Kerzel Hit and Miss

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Next is the connecting rod. First I drilled and reamed the holes for the wrist pin and crank. I also drilled four 1/8" holes that I will use later when milling the sides.
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Using a 1/2" end mill I milled out each end to form the inside radius of the ends.
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Then milled down the middle section, flipped and repeated on the other side.
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I used drill bits in the 1/8" holes to clamp the piece at the correct angle.
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Then milled out the middle section. Flipped over and repeated.
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Then rounded and profiled the ends on the rotary table.
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Here is the finished connecting rod.
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This weekend I made the head. First turned the shape.
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Then on the mill I drilled all the bolt holes, spark plug hole, and valve holes.
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Then used two drill bits to locate it properly in the mill vise to drill the intake and exhaust holes.
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Here is the finished head.
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Here are the completed valve guides and valves.
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Really enjoying your build. Thanks for taking the time to share it.
 
Beautiful looking engine. I am still following with interest.

Jim
 
Looking very swoopy---I like it.---Brian
Thanks Brian. I've never heard the term swoopy before, but I will take it as a compliment.

Really enjoying your build. Thanks for taking the time to share it.

Beautiful looking engine. I am still following with interest.

Jim
Thanks guys, glad you are enjoying the build.

Would be great to this engine running.
I agree Gus. I too would like to see this running but I still have a lot more parts to make.
 
Today was another first for me. I decided to try to make some intake valve springs. I made an insert to fit in my dial test indicator holder that has a point on one end and a .020 hole through it. I fed a piece of .010 spring wire through the insert and wrapped it around the shank of a no.28 drill bit. While hand turning the chuck I fed the carriage by hand for the first few wraps, then with the lathe threading gears set for 16 TPI I engaged the half nuts to feed the middle part. Then disengaged the half nuts and again hand fed a few wraps. After removing from the lathe and trimming of the extra wraps they look pretty good. I am not sure if I will relax them in a oven or not. Is this necessary?
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Swoopy is a compliment. It refers to the Art Deco look of the curves in the frame. You are doing a great job.---Brian
 
Nice looking springs Weez, I have been experimenting with a spring winding insert for my tangential tool holder.

I wil continue the experiments when I get home from Cabin Fever (still going, now in Nashville).

Jim
 
Thanks Jim. I was surprised at how easy it was to make springs. Good luck with yours.

Today I made the tension springs for the governor. I set the change gears up for 96 TPI which is the closest I could get to the desired pitch of .010"(the width of the wire). Then I wound a length of about an inch on a .093" diameter mandrel.
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Then trimmed to length and bent over the end two turns to make the eyes.
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Here are the final batch of springs including the .010" intake, .014" exhaust, and .020" cam follower springs.
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With summer here I have not had much shop time but I finally completed one more piece, a flywheel. After turning to size I used the rotary table to mill out the recess. I prefer to do this on the mill instead of the lathe.
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Then drill all the holes that make up the inner part of the spokes.
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Mill the top arcs of the cutouts.
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Mill both sides of the spokes.
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And the finished part. It needs a little cleaning/polishing but I think it turned out well. Now I need to make another one.
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Fantastic job Weez
I think one of the best things with the Kerzel Hit and Miss is that when you’re done it really is a great looking engine. Keep up the good work. I’ll be tagging along
 
Awesome work Weez! Nice spring winding too. I did mine manually on a threaded rod as per Kerzel and it was a bit tricky. In the end I used steel guitar strings which worked fine but I did have to play around with the inlet valve spring to get it to work just right. Keep up the posts ! :)
 
Thanks everyone for the compliments. I am glad you are enjoying the build. Progress has been slow since summer is here. I got the second flywheel done which should be the last of the larger parts.
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