SHED MATTERS 2

[doubleboost]

Hi
Stanley
I think I can smell that pipe from here
I have a lad looking out for some big bronze bushings to cast the cylinders out of
Looking forward to the "double build"

[micktoon]

Hi Stanley,
Your lay off did not last long then Good to see the next production run underway, looks good so far, you were not joking when you told Sarah Mrs Mcmaster had changed your life , that bar would have took some doing with the hacksaw.
Keep up the good work Stanley, you are probably the last engine works going at the moment !!

Cheers Mick

[Stanley]

John. That pipe is cruel isn't it.... I think about you every time I light up on a long auto cut.... I know why you stopped the fags and how it feels. I stopped smoking for three years when the fags started giving me bronchitis. I solved the bronchials but wanted a smoke every minute of the day... People who tell a really addicted smoker to stop have no idea.... In the end I cracked and went back on the pipe but luckily I seem to have no trouble with that, no cough and no ill effects, even my doctor has given up nagging because I'm in better nick than him!
Have a word with Mick, he has had an idea about the castings, I have mailed both of you this morning. The sooner I get them the better because so much of the build depends on having the castings done.... We have a bit of leeway once Terry delivers the steel because it will take me a while to get the shafts chopped out.....
See the mails for the cocks and valves, I shall be ordering them today......
As for Mrs McMaster, I bless the day she came into the shed, just think of cutting those blanks by hand....... It was cutting like that that broke all my 6" slitting saws! Keep your eyes open for me for some replacements.
Get Debs and Sarah on to shed matters so they can see their engines growing......

[Stanley]

It's a flywheel day but I started by doing some jobs and getting my ducks in a row. I'm going to use this Pratt chuck that was original equipment with the lathe when it was new. It has always annoyed me that the master socket wasn't clearly marked so I saw to it..... punched a zero into the case next to it.



I wanted to re-sharpen my cutters but before doing that I diamond dressed the wheel, adjusted the safety fence and gave the surrounds a good clean and vacuum. Then I reset the cutters, honed them and made sure they were cutting on centre. All these things take time but are essential!



Right! All set up and ready to go, let's go looking for a flywheel....



A while afterwards.... I have some shape in it, nothing measured, I just cut until it looks right.... Then after finishing the second side, centre drill and follow up with 3/16" and 1/2" drills before popping this 11/16" through. Ready for boring it tomorrow dead on 3/4". Quiet morning, no mistakes, gentle progress. And all the swarf cleared up and in the bin....



Just before I came away.... my mind has been working on mounting the wheels on a mandrel for final finish and polish and I wondered if this adjustable mandrel went down to 3/4". It doesn't, it's 1". Ah well, at least I checked.....

[micktoon]

Hi Stanley,
Got your E mails and I have spoken to John tonight so things are ticking this end too, I will contact Bob about the casting he has and that may be a quicker way of getting things moving. Sarah might get out of hospital tomorrow, not certain yet but sounds good chance, she will be laid up for some time so I will put a link on her laptop so she can find the posts to see the engine grow.
We all appreciate you doing this Stanley, its no mean feat building two engines not to mention a bloody nice gesture to cheer up two Geordie lasses that have had a rough time through illness, not many people would do it so top marks to you

Cheers Mick.

[Stanley]

Nice of you to say so Mick but remember it's good for me as well, walking Jack and working in the shed are a big part of my beat the bloke with the scythe strategy. A moving target is harder to hit!
The valves are in the post and should be here today.... It wouldn't surprise me if Terry turns up with the steel today.... I only lost my mojo for one day, it's back with a vengeance now and I have the bit between my teeth... It's up to you and John to keep me in the collar!

[Stanley]

I was late getting in the shed, Friday is always a busy morning but once in there, straight into boring the flywheel I almost finished yesterday.



No digital, no guessing and no mistakes.... Chasing 3/4".



Not long afterwards.... Last cut was a spring cut in reverse. Spot on 3/4" and just to make sure, checked with a standard. That'll do for me. I marked the flywheel with a 'D'. No favouritism, it's just that I found that letter punch before 'S'! The parts all have to be clearly marked.....



Straight into Sarah's flywheel.



Knocking off time. The back side is formed and I'm ready for this side. All the swarf cleaned up and we are ready for a clean start tomorrow morning.

[Stanley]

The drains and valves have arrived.



Straight into Sarah's flywheel!









By closing time the flywhhel was bored accurately, all the edges broken and marked with an 'S'. Progress!

[Stanley]

I'll have to have a bit of a think this morning, my crankshaft steel hasn't arrived! Looks like a major furtle in the treasure chest!

[Stanley]

It's been a funny old morning! I started the morning by having a good clean up, all the swarf out in the bin and Mrs Harrison's face wiped. I was going to swap the original Pratt chuck for the more modern Polish 3 jaw but then decided to put something right that has always bothered me about it. As far as I can see this was the only chuck that was ever used when the lathe started life at Bolton technical College and there are two signs of this. Number one jaw has half of its first thread broken off, at some time someone has tried to force it to enter when it wasn't properly engaged. Nothing I can do about that and it's no detriment really. The other thing is that the nose of the jaws is marked by careless us and running the cutter into it. I decided to see if this tip would turn it clean.



It was touch and go but it did it.



That looks better! While I was at it I decided to see how true it was running.



I chucked some silver steel which is probably as accurate a piece of stock as I have and indicated it. I got a bit of a surprise actually because it only ran out .0001" and some of that could be in the stock. Not bad at all for an old 3 Jaw. I'm not sure if the Polish chuck is any better.... So I'm leaving the Pratt on the nose.I then turned my mind to crankshafts and when I had a look in the far corner of the treasure chest I found a piece of 3" stock. I decided to get it out.



Easier said than done.... I had to virtually dismantle the shed to get to it so I could get hold. Not the ideal thing for an old fart like me. Never mind... it will be worth it!



While I was at it I got another lump out as well, easier than having to do this again! Problem is that when I got the stock out and measured the biggest its a quarter of an inch shy of what I need for the shaft! Bugger! Ah well, I found a handier place to store it, put everything back in place and tidied up. That was enough for one morning so I knocked off early.... Hopefully my steel will arrive shortly.....

[Stanley]

I'm still working on the treasure chest and steel. Can't do with being held up!

[Stanley]

I had crankshafts on my mind this morning and still no steel. I remembered that yesterday, while I was in the treasure chest, I'd seen a lump of 4" stuff so I dragged the saw out of the way again and went down on my knees. A major operation at my age! I found that what I'd seen wasn't a complete bar but a neat stack of the 4" slug you can see here. It would have meant a lot of swarf but at least I would have been doing something. I went to Plan 'B'. I can make the blanks for the con rods. They have a major diameter of 1.75" so I needed 2" stock. I found these in the treasure chest.



I decided against the stainless steel and as a last thought, rather than cut into the longer bars I looked in another corner of the shed and found just the thing, a 12" length of 2". I need 2 X 5" for the blanks so I put the other lengths away tidily and went and had a word with Mrs McMaster...



God bless Mick!



Not long afterwards I had 2 pieces 6" long. Time for some more muck shifting!



First job was to clean them up and find a face and a centre.



Not long afterwards I had two cleaner slugs.... Then I had an interruption....



My good friend Terry arrived with my steel. You can see how generous he is with me, I think he likes me.... Lots more swarf and chips in this lot!



Back to Mrs Harrison to chase two clean billets 5" long and 1.75" diameter. I realised that one big advantage of the old Pratt chuck is that the centre hole is big enough for me to sink the part of the bar turned down to 1.75" deep enough to do away with the centre so that made reducing the rest of the bar and facing to length a lot easier and safer.



Reducing the second bar. Once I had both bars down to diameter I did some blueing and marking and at closing time I had one slug accurate for length and diameter, the swarf taken out and the second on in the lathe ready for tomorrow.



Not a bad morning, we are making progress..... I'm ready for my afternoon sleep now....

[Stanley]

I was a bit late into the shed this morning, other matters got in the way of the serious stuff. First job was to tidy the steel Terry brought yesterday into a corner where it won't be under the feet.



Checked everything, honed the edge on me tool and got stuck in reducing this billet to 1.75" and exactly 5" long.



A bit of a think, the next job is to reduce most of the blank to the diameter needed for the clevis fork, 1 5/16". Than back into the lathe, get set up and do some more muck shifting.



Close of play. This one reduced to the minor diameter. I only need 1/4" on the foot end and I'll get that when we get to the stage where I'm sizing the centre for the rod. Next for shaving tomorrow. All swarf taken out and put in the bin. It's getting full but I haven't seen my scrap man since before Xmas. I'll have to do something soon. Making a lot of swarf is the penalty we pay for not having access to forgings or castings.....

[sister sarah]

Hi Stanley, I am now registered on the forum so can comment directly on project. So over the next few months I can watch engines develop. Its amazing what you have done so far and thanks for all your efforts
Love Sarah X

[chinatyke]

Just a thought Stanley, why don't you do the drawings for this engine and sell them on the internet? Or sell the drawings and full articles to one of the model-making or engineering magazines?

[Stanley]

Sarah! Welcome to the fold and so lovely to see you popping up after the scare you gave us all. It's nice working for you and Debs, it adds an extra bonus to the results. Sorry If I look slow but long experience has taught me that the more care I put into the work, the better the results. Nag John about the castings!
China, I don't do drawings and I have quite enough on my plate keeping up with my present workload! Don't forget that technically I am old and knackered and ought to be vegetating in my rocking chair, not making muck in a cool shed!
I've been looking back at earlier episodes of Shed Matters and as usual I am amazed that I did such complicated work. I get the same feeling when I read stuff I wrote years ago. I suppose my mother was right, I have an inferiority complex and am insecure.... I can remember how surprised I was when she told me that, a smart woman and she might have been right! So I shall just clog on and do the best I can....
Sarah, get Debs looking in on the site as well.....

[Stanley]

I checked everything, honed the cutter and got straight into more reducing. I was a bit late getting in the shed, cooking and washing had to be done!



Both blanks have got the two end diameters finished to size.



Both marked up for the limits of the centre section which will be 1/2".



Set up ready for more muck shifting and a different cutter honed and ready.



Knocking off time. I have the centre section finished, the junction with the major diameter cleaned up and I'm ready to get some shape into the other end which will become the jaws that fit on the crosshead. That's enough for this morning. All the swarf cleared away into the bin, ready for a flying start tomorrow.
If anyone sees the scrap chap around town, white Transit flat bed, give him a shout and tell him there is plunder in East Hill Street.... Otherwise I'm going to need a lift with the swarf bin down to the scrap skip at Gissings.....

[sister sarah]

Hi Stanley,

Steady progress being made. Its like waiting for the next episode of a best seller for me!

Love,

Sarah
xxxx

[Stanley]

That's the intention Sarah. Lovely comment and be sure I am aware you are checking in and watching.... It's a good thing, it spurs me on to take even more care, these will be the best engines I have ever made...... You're going to like the next bit when I've finished the connecting rod blanks..... Heroic machining at the limits of my tackle's capacity!

[Stanley]

I put a bit of shape on the fork end of the blank I almost finished yesterday...



And got stuck into the second one. This is the benefit of making engines in parallel, the second part is easier because everything is set up and you know exactly what you are doing.



Not long afterwards and we have two con rod blanks ready for fitting and finishing.



Things start to get serious now.....



Time for a serious chuck, 3 jaw off, 4 jaw on.



Clocking the first billet in. Not quite there yet but it's knocking off time and I'm hungry!

[micktoon]

Hi Stanley, top work so far and you are cracking on too. I am sure as you say these engines will be two of your finest yet, your skills are getting plenty practice too .
Keep up the good work.
Cheers Mick

[Stanley]

My 'getting rid of the swarf', skills are lacking! I left a message for Terry last night shouting for help.... There will soon be a lot more!

[Stanley]

I made sure the billet was running within a thou of centred and popped a centre hole in.



Then I faced the end off.



The result. The raised portion round the centre is no matter. Than I reversed the billet, set it up true and repeated the operation for the other end. Then the same for the other billet followed by a good clean up of Mrs Harrison and take the 4 jaw off and put it away.



Next, blue all four of the ends up, scribe a 1" circle (the cylinders are 2" stroke) and put a punch mark anywhere on the circle.



We need to mark the centre for the crank pin on the other end and to get it diametrically opposed I set it up on these centre blocks, set the existing punch marks up dead vertical and used another square to mark this end.



Once all the pop marks were in we need to centre drill them with the electric drill. We finish up with each end marked with two matching centres.



One small thing. If you look carefully at this centre drill you might be able to see that the shoulder is spherical, these are high precision drills I was lucky enough to find amongst a box of assorted centre drills at the steam rally at Harewood house. The advantage is that it doesn't matter if the centre drill is slightly out of line due to using the hand drill, the point of the live centre will still seat dead central. Only a small point but it's the small things that count!



Then set the collet chuck up in the lathe, put my silver steel centre in and turn it to 60 degrees included angle using the top slide. You know now that this is dead accurate. Doesn't need to be hardened of course because there is no friction on it, it's simply a locator.



Last job is to mount the driver plate. We're ready for turning between centres now.



One last job before knocking off. Give both billets a coat of white layout ink, we need to do some serious marking out tomorrow.
When I got back in the warm Wendy had mailed me offering to take my swarf down to Terry's skip for me. What a lovely lady. However I rang the council and asked if I could put it in the recycling bin. A long while ago they objected to it. They must have changed policy because she said it would be fine. I cancelled my request to Terry, mailed Wendy the thank her and tell her I am sorted and popped the solid lump of swarf in the brown bin. They collect the recycling on Monday. So that's that one off my back! Not a bad morning......

[Stanley]

The first job was some marking out. I've got the billet between centres in the lathe so I can turn it by hand and put light cuts on with a screw cutting tool.



Once both were marked I drilled and tapped one end....



And inserted a 1/4" whit set screw. This is the driving dog for the first cuts.



Then a complete refurbishment of the 9/16" cutter I'll be using to cut the meat out round the crank pin to cut down on interrupted cutting.





Then use the surface plate a gauge to mark the extent of the cut on each side of the billet. Same for both of them....



I didn't expect to be doing this. I had to elongate the slots slightly in the strong-backs because my billets are slightly bigger than the usual size. The Progress drill did remarkably well!



Close of play. The first shaft blank set up on the miller bed and cutting has started. The cutter is working well, the time spent re-sharpening it was well spent. This chopping out is a bit tedious but far preferable to a lot of interrupted cutting!

[Stanley]

First job this morning was to complete the major cut on the first blank.



Blue the bottom of the cut, and mark it for taking the two sides out. Set up under the mill again making sure the face was square.



A bit more careful work and the first blank is chopped out. Next for shaving!



The cutter was still working well but no harm in getting it back to top form. I dressed the wheel and did a very careful re-sharpen. Then back into the chuck.



Set up again and into some more careful but very boring milling. My El Cheapo mill is great but has its limitations. No heroic cuts, quietly and patiently away.



I was in the shed at 7AM this morning and by 10:00 I'd finished the big cut so I decided to knock off. Taking the two corners out tomorrow will be a doddle. While it was still warm from the cutting I blued it so it's ready for marking tomorrow morning. A good morning and as far as I can see, no cock-ups!