Things have slowed down at work and I'm back on a normal schedule. One of the things I did while
working was shoot off my big mouth and agree to make a pattern for a crankcase. Well I am finally
getting it done after promising many months ago that I would do it when I got time.
The prez of my metal club Rick does casting demos at the engine shows and some other clubs in
the area. Someone approched Rick at one of the shows about the Deezil engine. This fellow has
one of the castings for the crankcase but is afraid to machine it. He asked Rick if he could cast
practice cases. Well we figured why not. After the cases are cast he could still use the pattern
for his demo's and give the cases away to anyone who wants to build the engine.
Because there is no way to cast the cases exactly like the original, here is the plan. The cases will
be cast with MDMC (Metro Detroit Metalworking Club) on the front of the block instead of DEESIL.
This way the blocks we cast will never be confused with the "real" Deesil cases. The case will
be machined and a new crankcase drawing will be on our website for download. All the other
original Deesil parts will fit. The plans can be purchased on CD ROM from ron over at Model
Engine News.
After reverse engineering the casting I drew up the case in Alibre. Then I assembled 4 cases
on a hub and saves it as a STL file. The STL file was opened in CamBam and all the tool paths
were created. CamBam created some 280,000ish lines of code. I took the Gcode to the computer
in the garage and opened it up with Mach3 and here is how it went.
　
First roughing pass. The material was provided by Rick. It is called Renboard? It's kind of like a
cross between plastic and wood. It's very dense and stable. Machines real nice.
First pass
　
Third pass
　
Fifth pass
　
Seventh Pass
　
Ninth Pass
　
Roughing out complete
　
　
The center section was finished using a 1/8 inch cutter. The cutter started on the left side and went down following the contour of the part. The cutter moved to the right just a few thou and went down. The process was continued until the center section was finished.
　
　
Then because there were some tight spots to get into, a 1/16 inch cutter was used to finish the rest of the pattern.
　
　
Then the entire thing was cut out to the correct thickness to complete the first of 10 pieces.
　
The other pieces are simple and should not take long to make.
working was shoot off my big mouth and agree to make a pattern for a crankcase. Well I am finally
getting it done after promising many months ago that I would do it when I got time.
The prez of my metal club Rick does casting demos at the engine shows and some other clubs in
the area. Someone approched Rick at one of the shows about the Deezil engine. This fellow has
one of the castings for the crankcase but is afraid to machine it. He asked Rick if he could cast
practice cases. Well we figured why not. After the cases are cast he could still use the pattern
for his demo's and give the cases away to anyone who wants to build the engine.
Because there is no way to cast the cases exactly like the original, here is the plan. The cases will
be cast with MDMC (Metro Detroit Metalworking Club) on the front of the block instead of DEESIL.
This way the blocks we cast will never be confused with the "real" Deesil cases. The case will
be machined and a new crankcase drawing will be on our website for download. All the other
original Deesil parts will fit. The plans can be purchased on CD ROM from ron over at Model
Engine News.
After reverse engineering the casting I drew up the case in Alibre. Then I assembled 4 cases
on a hub and saves it as a STL file. The STL file was opened in CamBam and all the tool paths
were created. CamBam created some 280,000ish lines of code. I took the Gcode to the computer
in the garage and opened it up with Mach3 and here is how it went.
　
First roughing pass. The material was provided by Rick. It is called Renboard? It's kind of like a
cross between plastic and wood. It's very dense and stable. Machines real nice.
First pass
　
Third pass
　
Fifth pass
　
Seventh Pass
　
Ninth Pass
　
Roughing out complete
　
　
The center section was finished using a 1/8 inch cutter. The cutter started on the left side and went down following the contour of the part. The cutter moved to the right just a few thou and went down. The process was continued until the center section was finished.
　
　
Then because there were some tight spots to get into, a 1/16 inch cutter was used to finish the rest of the pattern.
　
　
Then the entire thing was cut out to the correct thickness to complete the first of 10 pieces.
　
The other pieces are simple and should not take long to make.
Last edited:
