Member postings for David K

Quick test of the cradle to the rear of the engine.

Next I cut a couple of pieces of hard wood from some old door frame I saved.
The first piece I cleaned up into a rectangle and routed around the top , the second
piece I drew a rough outline of the shape I wanted and attacked it with a flap disc
on my grinder. It carved up much easier than I thought and just needed a quick sand
into the final shape before I varnish.

After soldering the cradle it was put into a Citric acid bath for a few minutes then polished

Time to make a stand for the engine.
I wanted to make a carrier similar to the one used on full size engines so I
thought I would put my new silver solder skills to use and solder some stainless
pieces together.
I made a simple jig to hold the pieces while I soldered.

fitted manifolds

A selection of finished manifolds

A selection of finished manifolds

The pipes are then silver soldered into the mounts.

Once frozen the pipes are bent to shape over a former held in a chuck.
The exhausts bent ok but the tighter inlet bends were a problem so instead
of frozen water I filled them using a glue gun and let the glue harden.
Once bent I heated the pipes and pushed the glue out.

Some lengths of 6mm copper pipe are cut and one end crimped shut.
The pipes are then filled with water and placed into the freezer for a
few hours.

I milled a slot into a piece of scrap alloy to hold each mount while I milled
a m6 hole through the centre at 15 degrees to match the cylinder head ports.

Next a slitting saw is used to cut each manifold mounting off at 1/8'' thickness.

Inlet / Exhaust manifolds.
A piece of brass bar is milled to the shape needed then two m2 mounting holes
are drilled down the length of the bar.

Push rods now fitted, they are
simply stainless rod/wire cut to length and round the ends.

A cylinder can now be slid over the piston and held by a 8 M2 screws,
The slave rods are now connected to the master rod. You can see the slave
pins line up with cut outs in the main bearing so the bearing cannot undo.

Thanks Mal, I found the best way to gain experience is to buy some plans and jump in at the deep end.

Broken rings already , good job I made spares

Piston is then fixed by the gudgeon pin and the rings carefully fitted