Shop Work Page #38


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.


07/29/05 - 08/01/05
The work is continuing on the Hercules ignitor. These next photos show the progress. Photo #1 shows cutting a groove in a pin to hold the return spring. Photo #2 shows the old and the new pin. Photo #3 shows pressing the pin in the ignitor housing. Photo #4 shows the pin all pressed in...


Next a phenolic insulator bushing needed to be made to isolate the stationary point from the engine ground. Photo #1 shows turning the OD of the bushing. Photo #2 shows drilling a hole through the bushing. Photo #3 shows the bushing cut off and the opposite side being faced...


These next (2) photos show the bushing pressed in the ignitor housing and the stationary point assembled..


Photo #1 shows knurling a piece of brass to make a thumb knob for attaching a wire to the ignitor. Photo #2 shows drilling a hole through the center for tapping. Photo #3 shows tapping the knob. Photo #4 shows the completed thumb knob on the ignitor assembly...


Now the pivot point shaft can be finished. Photo #1 shows turning the stem to size after reaming the mating hole in the ignitor housing. Photo #2 shows a shoulder turned on the point end of the shaft. Photo #3 shows the pivot point shaft turned around with the opposite end being faced...


This photo shows a small point being turned for the pivot point shaft...


Here is a photo of the parts made or repaired so far for the Hercules ignitor...


In these (2) photos the edge for tripping the ignitor is trued up. Photo #1 shows the part in the vertical mill. Photo #2 shows the finished part...


The pivot point shaft still needs work. Photo #1 shows the shaft set up in the vertical mill vise using a 5" sine bar to get the proper angle so a flat can be machined. Photo #2 shows the completed flat. Photo #3 shows center drilling a hole where the point finger will be pressed in. Photo #4 shows the completed hole ready for the point finger...


This is a photo of the new point pressed into a small pin that will get pressed into the pivot point shaft...

08/02/05 - 08/04/05
Photo #1 here shows the pivot point shaft and the seat in the main ignitor housing all lapped in for a good seal under compression. Photo #2 shows drilling one of the holes for the spring pin...


The first photo here shows the completed ignitor. Photo #2 shows bench testing the ignitor. A battery and coil are wired up and the ignitor tripped by hand. Got a real nice spark...


In this photo here I tried to photograph the spark I was getting when hand tripping the ignitor. I guess I'm not that good of photographer, as the spark can't be seen in the photo...

08/05/05 - 08/07/05
Here in these next series of photos I have started working on fabricating a large boring head for boring the larger cylinder bores. The following photos are of making the drive housing / flange. Photo #1 shows facing a piece of 3.500 diameter stock. Photo #2 shows cutting it to length in the power hacksaw leaving some stock for machining...


The 3.500 diameter stock was then welded to a piece of 6.250 diameter X 1.25 thick stock. These (2) photos show the welding complete...


Next was to start making chips in the lathe. Photo #1 shows facing the flange end of the drive housing. I'm working the lathe and the tool bit pretty good in this first photo. Photo #2 shows the facing done and the OD being turned to size. Photo #3 shows the face and the OD completed. Photo #4 shows starting to drill a hole through the center of the drive housing...


These first (2) photos show drilling the hole up to a 1.9375 diameter. Photo #3 shows finish boring the hole to 2.002. Photo #4 shows the hole completed and all edges chamfered...


The drive housing is now flipped around in the lathe. Photo #1 shows facing the flange and turning the housing OD to size. Photo #2 shows the turning work all completed on the lathe for the drive housing...

08/10/05 - 08/14/05
Here in photo #1 you can see the drive hub / housing set up in the (4) jaw chuck for final boring. Photo #2 shows boring the hole to final size. Photo #3 shows the bore finished and edges chamfered...


Next is to drill the mounting holes. Photo #1 shows laying out the hole pattern on the back of the drive housing. Photo #2 shows setting the drive housing up in the vertical mill, picking up the first hole center...


These series of photos show the process of drilling the mounting holes. Photo #1 shows center drilling the first hole. Photo #2 shows drilling the hole, step drilling up to the final diameter. Photo #3 shows deburring or chamfering the holes. Photo #4 shows the holes all drilled and chamfered on one side...


The first photo here shows laying out the set screw holes on the drive housing. Photo #2 shows drilling and chamfering the holes. Photo #3 shows tapping the (6) set screw holes...


After some final cleanup, photo #1 shows the completed drive housing / hub. Photo #2 shows the drive housing / hub on the 2.000 diameter boring bar...


Now to fabricate the tool holder portion of the boring head. Photo #1 shows cutting a piece of 1" thick plate on the bandsaw. We need to wind up with a finished diameter of 8.000 for the tool holder. Photo #2 shows cutting the corners off the plate then it can be mounted in the lathe for turning and facing...

08/16/05 - 08/19/05
Here in these next (3) photos you can see a cylinder bore job I have been working on, for a 5 HP Thermoil engine. Photo #1 shows the new rings for it. Photo #2 shows the rings all gapped and assemblied on the piston. Photo #3 shows what the new bore came out like...


Now back to the boring head fabrication. After cutting out the 1" thick plate on the bandsaw I welded a large ring to one side for holding in the lathe chuck. Photo #1 shows the ring welded on the plate. Photo #2 shows the plate mounted in the 3 jaw chuck. Photos #3 & #4 shows step drilling a hole to a final diameter of 1.9375...


Photo #1 shows the outside diameter starting to get round with photo #2 showing the OD almost completed. Photo #3 shows starting to face one side of the plate, and photo #4 shows the first side all faced...


The first photo here shows boring the hole in the center to fit the new boring bar. Photo #2 shows the hole completed to size and all edges chamfered...

08/20/05
Photo #1 here shows the ring used for holding the plate in the lathe cut off and the back of the plate deburred. Photo #2 shows the plate in the (4) jaw chuck on the lathe getting faced off. Photo #3 shows the plate all faced. Photo #4 shows the plate on the new boring bar, pushed up against the drive hub, ready to transfer the mounting holes...


Here in photo #1 you can see a wiggler being used to position the mounting hole location under the spindle of the vertical mill. Photo #2 shows drilling the holes and deburring them with a counter sink tool bit. Photo #3 shows the (5) holes being tapped...


In photo #1 you can see all (5) of the mounting holes drilled and tapped. Photo #2 shows the plate all mounted to the drive hub on the boring bar. Next we'll weld the tool holder bars to the plate...


Shop Work Continued on Page #39
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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