Building a V12 crankshaft

Discussion in 'Finished Projects' started by ZAPJACK, Aug 26, 2012.

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  1. Oct 25, 2013 #41

    ZAPJACK

    ZAPJACK

    ZAPJACK

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    Pictures 129, 130, 132, 133 :
    Drilling the oil channels is the last process requiring precision. As the crank journals are hollow, there will be no way to drill the various walls without the drill skewing and breaking. To solve that problem, you need to insert a mild steel « martyr » buffer (see picture 133). The buffer must be fixed using Loctite. This trick should enable you to drill the channels easily. LeZap




    129.jpg

    130.jpg

    132.jpg

    133.jpg
     
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  2. Oct 27, 2013 #42

    ZAPJACK

    ZAPJACK

    ZAPJACK

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    Pictures 134, 136,138,139 :
    With the crankshaft completed, you now need to remove the templates located at the ends. Always use the under arm to minimize the flexion of the workpiece
    LeZap

    134.jpg

    136.jpg

    138.jpg

    139.jpg
     
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  3. Oct 29, 2013 #43

    ZAPJACK

    ZAPJACK

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    Picture 144 :
    Check the run outs as well as the homogeneity of each crankpin, which must be below 0.2 mm on the central bearing.

    Picture 146 :

    To recover this run out, you need to set the crankshaft on the milling machine as shown in the picture. Place the crankshaft between two V-leveling pads and a brass axle to press the crankshaft. Zero the X-, Y- and Z-axis by just touching the central bearing. In order to minimize the stress on the piece, it is recommended to heat it in an oven (220°C, 20 min). Once the piece is hot, place it under the milling machine and start with a 1.0 mm deformation. Remove the piece and check with a Pupitast indicator. As the piece must not cool down, put it back in the oven regularly. Deformation can be gradually increased, but only by 1.0 mm at a time, and up to a maximum of 5.0 mm. A residual deformation of two to three percents is acceptable.
    LeZap

    144.jpg

    146.jpg
     
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  4. Oct 30, 2013 #44

    John Rus

    John Rus

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    This is simply a work of art you have there!

    Are you going to make the rest of the Merlin or are you stopping at the crank?

    Keep up the fantastic work!
    John.
     
  5. Oct 30, 2013 #45

    ZAPJACK

    ZAPJACK

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    Yes, I will do it!
    LZ
     
  6. Oct 31, 2013 #46

    John Rus

    John Rus

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    If the crank is finished then you should start a "work in progress" thread on the rest of your beautifull engine. After you finish posting about your crank of course. Thm:

    Cheers,
    John.
     
  7. Oct 31, 2013 #47

    ZAPJACK

    ZAPJACK

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    Pictures 156, 162 :
    Crankshaft finished. Final weight 777gr (7000gr at the beginning)
    125 direct labor hours and 80 hours of indirect work such as: creation of a grinding machine, specialized tools, jig bearings, etc...
    LeZap

    156.jpg

    162.jpg
     
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  8. Oct 31, 2013 #48

    stevehuckss396

    stevehuckss396

    stevehuckss396

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    From what I can see, worth every minute.
     
  9. Oct 31, 2013 #49

    FannBlade

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    And people wonder why one-off's cost so much! :wall:

    Nice work....I will be waiting for the upcoming portion.
     

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