Water Cooled Webster

[bmac2]

I guess this thread started over in the “Questions and Answers” back in August. This will be my 7th engine and my first IC so I’ve decided on a Webster . . . sort of.
On the web site (http://home.comcast.net/~webster_engines/) I saw that the first Webster ran on January 3rd, 2004. After 10 years it would be interesting to find out just how many Websters there are in the world.

 

[bmac2]

I’ve been going over the plans and doing it up in CAD for a couple of months now and I start to think that with the Webster it’s what’s on the inside that counts. As long as these parts and their relationship to each other is maintained, that’s all that really counts.

 

[bmac2]

The size and style of the flywheel, frame, and the cooling, I just don’t think matter much. It says right on the web page “Very forgiving design - no super-critical dimensions”. Technically this could work.

 

[bmac2]

One of the things I noted on the web page under Cons: was.
“Limited run time due to inadequate cooling, but I kinda figured this going into it. This engine was never meant to run 24/7, just the occasional smoke, fire, and noise show for friends and family... well, OK, me. Needs more and / or larger cooling fins, a fan, or possibly a water jacket on the cylinder. Not a major issue and certainly one that's easily resolved by thermally isolating the carb.”
Going into this with the philosophy that ignorance is bliss. I’m going to try for water cooled Webster. As long as I can keep the relationship of the basic components the same it’s still a Webster, just in a pretty dress. Just might see how “forgiving” the design really is.

I’ve got over 60 meg of files (most of them now useless) sitting on my drive so I think it’s time to stop drawing pictures, and start making some chips. My game plan is to push the edge on my skill levels on this and do the things I’ve always admired on other engines as well as try and do one part each day. I’ll see how that works out.
I’m going to start with the water jacket. For my skill level it’s going to be the most completed bit of machining I think I’ve done.
I starting with a 1 lb 7 5/8 oz. lump of aluminum and squared it up in the mill.

 

[bmac2]

I cut it down to size in the 4x6. I must get that “slide in slide out chip tray” Hat56 mentioned to me back in the Q&A mounted under this thing before my wife notices the floor. The “Cut Off This End” is because I didn’t bother square up that face.

 

[bmac2]

Did a little rough layout on the sized block. I know a lot of people don’t but for me it’s just thinking out loud. Then set it up in the 4 jaw

 

[bmac2]

After drilling, drilling, and more drilling out to ¾”, I changed to a 5/8 boring bar to get it out to 1”.

 

[bmac2]

To cut the recess for the water jacket I found a small piece of stellite and ground it so I could plunge cut into the interior. It’s defiantly time for a cleanup.

 

[bmac2]

After turning it over to put a shallow round on the back I moved it over to the mill to hog out the tank.

 

[bmac2]

To round off the bottom I put a piece of 1” bar through the block then it’s just rotate, clamp, mill, and repeat.

 

[bmac2]

I just cleaned up the bottom of the block on my belt sander. I’m pretty happy with the way it turned out but I can’t decide to start cleaning the shop with the Shop vac or a shovel.

 

[bmac2]

I’m pooped, I’m happy and my wife is telling me there’s this thing upstairs called “supper”
Hey. Home shop weight loss program. “Lose 1 lb a day without dieting or excursive!”

 

[Swifty]

Nice going Bob, I will follow along with great interest.

Paul.

 

[bmac2]

Thanks Swifty
I’ve been watching your Nemett Lynx build. Good looking engine.

 

[johnmcc69]

You're off to a great start Bob! Looking good.

John

 

[bmac2]

This part is cut and paste from the Q&A. http://www.homemodelenginemachinist.com/f26/webster-engine-question-22718/
Following a tip I picked from Garry (gmac) out in the sunny Okanagan the cast iron cylinder liner is starting out pretty humble beginnings. $5.00 at Walmart for 5 lb of cast? I thought it was worth the risk.

 

[bmac2]

Spent a little quality time with the 4x6 and 45 minutes later . . .

 

[bmac2]

Can’t see any voids and it looked pretty consistent. Not that I know what it’s supposed to look like. I’ve got a Chinese milling vise I wish looked that good.

 

[bmac2]

Did a cleanup cut just to see how it would come out and it was hard to get a good finish on it but as Paul (Swifty) pointed out back in Q&A
“Bob, you will find that it will always be hard to get a good finish on cast iron due to its grain structure. Even if you polish it, the surface will always have pits in it. Of course, the better the quality the smaller the pits are.”

 

[bmac2]

Back to the here and now. Took the OD down to 1” and started boring out the cylinder.