_204054281.jpg

    Thanks,

    Edi
     
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  7. Nov 26, 2018 #27

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Completing the Water Pump.

    Preparing the gears on the lathe. Facing to right lenght
    IMG_20181116_192151950.jpg

    Reamering the hole 3mm
    IMG_20181116_192252121.jpg

    Pressed in the the gears on the shafts
    IMG_20181116_222049962.jpg

    The body is finished
    IMG_20181115_221246402.jpg

    Machining the wrench hex on the inlet plug. I have used a ER25 Hex block instead of the dividing head to avoid removing the aligned vise. :cool::cool: lazy!!!!
    IMG_20181117_160153636.jpg

    Turning the Outlet tubing. I also changed it a little bit. I have used a long 2.5mm drill bit for the hole
    IMG_20181117_173643101.jpg

    I will make another pulley, the small 2mm headless screw broke the hex wrench pocket inside the threaded hole (no way to remove it). I also made a mistake:mad::( on the front
    facing as you can see on the photo below.
    IMG_20181119_211603968.jpg

    Pump completed
    IMG_20181117_181339007.jpg
    IMG_20181117_181502718.jpg


    This weekend I got a good progress. I have finished the Fan, Exaust Flanges, and the Distributor Cap
    I plan to post it also today.

    Thanks,

    Edi
     

    Attached Files:

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  8. Nov 26, 2018 #28

    stevehuckss396

    stevehuckss396

    stevehuckss396

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    Looks good buddy!

    Nice looking parts. When you do your final assembly slop the o-ring down with some silicone grease real good.
     
  9. Nov 26, 2018 #29

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Hi Steve!
    Thanks for the kind words and the tip for the O-ring.;)

    Edi
     
  10. Nov 26, 2018 #30

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    The Exaust Flange.
    I did all four at the same blank.
    IMG_20181124_184847115.jpg
    IMG_20181124_192351604.jpg

    To remove the extra holding hight material, I clamped the intire blank on the vise and removed as much material as possible then, I turned a pin
    with the same inner diameter to avoid deforming when holding on the vise for the final cleaning
    IMG_20181124_195403651.jpg
    IMG_20181124_195605214.jpg

    Exaust Flanges finished
    IMG_20181124_203506678.jpg

    The Fan turn.
    I cut a piece of aluminum from a scrapped Notebook table. Cleaned a piece of a aluminum bar to get a flat surface then clamped the blank over the machined surface using small clamping device. I also used a bit of Loctite to assure good holding result.

    I did a program do machine the center diameter and drill the four fixing holes. First, I used a 1.5mm drill to tap 2mm thread on the aluminum base then re-drilled the four holes to 2mm to the thickness of the blank

    Next, I tapped the 2mm thread and fixed the blank with four M2 screw. Everything was done on the same fixing setup to assure concentricity
    IMG_20181125_184923223.jpg

    IMG_20181125_185413011.jpg

    Machining the contour on 3 passes with low feeding rate (thikness of the blank = 1.6mm)
    IMG_20181125_190027700.jpg

    IMG_20181125_191027717.jpg

    Finished Parts
    IMG_20181125_193556697.jpg

    Next work, I will be dealing with the Distributor Cap

    Edi
     
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  11. Nov 26, 2018 #31

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    As I did not purchased the Distributor Cap with the kit from Dirk, I decided to make it.

    First, I did the 3D drawing on the Fusion 360. The set of drawing I'm using does not have cap drawing so, I used as reference an original drawing from Bob Shores which shows the distributor assembly cross section and have the cap on it. I found that the drawing followed a scale of 2:1 then I took some dimensions with a caliper and sketched it on the Fusion 360.

    Drawing used as refrence
    IMG_20181122_202554222.jpg

    Drawing on the Fusion 360
    Capture_2018_11_22_16_02_37_965.png

    Capture_2018_11_22_16_04_38_684.png

    It is still not the final version, I will finish it when the Distributor is complete so, I will be able to test if the dimensions are OK specially the internal heights.
    For the diameters I used the distributor body dimensions, here I think there is no errors.


    Next, I developed the CNC program on the SprutCam and did a machining test using Corian. I found a Du Pont dealer here on my living city and he gave me a piece of Left over material in Black color

    The blank, it have 30 X 38 X 19mm
    IMG_20181125_201243111.jpg

    First part finished
    IMG_20181125_220419606.jpg

    Rounding the corners of the towers and the botton diameter
    IMG_20181125_220959385.jpg

    The top side finished
    IMG_20181125_224413594.jpg

    Removed the extra holding material on te bottom it was done onthe lathe
    IMG_20181125_230851881.jpg

    It was just a test. I will do some small adjustments on the program and confirm the dimensions then, make the final part.
    I decided use the Corian because it is recommended for the Spark Plug Isolator so, it could be used for the Distributor Cap as well as it machines very well and give you good finishing surface


    And here is the result of the Weekend work.
    IMG_20181126_075946236.jpg

    That is it for now!

    Thanks,

    Edi
     
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  12. Nov 26, 2018 #32

    michael-au

    michael-au

    michael-au

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    very nice work
     
  13. Nov 27, 2018 #33

    kuhncw

    kuhncw

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    Very well done. I like your tip for holding the exhaust flanges while machining the flange surface.

    Chuck
     
  14. Dec 18, 2018 #34

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Hi to all!
    Some more progress to report on the PeeWee V4

    Thank you Michael and Chuck!

    Pump Pulley
    I started turning a blank with an epigot (12mm) in order to hold it on a collet at the milling machine to drill the front 6 holes. I did this way to avoid the drill bit slipping on the angled surface.
    IMG_20181126_201209532.jpg

    Next drilled and tapped the 2mm hole for the fixing screw
    IMG_20181126_202337770.jpg

    Back to the lathe I machined the O-ring/belt groove and the 3mm shaft hole on the same setup to assure concentricity
    IMG_20181126_204859792.jpg

    Finished Pulley
    IMG_20181126_211856110.jpg

    Next one was the Fan Pulley
    For this pulley I could turn the belt/0-ring and the 3mm shaft hole on the same setup first
    IMG_20181128_203754150.jpg

    IMG_20181128_205754803.jpg

    Then moved to the milling machine to drill and tap the fan holding holes
    Here, Getting the center of the pulley
    IMG_20181128_212053123.jpg

    Holes drilled and tapped
    IMG_20181128_213825812.jpg

    The Fan Cap. Used the same process as the Pump Pulley, using an epigot
    IMG_20181201_093410541.jpg

    More is coming.

    Edi
     
  15. Dec 18, 2018 #35

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    The pulley with the fan.
    IMG_20181204_074911554.jpg

    Now is the distributor turn!

    Raw material for the distributor body, Magnetic Disk and the Rotor Disk. The wite material is Corian for the Rotor Disk
    IMG_20181201_104858108.jpg

    I have got a free sample of 12mm Corian from a local DuPont dealer. Cut it in a square shape and hold it on a 4 jaw chuck and complete turned the Rotor Disk
    IMG_20181201_110421759.jpg

    Here I'm turning the Magnetic Disk, mild steel material. This operation was reamering the hole next, fliped the disk over and faced to the final thickness
    IMG_20181201_114512199.jpg

    That is the Distributor Body.
    IMG_20181201_155015294.jpg

    Moved to the milling machine for milling operations. Here I also provided an epigot to hold the body in the collet at milling vise
    IMG_20181202_120716693.jpg

    I develop a CNC program for the fixing tab and cap holding profile
    IMG_20181202_160416903.jpg

    IMG_20181202_164833710.jpg

    The epigot on the top for supporting the body on the collet
    IMG_20181202_165252821.jpg

    Turning off the epigot on the lathe with light passes to avoid to damage the bearing pocket at the bottom
    IMG_20181202_170722957.jpg

    More progress to report.

    Edi
     
  16. Dec 18, 2018 #36

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    Continuing with the PeeWee progress
    I have decided to machine a shallow pocket on the Rotor Disk to better locate and glue the Rotor Conductor
    IMG_20181203_211623623.jpg
    IMG_20181206_221859376.jpg


    To machine the Rotor Conductor, I glued a piece of brass sheet on a aluminum stock as shown in the photo bellow. I tried to glue it with
    screw loctite but did not work so I used again the super glue. Did work very well
    IMG_20181204_075220885.jpg

    I have programed very light passes to ovoid the brass sheet to pull off. Worked nicelly
    IMG_20181204_200124830.jpg
    IMG_20181206_221733375.jpg

    Rotor Conductor glued with super glue
    IMG_20181206_221957861.jpg

    After turning the inside of the body and fixing the magnetics on the disk, I did an assembly test
    IMG_20181208_153405478.jpg

    Running free and smooth
    IMG_20181208_153443404.jpg

    Finished Distributor. Still need to fix the Hall Sensor inside. No detail about how to hold the sensor on the body.
    IMG_20181208_154559531.jpg

    To be continued...

    Edi
     
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  17. Dec 18, 2018 #37

    stevehuckss396

    stevehuckss396

    stevehuckss396

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    Nice work Edi! Looks really good.
     
  18. Dec 18, 2018 #38

    e.picler

    e.picler

    e.picler

    Edi from brazil

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    I have finished the Heads
    Drilled the runners and the Spark Plug holes
    IMG_20181209_110124849.jpg

    IMG_20181209_110347689.jpg

    IMG_20181209_202608356.jpg



    IMG_20181209_202828021.jpg

    The Crankshaft Pulley
    IMG_20181209_212132820.jpg

    Still missing the two holding screw
    IMG_20181209_222546282.jpg

    And, that's how the PeeWee looks like so far
    IMG_20181208_180002327.jpg

    IMG_20181208_180049612.jpg

    IMG_20181208_180117906.jpg

    IMG_20181208_180223304.jpg

    That is all I have for now.

    Thank,

    Edi
     
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  19. Dec 19, 2018 #39

    Cogsy

    Cogsy

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    You're making fast progress Edi - looks great!
     
  20. Dec 19, 2018 #40

    neil_1821

    neil_1821

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    Brilliant work Edi! I really want to make a peewee as there’s so much information and build threads on the internet, I really need to finish this locomotive that I’ve just started.

    Looking forward to the end result
     

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