Elmer's #43 with Reverse

[JMI]

Thought I'd make a engine that allowed a minimum amount of operator interaction and after following Zee's saga Elmer's 43 seemed a natural. Plus it let's me try out my newly purchased el-Cheapo Enco 5c collets and collet block set. So far - so good...

Crosshead build:

7/16ths? Close enough:

Drill and ream:

Remove, cut, mount in collet block and indicate:

Finish cylinder head end:


Some more drilling and milling:

Good to go...

Will start on the cylinder next.

Jim

 

[Twmaster]

Sweet! I'll be watching your build.

 

[4156df]

Jim,
Great start! Keep 'em coming.
Dennis

 

[Metal Butcher]

Looking good Jim! That four jaw chuck will certainly help a lot.

Zee... Zee... wheres Zee? Are you watching?

-MB

 

[zeeprogrammer]

Well this is neat! Real neat.
I'm looking forward to seeing this build and I'm sure I'll learn a lot.

In milling that piston rod guide (crosshead) it looks like you milled in X, which is what I did. But mine resulted in a lot of metal being pushed into the bore which was really troublesome. Did you cut in one pass? Looks like brass. Is it? Mine was 12L14.

The instructions that came with my kit showed that operation being done from the side. I did it the way you did (well no...you did it better). Any particular reason why you did it that way rather than from the side?

Looking forward to more.

 

[JMI]

In milling that piston rod guide (crosshead) it looks like you milled in X, which is what I did. But mine resulted in a lot of metal being pushed into the bore which was really troublesome. Did you cut in one pass? Looks like brass. Is it? Mine was 12L14.

The instructions that came with my kit showed that operation being done from the side. I did it the way you did (well no...you did it better). Any particular reason why you did it that way rather than from the side?

Hi Zee,

The engine will mostly be brass. The crosshead is brass. Milled it in 3 passes per side cause I didn't want to distort the piece in the vise so it was lightly clamped, hence the light cuts.
I cut it that way because it looked like the easiest way to get what was show in Elmer's plans. The corners in his drawings are square where if I came in from the side the corners would be have a radius as determined by the mill cutter size.
As far as metal in the bore I cleaned it up with a small file and emery cloth.

Jim

 

[JMI]

Almost done with the cylinder:

Drill the bore:

Size it:

More drilling and tapping:

Inlet and exhaust ports:

Still need to make the other cylinder head. Having lots of fun.

Jim

 

[zeeprogrammer]

That looks great!

I thought it was interesting that you used an end mill to size the bore. How does that compare to reaming? Do you expect to do additional operations on the bore like sanding or lapping?

Thanks.

 

[JMI]

I thought it was interesting that you used an end mill to size the bore. How does that compare to reaming? Do you expect to do additional operations on the bore like sanding or lapping?

Zee,

I usually ream the bore but I use chucking reamers and a round column mill and raising/lowering yada, yada, yada got lazy and just used an end mill on the under sized hole. I use "Clover" grinding compound if any lapping is needed.

Jim

 

[JMI]

The cylinder, crosshead and rear cylinder head:

and

Jim

 

[JMI]

Some progress has been made, "steam chest", valve plate and cover. The highlights:

Steam Chest:

Turned around in collet and drilled:

Hollowed out:

In Place:

Valve Plate:

Cover:

All together:

Beginning to look like something and needs to be mounted to it's base.

More to follow...

Jim

 

[zeeprogrammer]

Looking great.

What size end-mill did you use for the porting cover? My plans call for 1/32. Yours looks bigger.

I'm actually setting up to do the porting cover right now. If you hear a dim wail from eastern PA...then I broke the cutter.

Great progress...I'm still at a point where I have to think and prepare for a few days before I make a cut. ;D

 

[JMI]

What size end-mill did you use for the porting cover? My plans call for 1/32. Yours looks bigger.

Zee,

As per Elmer's drawing the 2 supply ports are 1/16" wide by 1/8" long and the center exhaust port is 1/8" x 1/8" square.

I'm actually setting up to do the porting cover right now. If you hear a dim wail from eastern PA...then I broke the cutter.

I know what you mean. Those tiny end mill are as pricey as they are fragile .

Jim

 

[zeeprogrammer]

As per Elmer's drawing the 2 supply ports are 1/16" wide by 1/8" long and the center exhaust port is 1/8" x 1/8" square.

Interesting...my plan shows .05 by .23....which means...which means...RATS...I screwed up! Ah well. I ended up with .031 by .23. Elmer's plans would be the right one. I suspect my plans were redone by a company so they could sell it as theirs.

Sorry if I'm off-topic...but your thread is a big help to me.

 

[JMI]

Have something for the engine to sit upon:

Jim

 

[JMI]

The column and bearing:

Milling steps:

and sides

indicating bearing:


the job to date:

This is the last post for a week or so. Having lots of fun, wish I didn't have to stop.

Jim

 

[tel]

Coming along nicely

 

[JMI]

Was able to get a few more parts done but it is slow goin'.
Started with the eccentric strap:

Was going to under drill then bore the hole for the eccentric but decided to just drill to size:

and mill:

make the crank:

and the eccentric itself:

the reversing handle is still being made:

Still having fun but it can be a little tedious at times.

Jim

 

[arnoldb]

Looking good Jim !

Regards, Arnold

 

[zeeprogrammer]

Looks great Jim.
How did you make that first curve on the eccentric arm?