32x40 H Gas Engine

[Brian]

(05-24-2014, 12:22 PM)TomG Wrote: It's coming along well Brian.

I'll bet that cast iron is fun to machine.

Tom

I can honestly say this is the dirtiest job i have ever done the machines get covered in fine black dust that is almost impossible to remove, when I have finished with the iron I am going to have to wash down the machines.
Future builders may be better using alloy for the barrel and piston and iron for the liner.
But the iron cuts well and is stable and it adds necessary mass to stop vibrations. so we cant have it both ways.
Brian

[EdK]

(05-24-2014, 12:46 PM)Brian Wrote: I can honestly say this is the dirtiest job i have ever done the machines get covered in fine black dust that is almost impossible to remove, when I have finished with the iron I am going to have to wash down the machines.
...

What I do to keep the dust down to a minimum is to use cutting oil when I machine cast iron. Keep it wet with cutting oil and it makes cleanup so much easier. YMMV

Ed

[stevec]

I just rely on the black cast iron "dust" to cover the rest of the mess in the chip tray and hope it doesn't hide tools.

[kcraig514]

If you think that cast iron is messy, try machining graphite.

[Brian]

Hi all sorry to have been away so long, but I have had a good summer sailing, then a computer failure that cost me dear, so iv'e got a lot of catching up to do.
 I have managed some time in the shop in between so this is the story so far.
the crank case was cut from 10mm plate and machined.
   
all the fixing holes were drilled using the X Y dro's on the mill it was strange drilling 44 holes without marking out, the came the trial assembly--- Magic all the holes lined up perfectly.

   

the plastic pipe is to test the alignment.

The head has had a lot of work --milling the combustion chamber--drilling the ports and valve guides- cutting the fins ETC.

   

The valves are from stainless steel.

   

   

It's coming along nicely, more later

Brian.

[TomG]

Hey Brian, welcome back!


Hopefully you didn't lose too much with your computer crash. Unfortunately, that is sometimes what it takes to make us back things up (voice of experience ). 

The engine is coming along nicely. I do enjoy reading your build threads.

Tom

[EdK]

  back Brian.

Ed

[Brian]

The latest parts made are the closure plugs that allow the valves to be fitted.
   

I am going to have to start thinking about rod and crank soon, the crank is lower than the center line to give a longer crank angle on the power stroke (desax) this gives better torque and helps  stop piston slap.

Brian. 

[Brian]

At last had the time to draw up the crank.

   

Looks like it just might fit and allow room for a oiling system for the big end.

Brian.

[TomG]

Brian,

Will the crank be one piece, or made in sections?

Tom