10/14/04 - 10/16/04
Went down to the Coolspring Power Museum for the October
swap meet and did some work on the 60 HP
Flickinger engine. Below are a few photos of putting the 3rd and final sideshaft on the engine. This
sideshaft goes from the crankshaft to the corliss box. The last photo shows what the sideshaft looks like
10/17/04 - 10/18/04
The first photo here shows starting to get the 20 HP Evans cylinder clamped down to the machine table. The
work being done to this cylinder is to machine the head mounting surface and hone the bore. The 5/8 threaded rod
should work fine for this setup. Photo #2 shows making some 3/4" thick plates that the 5/8 threaded rod can
mount to for holding down the rear of the Evans cylinder. Photo #3 shows tapping the 5/8-11 thread in the
plates. Photo #4 shows what the rear hold downs look like...
Now to get the cylinder positioned on the HBM machine table. Photo #1 shows running the indicator down
the bore, lining the cylinder up. This procedure is done for each quarter of the bore. Every 90 degs.
Photo #2 shows using the coaxial indicator to get the machine spindle on center of the bore...
Here in these (2) photos you can see that I have assemblied the Sunnen hone with longer stone holders and
also have the stone support bracket installed. Photo #1 is taken from the back end of the cylinder with
the second photo being from the head end of the cylinder...
Photo #1 shows the combustion chamber end of the cylinder starting to clean up. Photo #2 is of the back
end of the cylinder which is 100% cleaned up. This area has a lot less wear then the combustion chamber
end of the cylinder...
Well the honing continues on the 20 HP Evans cylinder. These (2) photos are just a couple of action shots
of the honing. It's not a fast process and takes time. One thing that's hard to see in the photos is the
use of kerosene to lube and keep the stones clean and cutting...
10/23/04 - 10/24/04
In these (2) photos you can see the finished Evans cylinder bore. The bore came out real well with the
honing. Photo #1 is looking into the new bore from the head end and photo #2 is taken from the crankshaft
end of the cylinder...
With the bore honed, machining was started on the head mounting face. Photo #1 shows taking the first pass
around the head mounting surface using a shell mill. Light passes of .015 were taken due to the setup.
Photo #2 shows the head mounting surface completed. Photo #3 shows lifting the Evans cylinder up off of
the Lucas HBM with photo #4 showing mounting it on a skid for shipping...
This is a photo of the next job for the Lucas HBM. It's a 2 HP Cook cylinder...
Ron Polle stopped over the shop and had a part to work on for his Lister diesel engine. In this photo Ron
has the part in the lathe turning the OD down. Ron has been building a standby generator using the Lister
as the power plant and is almost complete with the project. I'll have to ask Ron for some photos of the
completed project to post here...
These next few photos are of a push rod assembly for a 4 HP Flickinger compressor engine. The part that
needs to be made is the socket on the left in the first photo. Photo #1 is of a push rod assembly that I
barrowed to measure up. The ball rod on the right in photo #1, I will be using the existing part. Photo #2
shows a drawing I created of the socket that needs to be made. Forming the steel around the ball should
be the fun part...
In these (2) photos I am cutting the ball rod out of the socket. In photo #1 I have started slicing into
the socket with the die grinder and a small cut-off wheel being careful not to cut into the ball. Photo #2
shows the push rod assembly cut a part...
Photo #1 shows a piece of round stock put in the lathe and the OD turned to the proper dimension. Photo #2
shows the center drilling operation. Photo #3 shows the end all faced and drilling getting ready to start...
Spent a few minutes working on the 3 HP motor which is going on the 12" Hendy shaper. The first thing to
do is get the existing pulley mounting flange (hub) off of the motor shaft. Photo #1 shows removing the
hub with a puller. Photo #2 shows the 1.125 diameter motor shaft cleaned up and photo #3 shows the hub.
I think what I am going to do, is make a pulley that will mount right to this hub. It will save a lot of
machine work and time...
10/30/04 - 10/31/04
These (3) photos are of drilling and boring the ID of the Flickinger push rod assembly. Photo #1 shows rough
drilling the hole to .750 diameter. Photo #2 shows boring the ID to a diameter of .815. Photo #3 shows the
first end completed. Now to turn the part around and start the formed end...
Below are a couple of photos of cutting some 3" diameter bar stock on the power hacksaw. You will see in
the near future what this steel will be for...
The first photo here shows setting up the Evans piston in the press to remove the wrist pin. Photo #2 shows
the ram pushing the wrist pin out. Photo #3 is of the wrist pin and bearing. As you can see, the wrist pin is
really worn out. Photo #4 shows the wrist pin hole in the piston...
In these (2) photos I am just cutting the Flickinger push rod socket end off of the bar stock on the DoAll
With the Flickinger push rod socket mounted in a collet on the lathe, photo #1 shows center drilling for the
start of the hole that the ball will seat into.
(see the above drawing)
After the hole was drilled to the proper depth, photo #2 shows a ball end mill being used to create the round
socket for the
ball shaped pushrod.
Photo #3 shows the completed round bottom hole. It might be a little hard to see in the photo...
Photo #1 shows cutting the damaged end of a crankshaft, for an Ingersoll Sargeant air compressor, off in the
power hacksaw. Photo #2 shows the end all cut off...