Finally got back into the workshop

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Weldsol

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After getting the Sealion engine finished ( apart from maybe a cooling fan and drive to it plus some more tarting up) at the end of March an old problem flared up and the doctor said you need to change medication as we now recommend this new one so I believed her two weeks in I ended up with all the side effects no to man and to the point where I couldn't even walk a straight line let alone drive or use equipment with nice sharp cutters whizzing round so i was banned from the workshop for 4 1/2 months
Whilst brooding trying to find something to do I decided to go through all my business paper work to see what I could shred.
That's when I came across a set of drawings all rolled up with a rubber band. These turned out to be for a "Hoppy " horizontal four stroke engine designed in 1989 by B&R TITE so sitting and getting fed up I started think how I could make one of these.
Obviously B&R TITE used to supply all the castings etc so went online and nothing came up.
So I knew I would be safe typing on the keyboard and a PC mouse has never bit anyone to my knowledge so I re-drew all of the main castings then drew a square / oblong around each part to give the size of aluminium blocks to order going over the smaller parts I knew I had 90% of the materials kicking around in the workshop.
OK some round parts had to come out of square and visa versa but that just meant another sack of swarf to get rid of
So here are the GA drawings GA drawing 1.jpg GA drawing 2.jpg GA drawing 3.jpg GA drawing.jpg
 

GreenTwin

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Nice engine.

I have had my share of health issues, including COVID.
I had COVID very early on, before the vax'es came out, and so I never had any problems after than.

Luckily I am still functioning somewhat well, but some days its a challenge.

Nothing like a good engine design/build to clear the mind.

.
 

Weldsol

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Nice engine.

I have had my share of health issues, including COVID.
I had COVID very early on, before the vax'es came out, and so I never had any problems after than.

Luckily I am still functioning somewhat well, but some days its a challenge.

Nothing like a good engine design/build to clear the mind.


Thanks Green twin
After going through everything with the meds 5 weeks ago I got covid via the wife so that didn't help but hey Ho of we go again got my alloy blocks and have made a start will start posting some pic in the next couple of days
Paul
 
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Weldsol

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Made a start on the cylinder block, squared up the ends and one side
(the reason for only doing the ends and one side was once marked out for the ends all the rest of the sides will be profiled on the mill.)
The mandrel allows me to face the ends for mounting the cylinder to the crankcase and to transfer to the mill
you can see on the mandrel there is an undercut this allows the 10mm clamping to lock the cylinder in place and when removing the mandrel it will not damage the liner seat bores due to the raised edges caused by the 10mm grub screws.
Now I can face back to reveal the mounting faces, once one end is done it is just a matter of releasing the grub screws slide the block off the mandrel turn it end for end and refit and lock up the grub screws, now I can face to the correct length and then do the mounting face.
Then to the mill
Paulcentering block ready ffor boring.jpg Machining bore for liner.jpg Mandrel for cylinder.jpg cylinder block on mandrel for machining mounting faces.jpg Mandrel fitted and machining register.jpg
 

Richard Hed

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Nice engine.

I have had my share of health issues, including COVID.
I had COVID very early on, before the vax'es came out, and so I never had any problems after than.

Luckily I am still functioning somewhat well, but some days its a challenge.

Nothing like a good engine design/build to clear the mind.

.
When you had the covid, did yuou have 'dead brain' for a few weeks? I had a hard time breathing for 6 weeks after, and had what the butchers, oops, I mean doctors, called something like 'dead brain' but it was some other term where you had very fuzzy thimpfking. I had that for about 10 weeks. Some say I still have it or always had it.
 

Weldsol

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When you had the covid, did yuou have 'dead brain' for a few weeks? I had a hard time breathing for 6 weeks after, and had what the butchers, oops, I mean doctors, called something like 'dead brain' but it was some other term where you had very fuzzy thimpfking. I had that for about 10 weeks. Some say I still have it or always had it.
No this was only 5 1/2 weeks ago and I was over it (well tested negative ) in 15 days
paul
 

GreenTwin

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When you had the covid, did yuou have 'dead brain' for a few weeks? I had a hard time breathing for 6 weeks after, and had what the butchers, oops, I mean doctors, called something like 'dead brain' but it was some other term where you had very fuzzy thimpfking. I had that for about 10 weeks. Some say I still have it or always had it.
COVID definitely knocked me for a loop for about 4 weeks.
Ivermectin, vitamin C and D, and zinc has cleared the brain fog for me.

.
 

Weldsol

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Made a start on the cylinder block, squared up the ends and one side
(the reason for only doing the ends and one side was once marked out for the ends all the rest of the sides will be profiled on the mill.)
The mandrel allows me to face the ends for mounting the cylinder to the crankcase and to transfer to the mill
you can see on the mandrel there is an undercut this allows the 10mm clamping to lock the cylinder in place and when removing the mandrel it will not damage the liner seat bores due to the raised edges caused by the 10mm grub screws.
Now I can face back to reveal the mounting faces, once one end is done it is just a matter of releasing the grub screws slide the block off the mandrel turn it end for end and refit and lock up the grub screws, now I can face to the correct length and then do the mounting face.
Then to the mill
PaulView attachment 141443 View attachment 141444 View attachment 141445 View attachment 141447 View attachment 141448
Got a fair bit done on the mill yesterday

milling cylinder profile.jpg profiling the cylinder.jpg Nearly there on the profiling.jpg Profiling done.jpg

Paul
 

Weldsol

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Hard at it again today, got the inside milled out to give 1/8" wall then shaped a 2.5mm piece for the top plate and TIG welded all round then filed the radius around the outer edge.
I can't do the mounting holes yet as these have to spotted from the crankcase, and I want to do the liner as this will help lining up to the crankcase
PaulInternal milling.jpg cylinder.jpg
 

Weldsol

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Hard at it again today, got the inside milled out to give 1/8" wall then shaped a 2.5mm piece for the top plate and TIG welded all round then filed the radius around the outer edge.
I can't do the mounting holes yet as these have to spotted from the crankcase, and I want to do the liner as this will help lining up to the crankcase
PaulView attachment 141538 View attachment 141539
Got onto the crankcase which involved a lot of metal removing (thank God for ripper cutters) and at the same time to remember what bits to leave .

start roughing out crankcase.jpg Crankcase almost finished.jpg

One thing that came to light was because I had to use a 1/4" cutter for the internals the radius at the front corners interfered with the cylinder mounting bolt heads so had to make a small spot face cutter insert it through the 1/8" hole from the rear ( it wouldn't clear the main bearing blocks) then put a hand drill on it and pull whilst cutting. It worked out ok

Counterbore for crankcase.jpg

Next job will be the base / fuel tank

Paul
 

Weldsol

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Got going on the Base / fuel tank (yet another bag of swarf to go for recycling) cut out all the inside and did a rebate for the bottom plate ( to be TIG welded in ) then onto my adjustable angle plate to do the 5 degree
tapered outsides
roughing out fuel tank come base.jpg final cut on fuel tank.jpg Base with fuel tank.jpg

Paul
 

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