Shop Work Page #30


shop photo

This webpage shows the current jobs
being worked on in the shop.
Hope you enjoy the activity.



See
Page 1, Page 2, Page 3, Page 4, Page 5, Page 6, Page 7, Page 8, Page 9, Page 10, Page 11, Page 12, Page 13,
Page 14, Page 15, Page 16, Page 17, Page 18, Page 19, Page 20, Page 21, Page 22, Page 23, Page 24, Page 25,
Page 26, Page 27, Page 28, Page 29, Page 30, Page 31, Page 32, Page 33, Page 34, Page 35, Page 36, Page 37,
Page 38, Page 39, Page 40, Page 41, Page 42, Page 43, Page 44, Page 45, Page 46, Page 47, Page 48, Page 49, Page 50,

for more Shop Work.


11/06/04
This photo shows a head gasket that was cut out on the DoAll bandsaw and holes drilled with a fostner bit in the drill press. The gasket is made of 1/8" thick material that is pretty tough...


Well myself and a couple of friends worked on trouble shooting what went wrong with the callahan model. It lost compression at one of the last engine shows of the season. Photo #1 shows putting the piston and connecting rod back in the cylinder. Everything checked out okay with the piston and rings. After taking the ignitor a part, the problem was found. Photo #2 shows the broken isulator bushing. Notice the head of the bushing is broke right off...


These (3) photo show making a new stationary ignitor point bushing out of phenolic. Photo #1 shows turning the OD down. Photo #2 shows center drilling the bushing with photo #3 showing drilling a .136 diameter hole for the ID...


Photo #1 shows turning the OD of the bushing that will fit in the brass holder for the stationary ignitor point. Photo #2 shows trying out the fit of the brass holder on the new bushing. Photo #3 shows the bushing turned around in the lathe chuck and the head of the bushing being faced off...


The first photo here shows the stationary ignitor point all assembled and ready to be screwed into the head and setup. Photo #2 shows the head and ignitor assembly, all assembled back onto the engine...

11/07/04
Now to get back to working on the Flickinger push rod assembly. Photos #1 & #2 show turning the OD and facing off the end of the push rod socket that will be formed around the ball. Photo #3 shows a special tool bit ground to turn the radius that will be formed around the ball...


Photo #1 shows a form tool I barrowed to form the socket around the ball. This form tool has a hardened roller with a ball bearing that really made this tool work great. Photo #2 shows what the finish form looks like. This process was done cold without any heat applied and seemed to be very hard on the lathe, as a lot of pressure had to be applied to form the socket around the ball. Photo #3 shows drilling an oil hole in the socket. After some de-burring the Flickinger push rod assembly is completed. Photo #4 shows the completed assembly...


Here in these next few photos you can see some work being completed on the Igersoll Sergeant crankshaft. Photo #1 shows putting the crankshaft in the lathe. Photos #2 & #3 show drilling the crankshaft through to a 2" hole...


Photos #1 & #2 show boring the hole out to 2.375. Photo #3 shows a template made and fitted to the crankshaft throw that will be the pattern for some counter weights that will be added to the crankshaft...


In the first photo here the bored hole is finished to 2.375. The second photo shows the side of the crankshaft all faced off...

11/08/04
Here in these (2) photos you can see a cut being made on the hole just bored in the crankshaft for welding the new shaft in place. Photo #1 shows the tool ground and used for turning the chamfer. Photo #2 shows the completed cut / chamfer. Notice the use of the stead rest for added rigidity...

11/09/04
With the crankshaft removed from the lathe a piece of 3" diameter round stock is chucked in the lathe. Photo #1 shows center drilling the shaft. Photo #2 shows facing off the end of the new crankshaft. Photo #3 shows turning the area that will get pressed into the crankshaft through. Photo #4 shows the press fit diameter almost to size...

11/10/04
Photo #1 shows the diameter that will be pressed into the crankshaft throw turned to size with a radius turned on the end where the welding will take place. Photo #2 shows a nice chamfer on the OD where the second weld will take place. This will allow access to the area on the crankshaft that's need to be welded. Photo #3 shows rough turning the OD of the new shaft leaving material for turning the final diameter after the crankshaft is welded. Photo #4 shows the new shaft completed...

11/12/04 - 11/13/04
Well the Igersoll Sergeant crankshaft is back from the welding shop. These (2) photos show the beautiful weld between the crankshaft throw and the new shaft...


Here in this photo you can see a air line that was run accross the shop with (4) drops. In the photo the air line is running to the left and parallel to the I-beam. This will really help to keep all the air hose off the floor...



11/14/04
Photo #1 shows (2) pieces of flat stock welded to the crankshaft throws to help stabilize for turning. As pressure is applied from the live center, no flexing will happen accross the crankshaft throws. Photo #2 shows putting the crankshaft in the lathe with photo #3 showing indicating the crankshaft in the (4) jaw chuck. With the existing part of the crankshaft running true, photo #4 shows taking light cuts to true up an area on the new crankshaft for the steady rest to run...


Just back from the flame cutting shop, (in photo #1) you can see one of the new counter weights that will be mounted to the crankshaft. There will be one mounted to each crankshaft throw. Boy will these look nice rotating around as the engine is running. Photo #2 shows turning the small end of the crankshaft were the sideshaft gear and flywheel will mount. Photo #3 shows turning the area of the new crankshaft that will run in the main bearing journal. Notice the steady rest is removed for this operation. Photo #4 shows the new part of the crankshaft all turned to size and the side of the crankshaft throw faced and radius cut...

11/16/04
Below are (2) video clips of the work on the Ingersoll Sergeant crankshaft. The first video clip shows boring a 2.375 diameter hole in the throw. Video clip #2 is of turning the new shaft after it was pressed in and welded to the crankshaft throw. The videos are approximately 15 seconds long and are in Windows AVI format with a file size of 780K...

Boring Video Clip Turning Video Clip

11/20/04
Here in these (3) photos the Ingersoll Sergeant crankshaft is out of the LeBlond lathe and in the vertical mill. We will be milling in a .625 wide keyway. Photo #1 and #2 show indicating a long the side of the crankshaft journal to insure it's parallel to the table. Photo #3 shows indicating the top of the crankshaft journal...


Photo #1 shows taking the first pass. This pass can be a very good indication how your setup is. Photo #2 shows the keyway about half way done, with photo #3 showing the completed keyway...


In these (2) photos you can see how the counter weights came out. After cutting the slot width (on the bandsaw) where the weights will fit on the through of the crankshaft and a lot of filing, they fit the crankshaft perfect. Now they will be screwed to the crankshaft throughs with (2) 5/8 grade 8 screws each...



11/21/04
A friend of mine is restoring a 10 HP sideshaft Superior and these next (4) photos are of the sideshaft for the engine. Photo #1 shows center drilling the 1.500" diameter shaft. Photo #2 shows the end all faced off. Photo #3 shows a 1.4375" diameter being turned on the one end. The other end of the side shaft was then center drilled and faced off too. Photo #4 shows the completed shaft all cleaned up and polished...


These next (2) photos are of some work done on the Callahan model. Photo #1 shows new leaf springs put on the ignitor trip arm. Photo #2 shows the trip arm mounted on the head and if you look close you can see the ignitor points through the access hole in the head. The points are now all setup...


Well I wasn't sure if I wanted to put these photos up on the webpage, but by popular vote, their here. We have aquired an out house for my shop which needed some rebuilding. Photo #1 shows Ron Polle, Dave Yorks, and myself, rebuilding the bottom of the out house. We were also helped by my (2) sons Chris, Joe, and brother Jim. What a project! The second photo shows the out house in location and ready for use. Thanks guys for all your help...


Shop Work Continued on Page #31
See
Page 1, Page 2, Page 3, Page 4, Page 5, Page 6, Page 7, Page 8, Page 9, Page 10, Page 11, Page 12, Page 13,
Page 14, Page 15, Page 16, Page 17, Page 18, Page 19, Page 20, Page 21, Page 22, Page 23, Page 24, Page 25,
Page 26, Page 27, Page 28, Page 29, Page 30, Page 31, Page 32, Page 33, Page 34, Page 35, Page 36, Page 37,
Page 38, Page 39, Page 40, Page 41, Page 42, Page 43, Page 44, Page 45, Page 46, Page 47, Page 48, Page 49, Page 50,

for more Shop Work.





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