Mery 6-stroke kit.

Discussion in 'Engines From Castings' started by Jack3M, Jan 13, 2019.

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  1. Nov 14, 2019 #181

    Jack3M

    Jack3M

    Jack3M

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    Already cast them, just need to cut off sprue. They came out really nice. Will try to photo later
     
  2. Nov 15, 2019 #182

    Jack3M

    Jack3M

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    Just learned that Gary Martin has a set of water pump castings, no drawings, but some photos. He sent a photo of that awesome purple machine with one.
    KIMG1079.jpg
    As promised the casting for the nipples, and in the background a bit of the floor before it was done.
    20191114_120218.jpg
     
  3. Nov 18, 2019 #183

    Jack3M

    Jack3M

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    Well, the engine is completed. Still need to make up the oilers, fuel system, ignition system, water pump and cooling system, but these are all over and above the engine itself. There are a lot of little fiddly things to do still. Made up the holder for the hall sensor. Need to get black PLA to print out the final version.
    20191118_090632.jpg 20191118_090638.jpg 20191118_092242.jpg 20191118_092252.jpg
    The chalk mark in the last photo is where a magnet is on the backside of the gear.

    Also finished out the exhaust. Doing the elbows was pretty rewarding in that I did do the inside threading on them. Used the 4 Jaw to do that.
    20191118_120302.jpg

    Cant really say final photos, but first completed photos.
    20191118_133633.jpg 20191118_133709.jpg
     
  4. Nov 18, 2019 #184

    karlw144

    karlw144

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    Beautiful job Jack. Can’t wait to hear/see it running. Thanks for helping me along the path on this engine.
    Karl
     
  5. Nov 19, 2019 #185

    Jack3M

    Jack3M

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    Karl, As I mentioned in email, there is still a long way to go, but step one is complete
     
  6. Nov 19, 2019 #186

    PhilL

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    VERY VERY nice job Jack!!!
    That purple engine is killer isn't it? I spoke with him. He almost ruined it. He left plain water in the jacket and plugged it up with rust. That was where I realized I will always use machine coolant. I think I would cry if I rusted mine.
     
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  7. Nov 19, 2019 #187

    Jack3M

    Jack3M

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    That is good to know, never considered that aspect.
     
  8. Nov 22, 2019 #188

    Jack3M

    Jack3M

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    On to other items of need and interest in this project. Got to have elbows and T fttgs. Broke down and bought the tap and dies for 1/16-27 npt. Work well on the brass and bronze. Anyhow, the process.

    Drew up some elbows and T fittings in groups of 3 contiguous fittings in Fusion360. It has a nice feature of splitting something into parts on any given plane you choose. For molding at home in sand there is nothing less expensive nor as simple as my process. Years of trial and error and still improving. Mind you these are for 5/16 brass pipe, not large stuff.
    20191121_155749.jpg
    Printed out the halves on 3d printer using PLA. A touch too small to effectively use drawn in locators and time consuming to get the different sizes, so just drilled some holes for 1/16 pins to hold each half during the casting. Did two groups of castings this morning and used brass with a touch of zinc added as it has been melted several times. That was very nice to work with, not as sticky as brass can be. Had previously cast the T's in bronze.

    Not sure how many I will need in total for fuel and cooling at this point. It took all day to cast, clean, drill and tap them all. (and clean the mess from it all)
     
  9. Nov 22, 2019 #189

    karlw144

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    And you only did enough for one engine? Lol. Nice job.
     
  10. Nov 22, 2019 #190

    Jack3M

    Jack3M

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    That probably is't enough
     
  11. Nov 23, 2019 #191

    Jack3M

    Jack3M

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    I don't get it. I use the correct size tap and die and it doesn't start. NPT thread. What might I be going wrong? Finally had to go to 5/16-27 to be successful
     
  12. Nov 24, 2019 #192

    Jack3M

    Jack3M

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    tWell tried to make her pop, but no pop. Did valve timing according to Newsletter data. I am getting spark at the plug. Got one pop, just one. Nothing but issues with mixing chamber so I think this may be the issue. Sure seems to me like not even close to enough air. As I remember a #60 hole for the gas needle and a #54 for air as I recall. Those that have had success, was it with the shown mixer?

    Spark timing is either slightly before or right on TDC. Holding intake valve open to get fuel in has no effect.
     
  13. Nov 27, 2019 #193

    Jack3M

    Jack3M

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    Been getting some help and feedback. Trying to run on LP and use the mixer in the plans. Apparently just getting too much fuel and I need a demand regulator. Awaiting plans and more info, my assist person has personal stuff to attend to first and get me a file. Found a mixer plan/diaphgram/needle that I may just get. Not sure yet. Meanwhile I have the grease cups and, unfortunately, I am going to have to disassemble and strip the whole thing and redo the finish and see if I can reassemble without chipping the powder coat. It chips very easily. Am also going to contact the coat people and see if they have suggestions. Forward ho.
     
  14. Dec 2, 2019 #194

    Philipintexas

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    I used propane with a hand-made demand regulator and the diaphragm/needle valve from a Briggs-Stratton carb. Not difficult to make and it works well.
    Were you shocked at the “Tiny” restriction in the exhaust system? It seems counter intuitive to force the cylinders to exhale/inhale through such a small opening, but it would not work with a larger opening.
     
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  15. Dec 8, 2019 at 1:13 PM #195

    Jack3M

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    Well I find out today that the issue was resolved. You see, on the exhaust chambers, someone, cannot say who this might have been, someone, drilled the holes bass ackwards. LOL. So got to fix them up and give it another shot. No wonder it wouldn't run/fire/do anything. What a stupid mistake
     
  16. Dec 8, 2019 at 6:09 PM #196

    Jack3M

    Jack3M

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    That was it, still need to improve valve sealing but got popping now.

    During all this, have been putting a little time in on the water pump. Much of it was to make gears 8t, 16 dp. I had a set of cutters for 16 dp, but the 'count' of eight was not listed for any of the cutters. Took a chance and used the one closest....12-13t and got a good set. I had bought a set on Ebay, but they were only .375 thick and therfore would not work well with the ports. So made a set that were .5". Made one long gear on a shaft and cut them off. Will get photos down the road.
     
  17. Dec 9, 2019 at 2:05 PM #197

    PhilL

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    Damn gremlins!! I'm glad I'm not the only one with those little rodents!!
     
  18. Dec 10, 2019 at 12:33 AM #198

    Jack3M

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    Success. Need work on fuel system as it starves out. Need cooling system first.
     
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  19. Dec 10, 2019 at 2:23 AM #199

    PhilL

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    Very well done Jack!!!
    Isn't it a great feeling when it comes alive!
     
  20. Dec 10, 2019 at 4:17 AM #200

    karlw144

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    Well done. You’ll get the bugs out soon enough. Great community to help us along.
     

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