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Member postings for GarryC

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Thread: My little engine (continued)
23/10/2015 15:32:07

Just wanted to have a record of the setup..

452. the steam exhaust 14..jpg

Hopefully it'l not look too bad after painting..

Cheers

Garry

Edited By Garry_C on 23/10/2015 15:33:39

23/10/2015 14:24:34

Have to admit milling this flange with the boss merging with the outside of the cylinder bore was outside what I can do at the moment and I got into a right old mess...

This was the best I could come up with and had to make a recess for the Flange Boss to sit in....

452. the steam exhaust 13..jpg

Bit disappointed I couldn't do it as it should have been but not too unhappy with the way it looks..

452. the steam exhaust 12..jpg

I think I'll have a bit of a reassembly of the the engine so far - before moving ahead again..

Cheers

Garry

22/10/2015 13:09:06

Almost finished with the 4 flanges now...

The Studs for the Steam Exhaust Flange fitted (they are vertical - just a bad camera angle in the photo)..

452. the steam exhaust 9..jpg

'Just' the milling to shape left to do...

I think I'll probably leave this flange 'long' as its the exhaust - I'll see what it looks like after the milling is done452. the steam exhaust 10..jpg

Cheers

Garry

21/10/2015 11:09:46

Waiting now for the 1/2" x 26 tpi BSB Tap which should arrive later today. The OD should have been 5/8" but after being as careful I could setting it up in the Lathe the earliest I had a clean diameter was at 1.3mm undersize (last skim was 2 thou) so I'm hoping the wall won't be too thin - think it will be alright. The Exhaust hole looks quite 'chunky' and I can imagine quite a lot of steam flowing out of that, maybe it will need to be run outdoors or at least venting through a window...

Drilled to 11.5mm tapping size. The wall is just over 1.5mm thick. Unfortunately I think I picked the worst of the 4 flange castings for this one - if i had spent more time checking them and the various measurements I could have used a better one and may have got much closer to the correct OD - my fault that.452. the steam exhaust 8..jpg

Cheers

Garry

20/10/2015 14:20:42

Didn't get much time this morning, couple of quick photo's of what I did get done, along with setting up the Steam Exhaust Flange in the lathe ready to start working on it tomorrow...

I think its lucky for me that I left this one until last as it look likes it may the most difficult to get right. The cast hole is way off centre in the tiny raised boss on the Cylinder and I would be struggling to even attempt this and the flange with a file - as it is I'll no doubt find it difficult on the Mill as the boss almost becomes flush with the circular bore of the casting on one side..

452. the steam exhaust 4..jpg

The flange will likely sit in this approx position to line up with the exhaust hole in the casting.. The Boss on the flange as cast is slightly undersize and there is likely to be very little material left once it is drilled for tapping. Also I don't know if it can be seen very well in the photo but the boss doesn't seem to be quite straight coming off the flange base and with so little diameter material to skim....just have to see how it goes I guess.

452. the steam exhaust 5..jpg

The cast hole is not very round, which is fair enough, but I thought I had better tidy up the mouth of the hole so at least to have something to centre on when fitting the flange. The hole is not vertical through the casting but after a short way in slopes up to the steam ports and is quite a good clean cast I think. The drawing says 7/16" for the hole but it is already a good bit larger as cast. I've used a 14mm Slot Mill to tidy the hole just to a 2mm depth which I can also use to centre... 452. the steam exhaust 6..jpg

After tidying the mouth of the hole.

452. the steam exhaust 7..jpg

The potential for me to get this one wrong in some way is quite high I think..! But all very interesting to do.

Cheers

Garry

19/10/2015 15:08:44

Hi Bert, will do and thanks very much - that's one I owe you..!

Cheers

Garry

19/10/2015 13:19:20

Hi Michael

Thanks,I knew I seen that written down somewhere - that's great and I've just heard that they are about 1 thou thick which sounds ideal, I'll definitely get some...

[Pete if you read this - hint hint...plenty of cans in as well..]

Cheers

Garry

19/10/2015 11:26:52

Hi Bob

Thanks, I could maybe do with some thinner paper - I'm sure I read somewhere about an old tradition of using cigarette papers for such things. The paper I'm using for notes etc in the workshop is well over 2 thou thick, have to see what else I've got, but I think my main problem is as Jason says..smile

Hi Jason

I can see now why that makes complete sense... Thanks I will try and round off the corners of one of my ageing slot mills for the next engine.. smile

I see now my 5mm 'radius cutter is really way too pointy for this job..

452. the steam exhaust 3..jpg

Next up is the Steam Exhaust Flange and Boss. I know its not critical here but the drawing says the Exhaust Hole should be 7/16" but as cast its already larger... So I thought I would just clean up the end of the hole with an appropriate slot mill - the interior slopes nicely up to the steam ports..

452. the steam exhaust 1..jpg

Ready to start machining the Exhaust Boss face..

452. the steam exhaust 2..jpg

Cheers

Garry

19/10/2015 09:07:24

.. after a bit of experimenting and more 'learning on the job' I wanted to see if i could clean up the steam chest surface a bit using the mill and after trying a small 3mm flat end mill (which was not the thing to have done) and then back to the radius mill I can see I could have set it to come down onto the steam chest surface much lower without marking it....

I think I would have probably marked the end of the steam chest trying to clean with a file..I haven't done the ends and none of it really shows to the eye but am learning some useful things.... not sure I've come across having to machine down and 'blend' into another surface to date, may be wrong though..

451. milling the steam inlet flange 5.jpg

Cheers

Garry

Edited By Garry_C on 19/10/2015 09:08:09

18/10/2015 12:33:06

A couple of photo's of the finished Steam Inlet Flange. I'm quite pleased as it's better I think than my first effort, I need to have gone slightly lower with the cutter and cleaned up the steam chest surface a bit more with it but I'm getting a better idea of how to go about it...

Sorry too many photos of the same thing again...

Setting up to mill the Steam Inlet Flange.

451. milling the steam inlet flange 1.jpg

Just finishing the final cut - but i've missed some of the Steam Chest surface, should be able to improve on that again next time now I realise what I should have done.... The Radius Milling cutter comes down to pretty small diameter at the end, almost a point in fact - which I've not been allowing for..

451. milling the steam inlet flange 2.jpg

The finished Steam Inlet Flange 1.

451. milling the steam inlet flange 3.jpg

The finished Steam Inlet Flange 2.

451. milling the steam inlet flange 4.jpg

Almost getting there, hope to improve again in doing the Steam Exhaust Flange next..

Cheers

Garry

17/10/2015 21:00:05

Hi Bert

Thanks very much, just what I needed - so I've just ordered some and a few spares in different sizes as well..

Cheers

Garry

17/10/2015 18:33:14

Thanks Jason that's another handy tip, no spare ones or supplied lock nuts unfortunately but if I can't find any half thick nuts to order for the final assembly I can get some standard ones and turn them down as you say...

Cheers

Garry

17/10/2015 13:48:10

Thanks Jason, I'll have a look and see if I can find some half thickness ones for locknuts (as in your photo), I wouldn't have thought to do that. I presume that with these last two flanges for the Steam Inlet and Exhaust that I would just make some 'paper' gaskets to tighten down on to. Stuart have supplied a sheet (A4 Size or thereabouts I think) of 'gasket paper'..

That's a lovely looking engine and a great paint job.

Cheers

Garry

17/10/2015 12:06:09

Cheers Jeff

Still edging slowly forward..

Setting up to fit the Steam Inlet flange centrally on the Steam Chest..

449. steam inlet flange progress 2.jpg

The unthreaded part of the supplied studs were too long for the 1/8" thickness of the flange so the 4BA threads had to be extended slightly.

449. steam inlet flange progress 3.jpg

The flange now ready to go onto the Rotary Table for milling to shape - hoping to do better this time...

449. steam inlet flange progress 4.jpg

Ready to drill for the Displacement Lubricator hole.

450. the displacement lubricator fitting 1.jpg

The Steam Chest tapped 1/4"x 32 tpi ME threaded hole for the Displacement Lubricator.

450. the displacement lubricator fitting 2.jpg

Cheers

Garry

16/10/2015 15:29:12

Some but not much progress with the Steam Inlet Flange - I've not touched this one at all with a file and will do the rest on the Mill and RT now... The hole for the Displacement Lubricator will be through the opposite side..

449. steam inlet flange progress 1.jpg

Cheers

Garry

Edited By Garry_C on 16/10/2015 15:31:49

14/10/2015 12:53:10

Made a start on the Steam Inlet Flange today - I'll try not to duplicate the repetitive work and photo's here as I get these last two flanges done over the next few days...

Tapping 3/8" x 26tpi BSB Thread..

448. the steam inlet flange 1..jpg

Cheers

Garry

13/10/2015 09:39:22

Just checking the sizes for the 1/2" BSB Thread as well and I make it that Stuart have allowed 0.3mm to remove the casting 'skin' to the finish 5/8" size - bit tight that I think. Its no wonder I don't make much mess....!

edit: Hi Mike, yes I have had one or two just very slightly under as well... I guess it makes building even more challenging, I've always seemed to have just about managed to date and for me it is just a very slight 'niggle' really as otherwise i can't fault them and am learning heaps from building..

Cheers

Garry

Edited By Garry_C on 13/10/2015 09:46:54

13/10/2015 08:58:30

ah Stuarts' tight castings sizes strikes again then - the flange boss as cast is reading 16.17mm so 1/8" larger than 1/4" BSP OD would give 16.32mm. So I'll need to stick to the original sizes I think.

Thanks anyway Jason it was interesting to compare the two.. I have an idea that Stuarts's casting sizes are closer to drawing size now than they used to be - I have seen a few comments from others mentioning this....

Cheers

Garry

13/10/2015 08:24:00

Thanks Jason, that sounds good, and I already have 1/4" BSP taps....

I will want to connect to air to try it but when finished I'll be getting one of Stuarts' boilers and be running on steam, I've some reading up to do but thought of getting or making an 'Oil Trap' to maybe cut down on the mess for running indoors .. I would have one tap to buy either way so BSP sounds like the best bet...

So my info will now read..

1/8" BSP Thread (British Standard Pipe) - Tapping size - 8.8mm

1/4" BSP Thread (British Standard Pipe) - Tapping Size - 11.8mm

1/4 x 32 - ME Thread (Model Engineer) - Tapping Size 5.5mm (Displacement Lubricator)

Cheers

Garry

13/10/2015 04:58:53

The Steam Inlet and Exhaust Flanges next, also the fitting hole in the steam Chest for the Displacement Lubricator..

Inlet on the left and exhaust on the right in the drawings below.

447. the inlet and exhaust flange drawings.jpg

Just writing thread data here to refer to as I was getting confused...

3/8" x 26tpi - BSB Thread (British Standard Brass) - Tapping Size 8.5mm

1/2" x 26tpi - BSB Thread (British Standard Brass) - Tapping Size 11.5mm

1/4 x 32 - ME Thread (Model Engineer) - Tapping Size 5.5mm (Displacement Lubricator)

Cheers

Garry

Edited By Garry_C on 13/10/2015 05:02:10

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