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...