Matt, I believe that an IC engine would be too complex to build without some machine tools such as a lathe or mill, and as others have said, it may be so complex as to have you lose interest in the project before it is completed. In your case I would recommend starting with a pre-machined steam engine kit, or possibly an engine built from brass tubing, as someone else also mentioned.
You do have other options available to you, and they will become apparent if you take a minute to think about them. Here are some possibilities:
- Check around your neighborhood and with relatives. There may be an individual around that has some machining equipment and the knowledge and willingness to help you with your project. My 26 year old son is just starting to show interest in machining metal parts. Teaching him is very enjoyable and rewarding for both of us
- Maybe you could take some machine shop classes at school or at a local technical school where you would be allowed to work on such a project. Taking such classes would also give you the basic working knowledge you need for such a project.
- Watch estate sales and consignment auctions in your area. You would be amazed at the equipment that can be had from time to time and often at bargain basement prices.
- Start with something small and easy. By 'small' I really mean uncomplicated. A simple wobbler engine is a great way to get started. Kits and plans for them are very abundant.
- Enco has some books available on basic machine shop practices. Purchasing them may be a big help to you if you do not have other learning resources available. There is also a very good chance that your local library will have books available that cover the subject. You may even get lucky enough to stumble on a book of plans that you can utilize.
- There are quite a few plans available on the web. Go to http://www.john-tom.com/html/Engines.html and compare the IC engine plans against some of the steam engine plans. You will quickly see the difference in complexity between the various types. You will also notice that there are plans there ranging from very simple to very complex and everything in between, and most of them are free to download.
- If you live in an area where threshing shows are held, or old time power shows, make sure you attend one or more of those shows. They almost always have areas set up for guys like us to display our projects. You may be able to make a connection with someone there that can get you going in the right direction.
Whatever you do, don't give up. I built my first engine, which was a small single cylinder steam engine, when I was in a high school machine shop class (over 30 years ago). My second engine didn't come until about 15 years ago, and it was built with only a drill press and was soldered together from brass tubing. I've had a drill press and grinder for years, but I just purchased my first lathe 6 months ago. I haven't started on any engine projects yet, but have been turning out some other projects that have been on my list for a long, long, time.
Be patient, ask lots of questions, and don't be afraid to ask for help from others. Most folks in this hobby are more than happy to teach new people, both young and old.
Terry