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Sprocket

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My wife is a quilter, and their term for any incomplete project that has been put aside is a UFO, UnFinished Object. She also figures that what I make are quilts, of a kind
because we both take big pieces of material, cut them up into smaller pieces, then put them back together. And we both use threaded fasteners of a sort.
Years ago, I started the Gearless Hit and Miss engine by Philip Duclos from plans in Home Shop Machinist. I got the base and side plates cut out and the pillars made but not cut to exact length
IMG_1137.JPG
I had also finished the crank shaft, but for some reason I can't recall, I put it aside.

IMG_1132.JPGIMG_1130.JPG

With the stay at home order this spring, and finally being retired I started to work trying to remember why I'd stopped.
I think the crank shaft bushing holes were the problem, because my mill drill wouldn't keep register as I raised the head to change drill to reamer. But somewhere in there I acquired an old Bridgeport that makes a lot of things easier. So I drilled the bushing holes and other mounting holes and started back in.

There was a thread on making split bushings, and another on two piece con rods, all of which was sounding familiar.
IMG_E1118.JPGIMG_1120.JPGIMG_1122.JPGIMG_1124.JPG

Then I started on the cylinder and liner. Started with a chunk of aluminum about 2 3/4" dia. and 3" or so long, and removed a lot.
IMG_1133.JPG IMG_1142.JPG IMG_1159.JPG mounted on the rotary table to drill and square the base

I guess that's all the files I can attach right now. More later

Doug
 

ku4qb1

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I think a lot of UFOs are finally getting some much needed attention, lately. My oldest one is a 1/2 scale Maytag, 18 years old. I think, this time, I'll get those last couple of parts finished and get it running. Connecting rod, timer and carb....
Just a few more stitches! :)
 

Sprocket

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There are a couple of reliefs in the sides of the cylinder before you cut the fins, spaces for the intake and exhaust valve housings, and the valve lifter for the exhaust
IMG_1171.JPG IMG_1173.JPG

Cast iron cylinder sleeve IMG_1179.JPG

pressed into the cylinder IMG_1181.JPG

And a mandrel to hold it all so you can cut fins. I didn't have a tapered mandrel that big, so I made one that squeezed end to end.

IMG_1185.JPG


IMG_1190.JPG IMG_1193.JPG IMG_1192.JPG

When you stack up the parts, it starts to look like a motor!

IMG_1196.JPG The cylinder fins are rounded on the ends. Plans give instruction for making the cutter to cut that shape.

The cylinder head has fins in both directions IMG_1201.JPG
 

Sprocket

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Thanks, Andy.
Some more pics:
IMG_1212.JPG Fins, top and sides, ports for intake and exhaust,

IMG_1211.JPG That last little fin on the right is really sharp! Don't ask.

IMG_1214.JPG I'd made the plug with guidance from either Steve Hucks Or G.Britnell, can't remember who wrote that one up.
Plans called for a 1/4" plug, but it looked too small in the picture, so this one is 5/16"

There also was a thread on making valves. This is how I've done it in the past. Stem is 1/8" piano wire, top is stainless silver brazed on

IMG_1216.JPG IMG_1218.JPG IMG_1222.JPG IMG_1225.JPG
I sand it down .0002 or so it fits well in a 1/8" reamed hole.
Another trick some one here had was (Mark maybe?) for cross drilling the valve stems. Worked great. Can't remember how I did it before. It used a little fixture to drill the #60 hole 1/8" from the end. Guess I haven't transferred that photo yet.

IMG_1241.JPG IMG_1231.JPG IMG_1233.JPG
Valve bodies required cutting the seats down inside, which is blind. There are instructions for making that cut, but they depend on your cross feed in the lathe being a reliable measure, mine is not, so I ended up using a dial indicator to move to the point of being able to cut the seat with the compound.

Guess I'd better transfer those other pictures.

Doug
 

Sprocket

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Some more bits and pieces.
IMG_1275.JPG I found the picture of the fixture for cross drilling the valve stems. Again, it was something mentioned on this forum, but I can't think by whom. It worked well though. I annealed the valve stems before drilling because the piano wire seems pretty hardIMG_1277.JPG
The valve bodies both have finned covers, exactly the same, attached with 4- 3-48 shcs.
IMG_1247.JPG IMG_1249.JPG IMG_1250.JPG
IMG_1256.JPG IMG_1267.JPG Round, to rectangle, counterbored, finned and mounted on the valve bodies

I changed the intake pipe to add a cone for more of a venturi, and a bug strainer. ( it's really not an air filter)

IMG_1299.JPG IMG_1301.JPG IMG_1302.JPG Ran out of room!
 

Sprocket

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A couple more that didn't fit in the last post...

IMG_1314.JPG with the spray bar and needle valve

IMG_1317.JPG Attached to the valve body

IMG_1319.JPG And attached to the cylinder.

Doug
 

Sprocket

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That's right, Andy. The exhaust has a cam and lifter, but part of what makes it gearless is the way the lifter is made. Haven't gotten to those parts yet.

IMG_1323.JPG I had some ring material already turned to size, and even a couple of spares cut from the last 3/4" bore engine I made.The rings were a little thick, by a couple of thousandths, but I've used a little holder to sand them to thickness.

IMG_1321.JPG IMG_1322.JPG IMG_1320.JPG
Just before Memorial Day, the VFD that runs my mill failed spectacularly. Loud POP, the Magic Smoke all escaped, and a little fire started inside. I tried to blow it out a couple of times, but it just kept coming back. I guess that's why I have a fire extinguisher. I gave it the shortest blast of dry chemical I could, and it still made quite a mess. But the fire was out. Really stunk!
IMG_1280.JPG I got another one from Wolf Automation, came in a few days. Of course, nothing is the same shape or mount as the 10 year old one so, new mounting plate, etc.
IMG_1284.JPG IMG_1288.JPG But it's working again and life goes on. Never miss a machine so much until it's down!
I made the piston today, pictures later.

Doug
 

Sprocket

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I finished up turning the piston, and moved it to the mill for drilling the wrist pin hole and inside space for the connecting rod. There was a little stub left after turning, so i set it up in a V block, vertically,

IMG_1328.JPG IMG_1329.JPG IMG_1333.JPG

Squared off the stub, which gave me a good place to grip in the vice, and a way to get my con rod slot perpendicular to the wrist pin, and drill and tap the set screw holes.

IMG_1335.JPG IMG_1339.JPG IMG_1341.JPG

IMG_1343.JPG IMG_1344.JPG IMG_1347.JPG IMG_1348.JPG

With the piston finished, I split the rings, heated and opened them up, gapped them, made a wrist pin, and put the whole thing together. That's all the parts for now. I started the exhaust cam, but didn't get too far.

Thanks for looking,

Doug
 

Sprocket

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It's been a couple of weeks, but I've been working on some strange little pieces. This is a gearless engine, and something has to replace the gears to only open the exhaust valve every other revolution.
The exhaust cam doesn't look like a typical cam, and it's milled on the rotary table.
IMG_1371.JPG IMG_1372.JPG IMG_1373.JPG IMG_1376.JPG IMG_1378.JPG There is a half inch wheel that rides on this cam, and sits in the lifter

IMG_1383.JPG with an unfortunately shaped indexer at the other end.

IMG_1401.JPG IMG_1405.JPG

IMG_1398.JPG Between these and three different kinds of springs (one flat, one straight wire, and one wound), every time this piece goes up and down, the indexer rotates 1/4 turn and the long sides lift the valve, the short sides don't. Also the governor acts on this lifter to hold the exhaust valve open.
More later.
Thanks for looking.
Doug
 

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