OneGuyFromBarlick

Time to explain the Cunning Plan. As things stand, I am worked up until I get the castings. I can't weld the beds together until I have the holes drilled for mounting the cylinders as they are too awkward to get at if the target ends are attached to the bed. I can't mark the ends accurately until I have the cylinder lids so it struck me that if I make dummy lids for one cylinder I can get on with drilling the target ends, welding the beds and even drilling and tapping the cylinder faces. The dummies will also be the template for drilling the cast lids when I get them. This takes all the pressure off John and Mick as well. So, we start with the target ends....



The dummy for the target end will be located by a boss and in order to hold it properly and allow it to be drilled 3/8" for the bolt which will lock the two dummies in place on the cylinder for drilling I decided to make the hole 7/8". To do that I need to use a blacksmith's drill in the pillar drill. If you haven't come across them, these are bigger drills but shorter and with a half inch shank. Very useful to have about! There was a rag on the shank of the drill, they tend to suffer from slippage in the chuck if you don't watch it, so I started by skimming the shank of the drill.



Plenty of Trefolex and go steady, both holes drilled with no problem.



Next job was to de-burr the holes and do a bit of measuring to decide on the size of the lids and the PCD of the stud drillings.



The next job once I knew the diameter was to find a bit of steel I could use. This piece of old shafting will do nicely so Mrs McMaster was called on to cut two slices, a thick one for the front because it will have the boss and a thinner one for the back end.



It took 15 minutes to cut each slice but no time wasted. I needed an accurate centre line on each of the target ends so I did that while the first slice was under the saw.



I started getting two parallel faces on the first slice while the second was being cut.



One slice faced.....



And by clocking off time the larger slice was faced and because it is longer I could turn the outside diameter as well. I knocked off here and left a dirty lathe and this lid ready for its boss first job tomorrow.... Quite satisfied with the morning's work apart from the fact I knocked a lump out of the back of my hand while mounting the second cut in the saw. The blade sprang out and got me..... Ah well.....

I forgot to mention yesterday that now I have levelled the lathe and corrected the tiny misalignment I can make a very good job of reversing a workpiece in the chuck and matching the diameters. This wasn't possible before. Says much for the accuracy of the lathe and the 3 jaw chuck..... That time spent levelling the lathe was well spent!

Before I piled into continuing to make the dummy lids I had a good clean up, vacuumed the carpet and did the kitchen as well, those pesky chips get everywhere! Then I decided not to just grab the nearest cutter 'that will do' I sharpened a new one with less rake and luckily I had this one with the reduced end which will do nicely for getting inside the outer jaws, this will mean that I can easily reduce the thinnest slug to the correct diameter, 2.25". I marked the slug with the tool to give me my limits and set to to shift some muck.



I did this pic half way through just to show off the nice even non-stringy chips I was making. Funny how you can get into bad habits but easily improve with a bit of thought.



Not long afterwards I had both target ends a close fit on the boss. The more accurate this is, the more accurate your drillings will be. I broke the edges with the tool and then took this one out of the chuck.



I drilled the lid 3/8" for the holding bolt but didn't put the register on or the PCD. I'll do that stage to them both at the same time.



I popped the other lid into the chuck and as you can see the narrower tool is working out well.



At knocking off time I was ready to put the register on the lid which will locate in the bore of the cylinder. This one doesn't need the PCD for the stud holes because I shall drill it using the other lid as the master so all the patterns will be the same. I shall do the same with the final lids when they are ready so they will all be the same. Nice morning, everything to plan, off to bed now to rest my back! Quiet accurate progress.

I had a few jobs to do like shopping and writing an article but I was in the shed shortly after 08:30. I had the blank lid in the lathe correctly sized and it didn't take long to put an accurate register on it, break all the edges and bore it 3/8"....



It is a bit thicker than a normal lid but this will help to ensure the drill is aligned properly when we start putting holes in the casting.



Same process with the other lid except that I had to change the jaws in the chuck so I could use the boss. Register turned to size and checked and the PCD put on this face.



I knocked off at this point. The next job is to divide the PCD into six stud holes. Not just as easy as it sounds because I can't put a regular pattern in without fouling the drain cock drillings in the bottom of the cylinder. It will all become clear tomorrow!

Not often I post work in the evening but last night, in a break in my TV watching I set up the overhead gear on the Pickles 1927 lathe in the front room ready for marking the stud holes in the dummy cylinder cover. The leather belts can relax in position during the night under the influence of the counterweight and will be OK for today. This lathe is ideal for this as it has the dividing gear in the headstock. No need for the tangential gear in this case as I have a 12 division on the face of the tangent gear and need a 6 hole pattern.



Good tip here for setting cutters on centre, put a 60degree point on a piece of silver steel and chuck it. This gives you the centre. Adjusting the height of the tool is easy on Johnny's lathe as the saddle is mounted on the front of the bed and has a rise and fall mechanism incorporated in it. I've said it before but this is a turners lathe and a delight to use. Johnny did good when he made it in 1927.......

Once set up, dividing the circle and spotting the six stud holes is easy.



A tricky job made easy.



This is where you have to be careful because you have to position the holes so that you don't drill into the steam passage. This means that instead of mounting the cylinder the normal template way (Two stud holes in a straight line at the top of the flange), with six holes you have a single stud hole there instead and of course at the bottom as well. This means that the one at the bottom is going to foul the drilled and tapped hole for the drain cock at each end. My way round this is to offset the bottom stud hole enough to clear the cock.



These were soon drilled. The offset looks a bit peculiar but it will be at the bottom of the cylinder so nobody will notice it.



The next job is to reduce the boss so it is below the surface of the target plate allowing it to be pulled tight with a nut and washer. It's only a register now and not an aid to holding in the chuck.



That's better....



The next job is to put a witness mark on the centre on the dummies and cylinders matching the centre line on the target plate, (Checking again that you are avoiding all the steam passages!)



Before transferring the holes from this dummy to the blank, clamp the two together and put a witness on for the centre line. By the way, don't forget that at this point you are making a guide for the tapping drill so drill for that size, in this case for 2BA it's 4mm.



Once you've got the holes drilled mount the dummies on the cylinder casting using a 3/82 bolt through the centre and check that all your witness marks line up.



Then on with the boring but essential job of drilling the tapping holes for the studs in the cylinders.



Knocking off time, all the lid stud holes drilled. That'll do for this morning!

Getting close to sticking the beds together. Rods drying on the stove as I watched TV.

I need the hole pattern in the target ends. Remember that I'm still working to tapping size because these dummies will do for the next cylinder casting.



Opened up to 3/16", clearance for 2BA and all holes deburred.



Then I brought the engines in and stripped the parts off the beds.



I wanted the gussets on the valve chest side cut down so did it with the milling machine.



Then use an angle plate to set the bed and target up square.



Get set up in the yard and start sticking the bits together.....



The first weld. I improved a bit but not much.....



I kept going until I was finished, two hours overtime! Here they are, stuck together and ready for making sure the target ends are square and true. Not the best welding in the world but they won't fall apart and when I've finished making them pretty and painting them they will be fine. Good morning's work and my back, though still there, is a lot better. Mind you I tested it this morning!

I took my time getting into the shed, I want an easier day... Started by checking the vise for parallel with the Verdict metric indicator. It's within a tenth of a millimetre.... That'll do me.



I cleaned up, vacuumed the floor, sharpened the 3/4" end mill that did all the work yesterday and then set the first bed up on the mill with a long cutter. This is working at the limit for my el cheapo mill.....



The target ends aren't bad for truth. I have only taken enough off to make sure the bed for the cylinder end is flat and square. Then I had to move the vise and re-check it with the clock so I could reverse the beds and get at the remaining surface. At that point I knocked off, ready for a rest after yesterday!

I started by using the file to tidy up the end of the bed I milled yesterday. I had introduced more faults in it than I had cured so there was a lot of filing but in the end I got it flat and square.



I took a different route with the second bed. I set the vise by referring to the clearance between the cutter and the bed at various points.



This is how it came off the mill. a better result and soon filed up to look pretty.



The next job was to set up the beds again and tidy up the joint between the target end, the bed and the gussets. Remember this has all been subjected to a lot of expansion and contraction and any fabrication like this ends up with slight distortions. The object is to take enough off to straighten these out.



It didn't take a lot of squaring up and this bed has been filed and had all its edges broken. It's ready for painting. I put the other bed in and started to operate on that when I hit a problem. My handwheel on the mill came loose and I had to look for the retaining screw that had obviously fallen out.



I took all the treasures out of the vicinity and carefully swept up, the best way to find something you have lost on the floor.



After a frustrating twenty minutes I suddenly realised that it was this grub screw that had come loose and the reason I couldn't find it on the floor was because it was safe in its place, all it needed was tightening up! Then I had a good clean up and put all the treasures back in their place. Only problem was that in the process I got a blockage in the vacuum hose so that was another 15 minutes! I called it knocking off time.... There is all day tomorrow to do the second bed......

Not a lot to report this morning. I finished milling the second bed to square everything up and then went over it with a file and coarse diamond hone to break the edges and tidy it up.



Then I thinned some old fashioned red oxide paint down and gave the beds a thin coat for a base for the black finish. Then I knocked off early because I am looking after myself and want a good sleep before I watch Formula 1 this afternoon. Word from Mick that if the weather is good they will be in the foundry this afternoon.....

Word from Mick this morning that they didn't attempt the casting because the moulding sand wasn't quite tempered enough. I have told the lads there is no rush. The rest will do my back good.....
Later.... The paint on the beds has set but isn't dry so I am going to put the beds in the front room where it is warmer and have a day off apart from a bit of light cleaning and tidying and sharpening a couple of milling cutters. The rest will be good for me......

Later, at 09:30.


I took the beds into the front room where it is warmer to give the paint another 24 hours to dry properly.



After a bit of light cleaning up I dressed the wheel on the T&C grinder and sharpened the two 3/4" cutters I am using at the moment, backing them off first and gulleting the centres. That done I cleaned up the grinding dust and retreated to the kitchen. That's it for the day!

The beds are dry and will get a coat of black paint today. That will be the extent of shed work. Another easy day, it's doing my back good.

The good news is that my back is improving rapidly after doing nothing yesterday apart from giving the beds a coat of black paint. The bad news is that the paint isn't dry yet so they sit in the warmth of the front room hardening off. So, sorry Debs and Sarah, work is at a standstill for another day as I relax in my rocking chair reading......

The beds are dry but the bad news for followers of the engine build is that I have decided that it will be better to wait for the new castings before doing anything else. That doesn't mean there won't be light work and pottering in the shed but I shall spend most of my time resting and reading while my back heals itself. I'm happy to report that it's improving but I suspect mainly because I am giving it a rest. Old age isn't for cissies......

Same report today Lads....

Good news this morning from Mick the Shed. He and John have cast the parts needed to finish the two engines I am on with and are going to have another pour to make the castings for the next engine. In the end they had to cast them under cover because of the weather. I know they will be feeling relieved! Roll on the visit....
I've identified a small job that needs doing on the fly-shafts.... Not promising anything, I am still resting my back, but I will be doing it shortly.....

I think I am over the worst with the back. Not clapping hands and skipping yet but I have decided to have one more easy day and a bit of light shed work tomorrow.....

Hi Stanley, glad your back is improving and you will be fit enough to enjoy yourself in the shed again soon. I have had good day at Beamish museum today with John, Richards Sentinel waggon is still not finished but we were helping out with a Fowler B5 traction engine today, that John will have fim of during the week on Youtube. Its built 1900 and served in the Boer war, its a big old beast too. There was lots of good stuff there , plenty steam but also various WW1 trucks, military vehicles etc and the weather was lovely all day too.
Cheers Mick

Sounds like a nice day out but shouldn't you have been slaving in the foundry doing the rest of the castings? Hoping to do a bit of light turning in the shed today..... We'll see how things go.

I've done two and a half hours and apart from my back feeling tired, not surprising after a layoff, I'm fine and I think I've had a useful morning.



The first thing that struck me was that a week after being started up, the compressor was still holding the pressure I left it with. Nice!



The first thing to do was to re-assemble the flyshafts on their respective beds. The problem is on the left hand, 1/2" diameter, ends where the eccentrics sit. If you remember the last build I had to do some imaginative machining to get the eccentric rod to line up with the valve rod. I want to minimise the amount the eccentric is out of line and the first move towards this is to make sure the boss of the eccentric can be fitted as close as possible to the flywheel bearing pedestal. To this end I want to turn the shaft down until the swell of the 3/4" section in the bearing finishes flush with the pedestal. So the first thing to do was assemble the bearings and mark the shafts where the transition had to be.



I've set it up in the lathe so that I am turning away from the chuck. By doing it this way I don't need to put any pressure on the live centre and risk distorting the position of the crank bearing. Dead simple and I soon had both shafts tuned down so that they were flush in the pedestal.



The second shaft.....



The next matter I wanted to address was the length of the 1/4" studs which hold the pedestals down onto the raising blocks. To do this I made a small washer that I could put under the nut and then use the top of the nut as a guide to sawing the excess off the stud.



Here's a close up of the spacer in place. I won't bore you with any more pics of the operation, just quietly and patiently away.



By knocking off time I had them all done and here is the result. I could take some meat off the bosses of the eccentrics to get me further in but I am not going to do any more towards that until I have the cylinders complete and mounted, I can do some accurate measuring then. Not a bad morning and I am tired but pleased.....

I decided that if I did a bit of measuring and had a careful think I could mount the crosshead slides on the beds.



Nowt to it.... I milled a block of scrap so it was perfectly square and could be used as a spacer. Measured the position of the slide in the centre of the bed and popped two marks in with the 1/4" transfer punch. I made good punch marks.....



... and then popped the bed under the drill for the usual round of centre drill, tapping drill, tap and countersink all on the same setting.



I bolted the slide down on the bed and found I had cocked up, it wasn't square on the bed! It had evidently shifted while I was marking it....



So I did what I should have done in the first place! The block is OK as a spacer on its edge so I used that, then clamped the slide down and carefully adjusted it by tapping it into place. Then the transfer punch and the reinforcing mark with the regular punch and under the drill again!



That's better! Spot on this time. Now Sarah's engine needs the same treatment.



I took Debs engine into the kitchen and got the tackle together for the same operation on Sarah's. But that'll do tomorrow.......

Word from the North that the castings I need are being delivered today by carrier. I hope she comes this morning...... No excuses now!

Not a great deal to report this morning but all useful and no more cock-ups! As you can see, I used my head and a cramp to make sure the slide was positioned correctly. Usual register punch and followed by a good solid blow with a proper punch.



Then under the drill and the usual trick of doing all the operations on each hole on the same setting. No drama, quiet careful work and completely successful, Sarah's engine now has its cross head slide fixed firmly in the right place. Another little tweak I did was to bore the oil cups on both pedestals a bit deeper, I had skimped them somewhat when I made them. A good clean up of the lathe because I shall be brass turning next and want to harvest John's chips. While I was in cleaning mode I emptied the shop vacuum and bagged the metal for recycling. That's it, not the hardest morning I have ever done but I am prepared now for the castings, all I need now is an early delivery!

Castings didn't arrive yesterday. I shall have an easy morning and wait for delivery. I can't do any more without guesswork and that's asking for trouble.....



An engineer's sideboard.....