The machining competition has started... and now finished

[MaybeGuy]

just in case theres anyone interested... plus a documentation of it for personal reference, and so i can use the info while its fresh in my head for the portfolio to go with it

a while back i made a thread about my slightly optimistic idea to machine an entire engine in 5 weeks... those 5 weeks being 1 day a week for about 3.5 hours a day.

so basically making an entire engine in about 17.5 hours...

anyway, i've started this today, and in the first day have managed to make a very crude cam and the piston.

Due to the limited time i have available, i'm blitzing out the parts as quickly as i can, and sorting out the fitting of them when it comes to assembling it, and tidying up the finish etc when i get round to it.

heres the brass cam (1 of 2, second yet to be made) and aluminium piston.

https://img684.imageshack.us/img684/9884/08022010010.jpg

https://img237.imageshack.us/img237/2447/08022010009.jpg

the cam diameter is 20mm with a 13mm lift
piston diameter is 50.5mm x 55mm, bored out as thin as possible without the risk of it collapsing, with an internal step so as to support the gudgeon pin.

the engine wont run. it's just there to be an example of a DOHC engine and show the operation and valve timing.

considering the opposition (coursemates) are making things like universal joints, fly presses and sine bars, i think i've got a fair shot at aceing this if i can pull it off and finish it.

suggestions welcome.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!!
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

[Paulington]

A freshly machined piston is a beautiful thing.
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CBT: 27/08/08. Theory: 04/09/09. Module 1: 16/09/09. Module 2: 01/10/09.

[Kickstart]

Hi

Are you doing the head and barrel in alloy? Or could you do it in clear perspex?

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[MaybeGuy]

the plan was to make it out of aluminium, then do a 1/4 section of the barrel to show the inside and all the valves working etc.

i know i could make it out of better materials, but brass and aluminium are the fastest ones to do. the only polymer i have available is white or black nylon.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!!
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

[Kickstart]

Hi

Sectioning it should work as well (and gives you a different chance to show off your machining skills).

Think in plastic it would need to be clear perspex, and probably polished up.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[MaybeGuy]

made a shit load of progress since starting this (and funnily enough i'm almost finished). I'll be honest when i say the head i made isn't great, but the rest if it goes together perfecetly.

My plan was to make a 2 piece crank with an interference fit to press it together, but i managed to machine one out of a solid piece of brass which worked pretty well. that took 2 attempts the first one was finished, but as the machine was slowing down and i was backing off the tool, i caught it and snapped it. cant repeat what i said. loudly.

https://img96.imageshack.us/img96/2725/01032010055r.jpg

next was the crank case. started by drilling and reaming a 24mm hole through a block of ally, chopping off a 20mm section of it, then boring what i had left out to 70mm, then milling off the top leaving me with a very rough (now tidied up) crank case. the chopped off section would be bolted back on.

https://img63.imageshack.us/img63/8503/01032010056.jpg

https://img59.imageshack.us/img59/8449/01032010054.jpg

conrod was pretty simple. milled the flats on a round bar so it fitted between the crank webs, then drilled a hole for the big end, then cut a section out. i threaded it all the way through so it didnt clamp down on the big end, stopping it moving.

https://img31.imageshack.us/img31/7815/01032010058.jpg

https://img21.imageshack.us/img21/2681/01032010057.jpg

Piston was just drilled and had a peice of stainless bar through it. looked like this assembled loosely.

https://img694.imageshack.us/img694/4305/01032010059.jpg

the barrel... nothing ingenuitive here, just a bored out hole to fit a piston. same as any other engine.

https://img24.imageshack.us/img24/5271/01032010060.jpg

made a second cam

https://img10.imageshack.us/img10/2641/01032010061.jpg

then i cracked on with the head and sort of made it up as i went along.

started by reaming holes for the crank bearings (3/4 section to give me more working space but still hold a bearing) then milling the inside down to allow space for the cam lobe and valve movement.
the hole you can see is drilled into the valve guide to act as an inlet/exhaust.
springs theived from the stores, and as a temp measure, the screws are through it.

https://img710.imageshack.us/img710/5782/15032010078.jpg

flip it over and you can see the recesses made for the valves

https://img185.imageshack.us/img185/5540/15032010079.jpg

tatty as fuck, but it all moves nicely.

then finally, the near finished piece...

just need to fit the bearings and find a way to bolt it all together.

https://img202.imageshack.us/img202/8366/15032010077.jpg

with a couple of weeks to go, i'll use one week to attach it all together, then use the final week to tidy it all up so it looks all jazzy and stuff.

bear in mind, that this entire project was done using no specific measurements, and a ''that'll do'' attitude, the whole thing was made using this as a schematic drawing.

https://img40.imageshack.us/img40/2803/07092009057.jpg

i've also ordered an 8 tooth, 2 x 16 tooth 6mm pitch sprockets with a length of chain, and all bearings, so they should be here in time for next monday.

suggestions x
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!!
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

[c_dug]

If you have spare time could you look at attaching some sort of electric motor to the end of the crank to turn it over?

Not much purpose to that just it would be cool.
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[Fawbish]

Actually pretty mint
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"Oh....it looks like Average Joe's is forfeiting the match!" - "Yeah, its a risky strategy but lets see if it pays off for 'em Cotton."

[Carl_steveo]

I'm quite impressed Matt my opinion of you has changed slightly lol.
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Current: Honda Nsr 125
Live: Sunderland
Luke "cant be arsed to read your post, but suck my balls anyway."

[Minty]

[Robby]

You may be an irritating gobby dopehead twat, but you're certainly quick on a lathe.

Stick a flywheel on it so you have something to turn to make it move. A round finned barrel would look good and show you thought a bit about cooling, or at least some hint of finning on the square barrel.

Spark plug hole with an old plug in, if you have space.

[MaybeGuy]

i was thinking bolting a minimoto carb on and a bit of flanged copper pipe on the inlet/exhaust.
Sparkplugs not a bad idea. Ill try and find out what thread it needs to be (probably a metric fine?).

I doubt ive got enough time to make and mount a flywheel, but thats been noted too. I reckon 1 week is just about enough to finish it off and resolve any fuckups that come to light.

Bit late for a finned barrel dont you think?

leccy motor would be cool, but then theres the time to mount it and get hold of one. Maybe earlier, but at the mo i dont think theres time

im going to keep it afterwards, because fuck if im pumping £40 of bearings sprockets and chains into it for nothing. So i reckon ill see if i can make it run in my own time.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!!
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

[Kickstart]

[smegballs]

I'm sure B series NGK plugs are M14 x 1.25

[Ben.]

how many horses do you reckon that bad boy is kicking out then? bout 50bhp?

on a serious note. did you bother to work out the cc? and as said just bolt a starter motor to a fly wheel. you can fiddle about with how big a cog to put on it so that you can make it spin over really slowly.

well done. looks cool!
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[MattHirst]

I can see why all of you are impressed with it. But, and no offence, it looks like crap to me

Coming from a mechanical engineer, i use lathes and milling machines day in, day out and make far more complex components in a fraction of the time it's taken you to make them so you've not really rattled them off. Not to mention the poor finishes on most of the components (work out your speeds and feeds boi ) and the general poor craftsmanship, you've not even broken the corners on any of them for fooks sake

When you made the thread/post a while ago about making an engine, i thought it was actually going to resemble an engine and possible even work to some extent, i'm dissapointed little boy! Only reason you haven't got bad karma is because you have a cool name
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It's all fun and games until someone gets hurt, then it's bloody hilarious!!!

[MaybeGuy]

[Carl_steveo]

Seriously what do you lot do to be making this kind of shit. I want that as a hobbie/job.
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Current: Honda Nsr 125
Live: Sunderland
Luke "cant be arsed to read your post, but suck my balls anyway."

[Ariel Badger]

[MattHirst]

[Kickstart]

Hi

Slightly related, this might interest you.

https://www.exbilletengines.com/

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Pete.]

Here's some good info for anyone considering it as a hobby:

Basic info:

https://modelenginenews.org/rsch/build.html

Also this forum caters for all skill levels, and the members are very encouraging:

https://www.homemodelenginemachinist.com/
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[SoND]

Very nice work.
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[neatbik]

Nice one Matt. Im in a similar position as you, part of my college course is engineering based. I know how frustrating it can be to have severe time restraints, plus im sure i could work a lot quicker if i didnt have the totally over the top safety nazi rules and regs that colleges require - hence im sorting out a small lathe for my workshop

[Carl_steveo]