Below is a video of the boring and facing head on the Lucas HBM in action. This hole was bored to locate
the new piston casting in the lathe for turning the OD and ring grooves... Piston Boring Video Clip
01/17/05 - 01/18/05
This photo shows finishing up turning the OD of the piston to the final diameter...
These next (3) photos show facing the compression end of the piston. Photo #1 shows the face starting to
clean up. Photo #2 shows the entire surface being cut. Photo #3 shows the compression end of the piston all
Photo #1 shows starting to lay out the ring grooves. These will be roughed in and then the width cut to size.
Photo #2 shows cutting the first ring groove. Photo #3 shows the rough ring grooves in the piston. Click on the
video below to see the grooving tool in action...
This is a video clip of roughing in the piston ring grooves. RPM is 23 and the cross slide is being power
fed into a depth of .265... Rough cutting the piston ring groove, Video Clip
Photo #1 shows a special tool I grind up for cutting the piston ring grooves to width. The right side of
the groove is finished and the left side is what will be cut on all (4) ring grooves. Photo #2 shows the
Here the piston is turned around in the lathe for facing the back and getting the piston to the finished
length. Photo #1 shows facing the piston to length. Photo #2 shows putting a large 30 deg. chamfer on
the back of the piston. Photo #3 shows the piston facing and chamfering completed. Photo #4 shows turning
the piston around in the lathe...
This photo shows the little nub turned off that had the center drill in it...
Photo #1 shows scribing a line where the wrist pin hole will go through the piston. Photo #2 shows
indicating the piston on the Lucas HBM to get the spindle on center with the piston and parallel with
the machine table, perpendicular to the center line of the piston. Photo #3 shows center drilling the
wrist pin hole...
These (2) photos show drilling the wrist pin hole, stepping up through a few different drill sizes
finishing up at a diameter of 1.125...
Photo #1 shows starting to bore the wrist pin hole with the boring head. This will really make for a nice
straight true hole. Photos #2 & #3 are of boring the wrist pin hole at different stages. Photo #4 is of
the completed wrist pin hole finished to a diameter of 1.188. See below for a small video clip of boring
the wrist pin hole...
Below is a video clip of boring the wrist pin hole to size in the piston... Boring the wrist pin hole in the piston, Video Clip
Here in this photo I am mounting the shaft vise on the vertical mill with the photo showing indicating
the vise in. I am getting ready to cut some keyways in a new sideshaft for an Ingersoll Sergeant engine
restoration project a friend is working on...
Photo #1 shows the sideshaft for the Ingersoll Sergeant in the lathe with the ends getting faced of and
the sideshaft cut to length. Photo #2 shows polishing the shaft before milling in the (3) keyways...
The first photo here shows indicating the sideshaft to the vertical mill spindle. Photo #2 shows cutting
the first keyway using a center cutting end mill. Photo #3 shows cutting one of the keyways on the end
of the sideshaft. A steady stream of air is blown on the keyway and cutter to keep chips from building
up during the cut. Photo #4 shows one of the finished keyways...
A couple of locking spacer rings needed to be made for the sideshaft. Photo #1 shows facing off some
stock that we'll make (2) spacers out of. Photo #2 shows parting the stock in (2) pieces. Photo #3 shows
one of the spacers mounted on a mandrel for facing and chamfering the other side, after drilling and
tapping for a set screw. Photo #4 shows the completed Ingersoll Sergeant sideshaft and spacers with the
exhaust cam lobe in place...
After having the 2 HP Cook piston metal sprayed, the following photos show turning the OD. Photo #1
shows facing the back end of the piston. Photo #2 shows the OD starting to clean up. Photo #3 shows the
Below is a video clip of turning the 2 HP Cook piston OD... Turning the 2 HP Cook Piston OD, Video Clip
Below are (3) photos of truing up the piston ring grooves on the 2 HP Cook piston. Photo #1 shows
truing the groove up on the right side of all the grooves. Photo #2 shows truing the groove up on the
left side. Photo #3 shows the completed 2 HP Cook piston. Time to order the rings...
02/04/05 - 02/05/05
Here in the next (3) photos I did a little more work on the 3 HP motor mount for the Hendy shaper. Photo #1
shows the new serpentine belt pulley mounted on the motor shaft. Photo #2 shows the pulley turned 180 deg.
on the motor shaft. After doing some alignment, the pulley needed to be closer to the motor housing.
Photo #3 shows some more rework done to the motor mounting plate and the belt in place to take some more
I need to make (4) wrist pins for the 8 HP Associated project. Photo #1 shows cutting the wirst pins on
the power hacksaw. The material used is O-1 drill rod ordered to size, OD. Photo #2 shows center drilling
and facing off the end of the wrist pin...
Photo #1 here shows marking the length of the pin. Photo #2 shows facing the other end of the wrist pin.
Also notice I switched to the collect holder on the lathe. Photo #3 shows the first wrist pin
One Saturday February 5th, Stiles Bradley had a small get together for the first starting of a couple of
engines he has been working on. The first engine is a 8 HP Evans and the second is a 10 HP Ingersoll Sergeant.
Both engines started and ran quite a bit that day. Some photos of the event can be seen at the following
link, February 5th, Get together.
Below is a sound file of the 8 HP Evans running, with some small video clips of both the Evans and the
Ingersoll Sergeant running...
Video of 10 HP Igersoll Sergeant
I needed to make an offset key. Photo #1 shows indicating the vise to make sure things are parallel.
Photo #2 shows milling one of the sides of the key. Photo #3 shows the finished key with a .004 step
on each side...
Back to work on the (4) 8 HP Associated wrist pins. Photo #1 shows scribing a line for the OAL using
the height gage. Photo #2 shows facing one of the wrist pins to length. Photo #3 shows the (4) wrist pins
faced to length...
Photos #1 & #2 show a wrist pin in the piston, making sure things are coming out right. Photo #3
shows making sure the threads go all the way to the finished bored hole for the wrist pin...
Now to put (2) milled flats on each wrist pin where the set screws will contact it. Photo #1 shows
milling one of the flats. Photo #2 shows the (4) wrist pins completed...