Galloway Pattern Making

[GreenTwin]

Here are some screencaps for a Galloway that I plan to make.
Someone said "They already make Galloway casting kits", and my response is "Not like this one".

My dad owned a Galloway 7.5 hp, and so that is what got me interested in this engine, and interested in making some castings for one of them.

This is my dad with his Galloway at an engine show many years ago.

 

[GreenTwin]

I remember this engine running very smoothly, and I like the water hopper and the general design/look of the engine.

First step was to create a 3D model, shown below.

 

[GreenTwin]

The flywheels gave me a lot of grief.
I was trying to match the original ellipsoidal section and taper in both axis, and I think I finally got it pretty close.

Flywheel spokes are surprisingly difficult to copy accurately.

 

[GreenTwin]

Here are some bits and pieces.
I am not quite done with the model on this engine, but close.

The flywheels would be 12" diameter.
I forget the bore.

 

[GreenTwin]

More pieces.

 

[GreenTwin]

I made the base and the cylinder as separate 3D models, and then merged them into a single assembly.

 

[GreenTwin]

The merged frame/cylinder.

 

[GreenTwin]

The head and valves.

 

[GreenTwin]

More head and valves.

 

[GreenTwin]

Piston.

 

[GreenTwin]

An assembly drawing, exploded view.

 

[GreenTwin]

Here is my first pass on patterns and coreboxes.
Not quite done with these.

Piston core.

 

[GreenTwin]

Split flywheel pattern with draft angle and machining allowances added.

 

[GreenTwin]

Cylinder cores and coreprints.

 

[GreenTwin]

Cylinder head cores and coreprints.

 

[GreenTwin]

Flywheel sections showing the ellipsoidal spoke section.

 

[GreenTwin]

Water hopper cores and coreprints.

 

[GreenTwin]

Dabbling around with the frame core and coreprints.

 

[GreenTwin]

And so that is how I do it.

Part line is down the long axis of the cylinder/frame, in a vertical plane.

Patterns will be 3D printed.

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[GreenTwin]

And here are patterns printed for a Dake, which shows the patterns after printing.

Generally speaking, everything has 3-5 degrees of draft angle, in most cases.