PIP 3 Cylinder Radial

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The stanchions were machined on the manual lathe and thread with a dia
These are then installed on to the cylinders and a slot is then milled for the rockers
The cylinder and head are all one piece on this engine


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Making the cylinders I think was one of the most challenging parts of this engine, there are so many set ups
The first part was the easiest turning the centre out and machining the fins,
CNC lathe was used to turn the fins
Internal boring was done on the manual lathe

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After the fins are finished the cylinder is mounted in a chuck mounted on the mill table, I used CNC to drill the mounting holes in all the cylinders


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Next op done in the dividing head, using a ball nose cutter a grove was cut through the fins in line with each bolt hole, this is to allow bolts easy access to the mounting holes

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Next is to machine the top of the cylinders to the correct dimensions and the turn the fins, this be comes the head
A fixture is made to hold the cylinders so they can be turned in the lather

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Once the top is turned to the correct shape the fins are turned
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This is the fixture that is used to mount the cylinders to the rotary table
The rotary table is mounted on to a tilting table, so the rotary can tilted to a 30° angle using a centre drill, drill down until almost all the countersink part of the drill is in the material
This countersunk hole will be used to line the cylinders up with the spindle on the mill, there is no other way to line up where to drill the pug hole and the valves etc


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Now the Roary table is tilted to 30° and also at an angle of 41.9° to the table
A dead centre is placed in the quill and this is then used to line the spindle up with the hole that was first drill into he top af the fixture, this will put the cylinder in the correct place too drill the hole foe the spark plug and have it come out in the right place with on the cylinder

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As the rotary is setup now all the hole for the spark plug, the two valves and one rocker stanchion, after these holes have been drilled and tapped the the angle table that the rotary is bolted to is turned to face the other direction at an angle of 41.9° and the other rocker stanchion can be drilled and tapped


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Next step is cross drill the stachions, this is done by milling a slot and a piece of aluminum that is the same as the width of the stanchion and finding dimension from the open end of the slot and the placing the stanchions on the cylinders into the slot ar drilling the hole

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so if your luck has held out to this point they should look like this

Still have to machine the inlet and exhaust ports yet

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Spark Plugs are made using corian for the insulators, the corona is cut off a piece scrap I got from a kitchen manufacturer, it is the turned down until it is round.
The bottom end and the insulators are machined on the cnc lathe


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The insulator is drilled with a 1mm drill

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After the end phase been milled and a tag is left it is bent over using this fixture

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The plug is then place into the fixture to be swaged together
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A 1mm stainless tin welding wire is used for the electrode
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Before I hade surgery on my hand
I assembled the parts I have made, there are no sleeves in the cylinders, no pistons or rods installed
And it is mounted on a temporary stand just for display
Another couple of weeks and I should be able to work on it again
 

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Really nice work. That one piece cylinder and cylinder head is another reason I chose the Edwards radial over this engine.
It took awhile to figure out all the angles, the more you do on the cylinders the more nerve wracking it gets,
One mistake can put you a long way back
 
Great work! I’ve been mulling over the PIP plans for a while now and am considering this as my next project. One thing I noted, the plane call for a GMS 23100 carburetor that is unobtainum these days. Have you found a suitable replacement? I can’t find any specs on that carburetor so curious if you have an idea what will work. TIA and keep up that great work!
 
Great work! I’ve been mulling over the PIP plans for a while now and am considering this as my next project. One thing I noted, the plane call for a GMS 23100 carburetor that is unobtainum these days. Have you found a suitable replacement? I can’t find any specs on that carburetor so curious if you have an idea what will work. TIA and keep up that great work!
Hi
I haven't given it a lot of thought yet but I think an RC carbs from a 40 or 60 size engine should be ok
I will probably make my own carby
 
Should
Hi
I haven't given it a lot of thought yet but I think an RC carbs from a 40 or 60 size engine should be ok
I will probably make my own carby
That sounds reasonable. Should you find something that works well please let us know here. I’ll probably be in the market for something in the coming months.
 

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