OneGuyFromBarlick

More progress on the crank pin brass. It is ready now for fitting and getting a con rod. I have made and fitted the oil reservoir and its plug. A nice bit of knurling for David....

This morning's task was to start making the connecting rod. The piece of rectangular bar that Stuart provides is not big enough to properly fit the crank pin brass so I went digging in the scrap box. I spent almost half an hour on the first piece of old shafting I found because it had a hard shop in it that was impossible to turn even with Carbide indexed cutters. I found another piece of rusty old shaft which proved to be more amenable so I spent the rest of my hour and a quarter getting this cleaned up and ready for marking and turning.

I started by doing my measurements and a fag packet drawing and then started to reduce the stock to a con-rod blank. There was a lot of metal to take off and I did not push matters. I took a lot out of it and cleaned up afterwards so I have a clean start tomorrow. There is no rush and I don't want any mistakes....

More work on the connecting rod and again it's stock removal. This is where I am at finishing time. I am at the stage where I can start finishing tomorrow. You might notice that I have cleaned up my chips and have another clean start tomorrow.

Slow but accurate progress on the con rod. I was puzzled this morning by discrepancies in the size between this engine and the last I made. I had to solve that problem first. Then I reduced the diameter of the shank, parted the rod off from the parent stock, finished the face of the foot of the rod and put a centre mark in it to aid with setting out the bolt holes. Steady progress with no errors.... That makes it a good hour in the shed.

More work on the connecting rod. The job this morning was to refine the shape of the rod and get it ready for milling the end that fits in the crosshead. The danger here is that the smaller your sizes get the more chance there is of a mis-step and destroying all the work that has gone into this part. So everything was very slow and careful and I have finished up with a rod that is ready for milling down to shape and size for the crosshead. But that's for tomorrow!

This morning is further refinement of the con rod. Converting each end to a flat that fits either the crosshead or the crank pin brass. I ran into a problem with my milling cutter and had to do a complete regrind on it which took time so that explains why I have only finished one end. (If any explanation is needed!)

I started by making sure the crank pin brass fits the pin so I could do some accurate measuring to size the connecting rod. Once I had the dimensions I could mark the foot of the rod up and start milling it to size to fit the crank brass. I did the easy side and then finished up with the dodgy side where I have so little hold. That last cut is for tomorrow if I am brave enough!

I decided to saw the excess off the other side of the rod instead of milling it. Both options were high risk but sawing was marginally preferable. At this stage the big fear is a slip up destroying all the work put into it. Then I gave it witness marks and did a trial fit after drilling the holes for the fastening bolts. As you can see all is well. Now I have to modify the brasses so that the bolts are long enough. That's for tomorrow. For now the rod is safe!

Stanley could save the day, I'm after a bit of copper sheeting about 6in square. It's for a semi permanent fix on a hot water cylinder. Is that something you would have in your treasure chest?

Sorry Kev, everything I have will be too thick. Have you considered a piece of tin plate cut from a food can? It will solder to the cylinder and last long enough to see you out.

Stanley wrote: ↑29 Jan 2023, 03:44 Sorry Kev, everything I have will be too thick. Have you considered a piece of tin plate cut from a food can? It will solder to the cylinder and last long enough to see you out.

I did consider something like that but it's got to support the spigot for the cold water feed. I can get a piece 1mm thick from a supplier on Amazon. Thanks for looking

Almost every dimension on the con rod and crank pin brass has been refined and the hole for the crosshead pin has been positioned and drilled. Tomorrow I shall make the pin and fit it to the crosshead.

Ken has come to my rescue with some sheet from an old cylinder. Aren't sheds wonderful things.

Good! I agree, there is much to be said for a good shed. I've seen the pic of the patch and it looks as though it will do the trick!

One image is all that is needed this morning. I have been working on refining and finishing the crosshead and measuring for fitting the connecting rod. This morning is a good example of why everything should be checked and rechecked. The drawing tells lies, if it was drilled and tapped to those measurements it would be useless and fit only for scrap. I have corrected the drawing and finished the crosshead so that it is correct. I have found my stock and got set up for making the crosshead pin. That will be done slowly and carefully tomorrow.

I started the day by making and fitting the crosshead pin and then put the tackle away and stripped the base castings down as the next job is to paint them and make the permanent wooden base.

Not a lot to report today. I spent three quarters of an hour painting the castings black where necessary. Not my favourite job but there you are, it's done.

The paint had dried so I started building the engine. I can't put it on the base until I have made the wooden plinth that the base sits on. The good news is that now I have fitted the piston and rod connected to the Connecting Rod I have been able to turn the shaft over to prove that I got the measurements right and the stroke doesn't foul either end of the cylinder. Quiet careful work. Very satisfying!

I decided I had to cut the blank for the wooden plinth and fit that temporarily while I build the engine as I can't see decent weather in the near future so I can finish it outside. Nothing is easy and I found I had to sharpen the blade in my smoothing plane. It all takes time! Once I had the base somewhere near I mounted the castings on it and built the engine up as far as I have finished parts. Everything is fine and functioning and now I am ready to make the valve, its motion and the eccentric. That doesn't depend on weather so I shan't be held up.

That is looking very good, Stanley. The weather forecast here in Rochdale says it will be dry on Sunday but then we are further south and over a couple of hills

It turns very smoothly Bob and is tight, not too much play in fits and bearings.

I think it will be dry enough later this morning to finish my base board outside so this morning I removed it from the castings and put the flywheel in the lathe so I could refine the finish ready for fitting. I look forward to getting in the yard and putting the moulding on the base board. I finished the morning by cleaning Mrs Harrison.....

It stayed dry..... so I cut three base boards and finished one of them.

I started the morning by gluing the protective rubber to the bottom of the baseboard so as not to scratch furniture! Then I started on the3 bronze casting for the steam valve and started the process of transforming it into an accurate valve. I have made a good start but there is still an hour or so's work in it. That's for tomorrow!