Discussion in 'Engines From Castings' started by e.picler, Aug 25, 2018.
Nice work on the castings, will be watching the progress of this engine
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.
Locating the edge
I used a 16mm flat end mill to make the recess for the combustion chamber
Locating the intake runner
More pictures on the way.
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
Pressing in the valve cages into the holes
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
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
I have machined it on the CNC milling machine
To be continued.
Hi again! Continuing with Timing Cover progress.
Here I'm using a 4mm ball end end mill to add a radious on the botton of epigot
Drilling the patern holes
Timing Cover finished on milling. It still need the bearing sitting hole on the back, it will be done on the lathe
Next will be the Waer Pump
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)
Finished the first side
The botton holding extra hight material (3.5mm) was removed
I gave a light cleaning pass on the top surface to guarantee a very flat surface for good sealing against the body surface
Water Pump body is the next.
It was also machined on the CNC
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
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
Completing the Water Pump.
Preparing the gears on the lathe. Facing to right lenght
Reamering the hole 3mm
Pressed in the the gears on the shafts
The body is finished
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. lazy!!!!
Turning the Outlet tubing. I also changed it a little bit. I have used a long 2.5mm drill bit for the hole
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 on the front
facing as you can see on the photo below.
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.
Looks good buddy!
Nice looking parts. When you do your final assembly slop the o-ring down with some silicone grease real good.
Thanks for the kind words and the tip for the O-ring.
The Exaust Flange.
I did all four at the same blank.
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
Exaust Flanges finished
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
Machining the contour on 3 passes with low feeding rate (thikness of the blank = 1.6mm)
Next work, I will be dealing with the Distributor Cap
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
Drawing on the Fusion 360
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
First part finished
Rounding the corners of the towers and the botton diameter
The top side finished
Removed the extra holding material on te bottom it was done onthe lathe
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.
That is it for now!
very nice work
Very well done. I like your tip for holding the exhaust flanges while machining the flange surface.
Hi to all!
Some more progress to report on the PeeWee V4
Thank you Michael and Chuck!
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.
Next drilled and tapped the 2mm hole for the fixing screw
Back to the lathe I machined the O-ring/belt groove and the 3mm shaft hole on the same setup to assure concentricity
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
Then moved to the milling machine to drill and tap the fan holding holes
Here, Getting the center of the pulley
Holes drilled and tapped
The Fan Cap. Used the same process as the Pump Pulley, using an epigot
More is coming.
The pulley with the fan.
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
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
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
That is the Distributor Body.
Moved to the milling machine for milling operations. Here I also provided an epigot to hold the body in the collet at milling vise
I develop a CNC program for the fixing tab and cap holding profile
The epigot on the top for supporting the body on the collet
Turning off the epigot on the lathe with light passes to avoid to damage the bearing pocket at the bottom
More progress to report.
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
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
I have programed very light passes to ovoid the brass sheet to pull off. Worked nicelly
Rotor Conductor glued with super glue
After turning the inside of the body and fixing the magnetics on the disk, I did an assembly test
Running free and smooth
Finished Distributor. Still need to fix the Hall Sensor inside. No detail about how to hold the sensor on the body.
To be continued...
Nice work Edi! Looks really good.
I have finished the Heads
Drilled the runners and the Spark Plug holes
The Crankshaft Pulley
Still missing the two holding screw
And, that's how the PeeWee looks like so far
That is all I have for now.
You're making fast progress Edi - looks great!
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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