Well I imagine you are getting sick of seeing the machining of 15 HP Titusville Olin main bearing brasses
by now. I will not be posting as many photos of the work on the brasses as I am starting to work on
the third and final set. Photo #1 shows starting to true up the first surface on one of the bearing
halfs. Photo #2 shows the high spots being hit. Photo #3 shows taking a finish pass...
The first photo here shows what the first surface looks like completed. Photo #2 shows flipping the
bearing half over and starting to true up the opposite side...
Shaping Video Clip
Below is a video clip of the Hendy Shaper truing up the first bearing surface. The shaper is running at
72 strokes a minute. The video is approximately 15 seconds long and is in Windows AVI format with a file
size of 638K... Shaping Video Clip
Here are just a few photos of some more of the work on the last set of Olin brasses. Photo #1 shows
finishing truing up the last bearing half on the shaper. Photos #2 & #3 show drilling the mounting
holes in each bearing half. Now they can be bolted together and spun in the lathe...
Well the Callahan model came back to the shop for an emergency TLC session. The Callahan model has been
running steady almost every weekend, all summer at the engine shows. After doing a little trouble shooting,
a couple of things were noticed to be out of adjustment, and things were sooted up pretty good in the
combustion chamber. Photo #1 shows the model with the head removed. Photo #2 shows the ignitor which is
built into the head, all full of jet black crud. Photo #3 shows some of the other parts disassembled
for cleaning and adjustment...
This photo shows shims cut, and the Olin bearings ready to be bolted together. Then they can be mounted
in the lathe for turning...
08/28/04 - 08/29/04
Here in these first (2) photos, the 8 HP Associated is being mounted to the Lucas Horizontal Boring Mill
table. Photo #1 shows (2) "V" blocks being nested under the head mounting studs to allow the boring head
to exit the cylinder bore. Photo #2 shows the angle plate and "V" blocks in place...
Photos #1 & #2 show making a small exstension for offsetting the mounting an indicator. I need
to reach around and down the side of the cylinder, to get to the mounting surface for indicating the
cylinder in. Photo #3 shows the indicator and setup. The indicator exstension was made from a piece of
.3125 dia. drill rod. You can never have enough parts for setting the cylinders up...
09/01/04 - 09/02/04
In these next series of photos I am making (2) mounting brackets to secure the 8 HP Associated cylinder
to the table of the HBM. Photo #1 shows cutting some 1/2" flat stock on the power hacksaw. Photos #2
& #3 show drilling the mounting holes in the bottom plates...
After fixturing the (2) items 90 degrees to each other and tacking in place the mounting brackets are
welded. Photo #2 shows drilling the hole that will mount to the cylinder flange mounting bolt hole. Photo #3
shows one of the brackets in place. Next a gusset will be added to the bracket assembly for strength...
Here in these (4) photos you can see a gussett that was added to each mounting bracket. This is done to
stregthen the mounting bracket and help to really stablize the cylinder during boring. Photo #1 shows
cutting the gussetts on the bandsaw. Photo #2 shows welding the gussetts onto each mounting backet. The
last (2) photos show the mounting brackets all bolted into location on the machine table and supporting
09/10/04 - 09/11/04
One of the things that's hard to show in photos is all the time spent setting up / indicating the
cylinder on the Lucas HBM. With all the mounting brackets fabricated it's time to final indicate the
cylinder in. Photo #1 shows verifing the cylinder mounting face. Photo #2 shows indicating the bottom
of the cylinder setup which is actually the top of the cylinder bore. Photo #3 shows indicating the top
of the cylinder setup which is actually the bottom of the cylinder. All (4) quadrants of the cylinder bore
are indicated along with original machined surfaces, with shims being placed to dial / position the
With the cylinder all located and fastened to the HBM table the spindle is put on center using a coaxial
indicator as seen in photo #1. Once on center of the cylinder bore a small short shaft is put into the
spindle to check the clearance between the support bar and the rear mount. In photo #2 you can see there
will be about .060 clearance. I was going to mill a slot if more clearance was needed. Photo #3 shows
the boring head and tool mounted onto the HBM spindle. Photo #4 shows the setup starting to really take
shape and a test run taken through the cylinder bore...
A good friend of mine who pumps oil in Pa. called and needed a few hot tubes made quick. I took a break
from the 8 HP Associated cylinder bore job and made up a couple of hot tubes. Photo #1 shows center
drilling the 303 stainless bar stock. Photo #2 is of turning the OD down to .562 and photo #3 shows
the finished OD. The only 303 stainless I had in the shop was some .625 OD, so I had to turn the OD down
quick. Photo #4 shows drilling the hot tube...
Here in these next (4) photos the work continues on the hot tubes. Photo #1 shows threading the end
of the hot tube for a 1/4 NPT pipe thread. Photo #2 shows the completed thread. Photo #3 shows the
hot tube in my other lathe getting the top crowned with a die grinder and sanding disc. Photo #4 is
of the completed hot tube. Need to make one more...
09/18/04 - 09/19/04
For the September work weekend at the Coolspring
Power Museum, my friend Stiles Bradley and I went down and did some work on the 60 HP Flickinger
air compressor engine, which is located in the "Windy City" building at the Museum. To see some photos
of the work completed check out the 60 HP Flickinger webpage.
60 HP Flickinger, Compressor Engine
09/21/04 - 09/22/04
With all the hot tubes completed I jumped back to boring the 8 HP Assciated cylinder. Before I sent the
cutter through I decided to mount a support bearing to the cylinder that will help stabilize the
cutting/boring tool during the entire length of the cylinder. These (2) photos show the support bearing
almost in position with some clearance that needs to be made in the cylinder mounting bracket. Where the
white soap stone mark is, will need to be removed...
After tearing down the boring tool setup I mounted a 2" diameter shell mill to the machine spindle, with
photo #1 showing starting to mill the clearance for the support bearing. Photo #2 shows the clearance
For the support bearing mounting holes to line up with the stud locations on the cylinder some holes
needed to be slotted. The first photo here shows the holes being slotted in the vertical mill. The second
photo shows the support bearing in it's approximate location with some 3/4" threaded rod for mounting. Next I
will need to make some spacers to go between the support bearing and the cylinder so things can be
09/25/04 - 09/26/04
Here in these photos I started making some risers / spacers for the support bearing. Photo #1 shows drilling
a .781 (25/32) hole in the round stock. Photo #2 shows facing off one end of the round stock. Photo #3
shows the first end all completed with chamfers both internal and external...
The next step was to cut the risers / spacers to length, leaving some material for milling to length.
Photo #1 shows cutting the round stock to length in the power hacksaw. Photos #2 & #3 show the (2)
risers / spacers set up in the vertical mill. This was done to ensure both risers / spacers are the same
After milling the risers / spacers to length I put them back in the lathe for chamfering. Photo #1 shows
one of the finished risers / spacers. Photo #2 shows the risers / spacers in location and ready to be
tightened down. This setup will really help to stabilize the boring tool..
The next step before tightening everything down is to make some good heffty flat washers that would
cover a large area when mounting the support bearing. Photo #1 shows cutting a piece of 1/2" thick flat
bar stock, 2" wide by 3 1/2" long. Photo #2 shows drilling a .781 (25/32) diameter clearance hole in the
stock for the 3/4" threaded rod. Photo #3 shows what the (2) flat washers look like in use mounting
the support bearing...