josodl1953
Well-Known Member
I made parts for the intake manifold.
Machining...
Finish machined and polished.
Machining...
Finish machined and polished.
Demoiselle boxer twin
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Did you machine the elbow from a single solid blank, or did you silver solder parts together? Either way it looks great!
josodl1953
Well-Known Member
Hi Andy,
The parts were made from solid, milled, drilled, turned, filed, sanded, polished.... with the occasional amount of elbow steam.
The milling operation is shown above. You cannot solder aluminium with silver, there are methods of soldering aluminium but the melting point of some of this soldering metals is only 10-20 degrees lower than the melting point of the alu itself so this operations are always a bit tricky.
I did, however ,do some silver soldering on the exhaust tubes. I used copper tubing with some flanges that were left over from the Edwards project. Flanges were soldered before the tubes were bent. The soldered flanges were bolted to a piece of aluminium that I used for machining the center holes of the flanges.. Prior to bending I filled the tubes with lead by putting small pieces of lead in the tubes and heating them up with a torch till the lead was molten.
After that, bending was easy with an old bending jig that I had lying aound for many years.
After bending, the lead was removed by heating again.
Finally, a bit of polishing...
Jos
The parts were made from solid, milled, drilled, turned, filed, sanded, polished.... with the occasional amount of elbow steam.
The milling operation is shown above. You cannot solder aluminium with silver, there are methods of soldering aluminium but the melting point of some of this soldering metals is only 10-20 degrees lower than the melting point of the alu itself so this operations are always a bit tricky.
I did, however ,do some silver soldering on the exhaust tubes. I used copper tubing with some flanges that were left over from the Edwards project. Flanges were soldered before the tubes were bent. The soldered flanges were bolted to a piece of aluminium that I used for machining the center holes of the flanges.. Prior to bending I filled the tubes with lead by putting small pieces of lead in the tubes and heating them up with a torch till the lead was molten.
After that, bending was easy with an old bending jig that I had lying aound for many years.
After bending, the lead was removed by heating again.
Finally, a bit of polishing...
Jos
Hmm, thought I had replied to this, but my reply isn't showing up. Maybe I just thought my reply and hoped everyone would read me mind ... 
I hadn't realized the part was aluminum - certainly understand that solder was not an option in that case. Again, great work!
I hadn't realized the part was aluminum - certainly understand that solder was not an option in that case. Again, great work!
josodl1953
Well-Known Member
Today I finished the cylinder barrels. Cooling fin cutting is a tedious job but the result is nice.
I used a mandrel for cutting the cooling fins so I did not need to clamp the barre in the chuck on the already machined fins.
I used the mandrel earlier for the Edwards barrels.
I used a mandrel for cutting the cooling fins so I did not need to clamp the barre in the chuck on the already machined fins.
I used the mandrel earlier for the Edwards barrels.
josodl1953
Well-Known Member
I did some milling on the crankcase, mainly for weight reduction purposes.
The lead fill on the tubing is brilliant.
I have seen someone else using water in the tube, with the water frozen, and the result is the same, ie: no crimped tube.
.
I have seen someone else using water in the tube, with the water frozen, and the result is the same, ie: no crimped tube.
.
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Once the pipe was filled, did you just bend the tube over by hand? (most I've seen have some kind of lever arm & sliding shoe).
Is that material like what used in automotive brake line (easier to bend) or if its plain copper pipe, did you have to anneal beforehand?
Is that material like what used in automotive brake line (easier to bend) or if its plain copper pipe, did you have to anneal beforehand?
josodl1953
Well-Known Member
Hi Peter,
I bent the pipe by hand because I did anneal it . The pipe came out of my "stock" , it is just ordinary plumbing quality copper.
The only special thing about this is that the original dimensions were 8 x 6 mm which I found a bit heavy. So I turned the OD down to
7 mm which, apart from weight reduction, made is easier to bend.
Last week I made the cam gear cover. A bit fiddly, fitted to the rear cover with 8 M2 Allen bolts. But in the end it looks rather nice .
Jos
I bent the pipe by hand because I did anneal it . The pipe came out of my "stock" , it is just ordinary plumbing quality copper.
The only special thing about this is that the original dimensions were 8 x 6 mm which I found a bit heavy. So I turned the OD down to
7 mm which, apart from weight reduction, made is easier to bend.
Last week I made the cam gear cover. A bit fiddly, fitted to the rear cover with 8 M2 Allen bolts. But in the end it looks rather nice .
Jos
I am impressed with your build!!---Brian Rupnow
josodl1953
Well-Known Member
Thank you Brian. Progress of this build is slowly but steady...
I bolted all parts together that are ready so far to see what it will look like.
Well, it looks like this:
Next to make are the internals, cam gear, pistons, etc.
Jos
I bolted all parts together that are ready so far to see what it will look like.
Well, it looks like this:
Next to make are the internals, cam gear, pistons, etc.
Jos
