Senior project

[Chippie]

My next project is the Senior engine from a kit from the Engineers Emporium, bought for my recent birthday.

 

[DanZac]

Looks like a great project, open crank engines always look great. The fact that you can actually see stuff happening makes them fascinating to watch.

 

[gaz1]

i prefer a proper working type of one

have a good look at the sliders on this

this is while in use

 

[roofman]

i prefer a proper working type of one

have a good look at the sliders on this

this is while in use

I prefer bacon and egg and it has nothing to do either with the OP,s post about building a kit engine

 

[slim_boy_fat]

@Chippie From the thread title, I thought you were going to build an OAP. (sorry)

 

[Chippie]

Ok, made a start on a couple of simple parts….just a turning job or two…
First up the gear/cam shaft…then a simple bush for the cam/gear…(not necessarily in that order..).

Havent started on the major castings yet,..too much on my mind at the moment..

Stay tuned…

 

[mike os]

@Chippie From the thread title, I thought you were going to build an OAP. (sorry)

We'll actually he is

 

[Chippie]

Some more parts made today, these 3 make up the rocker assembly for the ex valve…see the first post, picture…
The pivot arm looks like it was plasma cut, the surface was very hard, a file wouldn’t touch it…so I cleaned it up as best as I could without reducing its dimensions too much.
The plans call for the pivot pin to be made from ms, I decided to make it from harder wearing Silver steel, I might add a phos bronze bush to the rocker, later on.

 

[Chippie]

Some more parts made.
Cam roller bearing pivot, push bar for the exhaust valve and the support block.

 

[Chippie]

A bit more…..
Made a start on the con rod….(horrible thing! )

I bushed the litte end eye with some Phosphor Bronze rather than Brass….then reamed to 12mm

Although the big end is tabbed from blocks of Brass…( should have been Steel with Bearings imho..) it’s reading for final boring in the lathe to 16mm

 

[500e]

Hate lathes with no raised edge behind the chuck.
I always make a fence around the head stock if flat.

 

[Chippie]

/Hate lathes with no raised edge behind the chuck.
I always make a fence around the head stock if flat.

You mean, 'so things can fall on to the rotating chuck? '

I dont ordinarily have items on the top like that...for that reason...Safety first as always..

 

[500e]

 

[Chippie]

A few more bits….
Two valves, made in two parts, 303 stainless, valve spring caps, again 303 stainless…machines nicely.

 

[Chippie]

Continued…….

Finished the crankshaft today….
A pressed assembly, then cross drilled and pinned, with the pins silver soldered in….
The webs are black mild steel, look to have been laser cut/profiled. The main shaft and crank pin are made from EN3A….bloody hard stuff! When it came to cutting the 4mm keyways….had to use a Carbide end mill…

 

[roofman]

Continued…….

Finished the crankshaft today….
A pressed assembly, then cross drilled and pinned, with the pins silver soldered in….
The webs are black mild steel, look to have been laser cut/profiled. The main shaft and crank pin are made from EN3A….bloody hard stuff! When it came to cutting the 4mm keyways….had to use a Carbide end mill…

View attachment 421488 View attachment 421489

did you cut them keyways? nice job

 

[Chippie]

did you cut them keyways? nice job

Yes, milled out with a 4mm Carbide end mill….nice and sloooowww….plenty of lubricant and keep clearing the swarf….EN3B seems very hard to cut..

 

[Misterg]

EN3B seems very hard to cut.

I don't like using it. I bought some 'bar ends' from ebay that were supposed to be EN1, but I'm pretty sure they were EN3 - they were very silver, had pale blue paint on the ends and machined like poop.

Enjoying the build - keep it up

 

[Chippie]

Made a start on the piston, machined from billet, finished diameter is 38mm and is 50mm long. (It is over length at the moment)
The crown is profiled, so going to need a radius on it…
Machined out the underside for the little end, need to drill and tap the bosses for the gudgeon pin retaining grub screws (M4) and machine the piston ring grooves…

Then a final clean up and polish……

 

[Chippie]

A productive afternoon, with a celebratory beer…( well cider..)

Piston rings were supplied with the casting set, so no making required..( phew! )
Gudgeon pin is 12mm silver steel, drilled thru for lightness..