01/09/06 - 01/10/06
These (2) photos show a chamfer / lead-in put on the cylinder bore to aid in assembling the piston and
rings into the bore...
Photos #1 & #2 show cutting (2) grooves in the head mounting surface to help hold the head
gasket in place. This is done using the boring head. Photo #3 shows the completed grooves...
Next the Sunnen hone is assembled and set up for honing. These (2) photos show the hone in place and
ready for honing...
These next (2) photos are of the honing operation...
It might be hard to see in these (2) photos, the cross hatching. This will help seat the new piston
rings...
These (2) photos show the completed bore...
01/14/06 - 01/15/06
With the bore all completed the next step was to break the razor sharp edges around the intake and
exhaust ports. This is done with a right angle die grinder and tapered burr bit. After the de-burring
the entire cylinder bore and head mounting surfaces are coated with a wax type spray to keep them from
rusting...
The piston for the Bessemer cylinder is now prepared to get metal sprayed. Notice in these (2) photos
the pins that keep the piston rings from rotating are ground down so the piston ring grooves can be
machined after spraying...
The next cylinder to go up on the HBM is for a 10 HP Bovaird & Seyfang single valve engine.
Photo #1 shows cleaning up the cylinder mounting surfaces, as it will be mounted on the HBM using the
same surfaces. Photo #2 shows the cylinder getting moved around the shop...
Before setting the cylinder up for boring there are a couple of cracks in the water jacket that need
to be repaired. The next (3) photos show removing the last repairs material and "V"ing the crack out
for welding...
This photo is of a small machinist hammer that was pulled out of the scrap bin. (2) new ends were
made, one brass and the other copper. See, one mans junk is another mans treasure...
01/18/06 - 01/19/06
In these (2) photos you can see I have started welding on the 10 HP Bovaird & Seyfang cylinder.
Notice that this is being welded cold, skip welding, and keeping the weld only about 1/2" long.
This procedure helps to minimize the stress put into the iron from welding...
While the cylinder is cooling, you have to be patient, I started work on a pair of International
pistons that need to have the piston ring grooves trued up for new rings. Here in this photo the piston
is being put in the lathe...
Notice the welds are starting to look a little longer. This type of welding takes a lot of time but
you get really good results. Note: After each weld is placed, I hit it for approximately 1 minute with
the chipping hammer to help releave any stress building in the weld as it cools...
Photo #1 shows starting to grind the keeper pins out (see groove #4) so the grooves can be turned.
Photo #2 shows shows all the pins ground down in all (4) ring grooves. Photo #3 shows indicating
the piston, getting it on center...
Here in this photo, the weld on the Bovaird water jacket is completed. I am real happy with how it
came out...
This next series of photos show machining the piston ring grooves. The first (2) photos show turning
the right side of all the ring grooves. Photo #3 shows turning the left side of the ring grooves,
making all the grooves the same width. Photo #4 shows the completed piston ring grooves...
01/23/06 - 01/24/06
The piston rings came in for the Tom Thumb cylinder bore job. Photo #1 shows putting the rings in the
cylinder to measure the ring gap. Photo #2 shows the rings installed on the piston...
These next (4) photos are of the work being done on the second Internation piston. Photo #1 shows
indicating the piston in. Photo #2 shows the piston ring keeper pins all ground out with the die
grinder. Photo #3 shows all the left sides of the ring grooves cut with the first right side of the
ring groove starting to be cut. Photo #4 shows all the grooves turned and trued up...
01/25/06 - 01/26/06
Photo #1 shows drilling a pilot hole in each piston ring groove that will be threaded and a new pin
loc-tited in place to keep the ring orientated. Photo #2 shows each hole threaded. Photo #3 shows the
new pins in place and ground down under the OD (surface) of the piston. The new pins were installed on
both pistons. Photo #4 shows the completed pistons. Now to order the new piston rings...
01/31/06 - 02/01/06
For the past few years I have been wanting to do some machine work on the
25 HP Swan crosshead. I went down to the
Coolspring Power Museum where the Swan is on
display, and removed some of the crosshead parts that need some attention. Step #1 is to true the
babbitt up on the top surface of the crosshead. Photo #1 shows setting up a sub-plate on the vertical
mill. Photo #2 shows getting the crosshead setup on the sub-plate...
These next (2) photos show making some clamps for securing the crosshead to the sub-plate...
In these (3) photos you can see how the crosshead is secured to the sub-plate. Just a light skim passes
will be taken on the babbitt to true it up...
02/02/06
Photo #1 shows the profile ground on the HS tool bit. The radius is .06 with a lot of relief on the
back side and on the vertical edge. Photo #2 shows the first pass and you can see the high areas of
the babbitt. Photo #3 shows the left side starting to clean up real good. A few more passes and the
entire surface should be cleaned up and flat, parallel with the bottom surface...
02/03/06 - 02/05/06
In these (2) photos you can see the babbitt starting to clean up. Photo #2 shows a pass I hand feed
to get the cross hatch pattern for holding oil. The table was raised .001 and then feed by hand in
the reverse direction...
These are (4) photos of machining the other side of the crosshead. Photo #3 shows what the setup
looks like on the mill...
Ron Polle came over the shop and is making a guide for the lifter on one of his diesel engines. These
(3) photos show the boring and measuring operation...
Another friend stopped over the shop with a brocken mag bracket. I did a little grinding and "V"ing
out and then welded the bracket together. After some cleanup on the weld it should look pretty
good...
In this photo I started cleaning up the 10 HP Bovaird & Seyfang single valve piston. The old rings
were taken off and the piston ring keeper pins ground down. Then the piston was cleaned throughly in
preparation for metal spraying...
Here in this photo I took a small hone and cleaned up the (2) holes for the wrist pin in the
crosshead...
I got the piston back for the Bessemer bore job and turned the OD and cut the piston ring grooves...
These (3) photos show drilling and tapping the holes for the new keeper pins...