Shop Work Page #41
This webpage shows the current jobs
being worked on in the shop.
Hope you enjoy the activity.
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for more Shop Work.
Shop Work Continued from Page #40
10/29/05 - 10/30/05
Here the work is continuing on the 10 HP Superior cylinder setup. Photo #1 shows indicating the cylinder in all (4) quadrants, front to rear. Have gone through this a few times till I am happy with the setup. Photo #2 shows an indicator used as reference when doing moves to get the cylinder lined up on the HBM. This indicator will stay on the machine and cylinder the entire length of the job. Photo #3 shows traming the bore. Notice the large button used on the indicator to help ride over the pits in the cylinder bore...
Next we need to get the machine spindle on center with the bore. A spot in the bore that shows the least amount of wear and is round (almost), is choosen and the coaxial indicator setup. The photo below shows the indicator setup. The green indicator base in the photo, just keeps the barrel of the coaxial indicator from turning...
These (2) photos shows squaring up some stock and getting it to size on the shaper. Photo #1 shows the cut taking place with photo #2 showing the complete piece all to size. These pieces will get welded to the new cutter head for holding the tool bit in place for boring...
This photo shows milling a 45 deg. chamfer down the (2) sides for welding to the cutter head...
11/04/05 - 11/06/05
In photo #1 you can see the holes laid out for the (6) set screws. Photo #2 shows drilling the holes in the drill press. Photo #3 shows all (6) holes drilled. Photo #4 shows tapping all (6) holes for a 3/8-16 thread for the set screws...
Photo #1 shows the rail positioned on the cutter head. Photo #2 shows the rail all clamped and the first welds placed...
This series of photos show the rails being welded to the cutter head. The last photo shows the finished welds...
Next was to true the tool mounting surfaces up after welding. Photo #1 shows the cutter head being machined in the vertical mill. Photo #2 is just before the finish pass was taken on the first rail...
Photo #1 is of taking the finish pass on the first rail. Photo #2 shows milling the other rail. Photo #3 shows the milling completed for truing up the tool mounting rails...
In photo #1 you can see the excess material being trimmed off the rails in the band saw. Photo #2 shows turning the OD of the cutter head in the lathe. Photo #3 shows the turning of the OD completed. Photo #4 shows the completed cutting head ready for action...
11/11/05 - 11/13/05
This photo shows what the actual tool bit will look like in the cutting head...
In these next (3) photos I am making a 2.000" diameter bar I can put in the out board bearing for indicating it into position. Photo #1 shows facing the end off. Photo #2 shows the first end all faced off, chamfered, and center drilled. Photo #3 shows the other end all faced and the bar completed...
Now to get the boring bar and the cutter head all set up. Photo #1 shows the 2.000" diameter boring bar in place with the cutting head in an approximate location. Photo #2 shows the out board bearing end of the set up. Photo #3 shows the cutting head just coming out of the cylinder bore. The position of the cutting head is now nailed down...
Time to take the first pass through the cylinder bore. After setting the tool bit up the first pass is taken. This pass tells the story as to how well I mapped out the existing bore. Photo #1 shows the first pass starting. Photo #2 shows the first pass in about 2" to 3", notice the pits still visable. Photo #3 shows what the entire set up looks like on the HBM...
These next (3) photos show the completion of the first pass. Photo #1 is taken looking in from the back end of the cylinder, towards the head end. Photo #2 is looking in from the head end during boring. Photo #3 was taken just as the first pass is almost completed, looking at the head end...
Below is a small video clip of the boring operation...
Boring the 10 HP Superior Cylinder, Video Clip
11/16/05 - 11/19/05
Here in these photos you can see some changes made to the setup. Photo #1 shows the HBM spindle moved out 16" inches. Photo #2 shows a chain put over the cylinder. These changes were made to help stabilize the cylinder during the boring operation...
Photo #1 shows the final boring pass being taken. In photo #2 you can see the hash marks on the cylinder which indicate 6 passes total were take to true and clean the bore up...
These (3) photos are various shots of the finished bore...
The next operation is to hone the cylinder. Photo #1 shows the Sunnen hone all setup and ready to go. Photo #2 shows the operator advancing and retracting the hone through the bore. Photo #3 shows what the entire honing operation looks like...
In these (2) photos the Superior cylinder bore is complete. The photos are trying to show what the cross hatching came out like...
Time to take the Superior cylinder off the HBM. The bore finished up at 9.162. A total of .141 were removed to true and clean up the bore. That's .0705 a side. The bore really cleaned up nice. The next step now is the piston work...
Below is a small video clip of honing the Superior cylinder...
Honing the 10 HP Superior Cylinder, Video Clip
11/21/05 - 11/23/05
In this photo here you can see the wirst pin pressed out and the keeper pins ground off. This had to be done before the piston can be metal sprayed. Now to get it built up...
Why the Superior piston is out getting metal sprayed I jumped back to work on the Hercules ignitor. Photo #1 shows tapping a hole for the ground screw. Photo #2 shows the brass ground screw. Photo #3 shows reaming the hole for the pivot point shaft. Photo #4 shows spot facing an area where the pivot point shaft will seal compression...
These (3) photos show making a spring anchor pin in the lathe. A groove had to be cut that the spring clips into...
Photo #1 shows reaming the hole the spring anchor pin will get pressed into. Photo #2 shows pressing the pin in. Photo #3 shows the pin pressed in the hole. The ignitor is starting to take shape...
These next (4) photos show making a small brass nut for securing the hot wire to the ignitor stationary point shaft...
In these series of photos I am making the stationary point shaft. Photo #1 shows center drilling and facing the end. Photo #2 shows turning the OD of the shaft. Photo #3 shows setting up to thread the end of the stationary point shaft...
Photo #1 shows the threading operation. Photo #2 shows the completed thread with the brass nut on it ...
The first photo here show the stationary point shaft turned around in the lathe getting center drilled and faced. Photo #2 shows a hole drilled and reamed for the point material to be pressed into. Photo #3 shows pressing the point into the stationary point shaft...
Photo #1 shows the point being turned to size. Photo #2 shows the completed stationary point shaft ...
Here in photo #1 work is starting on the pivot point shaft with the OD being turned to size. Photo #2 shows the shoulder being faced. Photo #3 shows a step turned on the large end...
Photo #1 shows the pivot point shaft turned around in the lathe, being center drilled and faced. Photo #2 shows the lathe work completed on the pivot point shaft...
11/25/05
The piston is back from being metal sprayed. Photo #1 shows the OD turned to s1ze and the piston ring groove being cut on the left side. Photo #4 shows the 4th and final groove being cut on the left side. Photo #3 shows starting to cut the right side of the first groove. This is where all the grooves will be finished to the same width...
These (2) photos show the completed 10 HP Superior piston...
Shop Work Continued on Page #42
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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