|
|
|
|
|
|
|
|
|
The columns,4.5kg of 1.5"mild steel bar turned down to weigh 1.2kg |
|
|
|
|
|
|
|
|
|
|
|
|
Boring the HP Cylinder |
|
Note the extension for the boring head |
|
|
|
|
|
|
|
|
|
|
|
Pistons, Piston Rods and Crossheads |
|
|
|
|
|
|
|
|
|
|
|
|
Connecting Rod, upper bearings and wristpin |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Top View |
|
Note the altered cylinder cover stud location so that the cylinder drains do not open onto the studs |
|
|
|
|
|
|
|
|
|
|
Progress at November 2001...all the up and down bits |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Looking up under the cylinder block |
|
|
|
|
|
|
|
|
|
|
|
|
MkI Crankshaft Components |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Crankshaft fitted in engine |
|
|
|
|
|
|
|
|
|
|
|
|
|
The up and down components, HP |
|
|
|
|
|
|
|
|
|
|
|
|
|
Boring the main bearings. Only numbers 1 & 5 were bored in this fixture, the others were line bored as shown in an adjacent photo |
|
|
|
|
|
|
|
|
|
|
|
|
Line boring the main bearings...an interesting setup! |
|
|
|
|
|
|
|
|
|
|
|
|
Progress as at 10 May 2002 |
|
The engine is driven by an electric motor under the bench at 310 rpm...magic! |
|
|
|
|
|
|
|
|
|
|
|
The IP receiver. Modified to increase the volume |
|
|
|
|
|
|
|
|
|
|
|
|
Boring the eccentric straps |
|
|
|
|
|
|
|
|
|
|
|
|
Eccentric straps pre & post machining |
|
|
|
|
|
|
|
|
|
|
|
|
|
Boring the eccentric sheaves. Reamed to final size |
|
|
|
|
|
|
|
|
|
|
|
|
Progress as at 8th August 2002. Engine has been run up to 400rpm with minimal vibration (It is not bolted down) |
|
|
|
|
|
|
|
|
|
|
|
|
Main bearing oil reservoir lids |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Big end bearing oiler. Fabricated from "squashing" a piece of tube and sawing in half lengthwise at an angle |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Quadrants. I "cheated" here and had them machined "outside" on a CNC machine. I regretted this decision (as they were not parallel by 0.002") |
|
|
|
|
|
|
|
|
|
|
|
|
The machining jig for the quadrant gibs... I should have made one for the quadrants |
|
|
|
|
|
|
|
|
|
|
|
|
Close up of the finished gibs in the jig
By the last one about 5 minutes work |
|
|
|
|
|
|
|
|
|
|
|
|
|
Machining the quadrant pins for the eccentric rods. The picture shows an essential bit of tooling...the six post lathe stop |
|
|
|
|
|
|
|
|
|
|
|
|
The quadrant assembly and a few of the 12 pins (+ 2 spares) The first pin took a few hours to set up, the last about ten minutes total |
|
|
|
|
|
|
|
|
|
|
|
|
The valve gear mockup I used to measure regulator arm movement. This is the ahead position "as designed"
(See Problem Page) |
|
|
|
|
|
|
|
|
|
|
|
|
|
The astern position "as designed". Note the drag links in the horizontal position |
|
|
|
|
|
|
|
|
|
|
|
|
|
Wayshaft as redesgned
Moved 2 1/2" to port and down 3/8" |
|
|
|
|
|
|
|
|
|
|
|
|
|
The wayshaft from above
Although this appears to make the engine wider it is actually the same width as the original design when it was running ahead |
|
|
|
|
|
|
|
|
|
|
|
|
HP Valve Gear Complete
46 Machined Parts
34 Bolts
24 Nuts
32 Shims
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reversing Bellcrank
(Fabricated at this stage) |
|
|
|
|
|
|
|
|
|
|
|
|
My Solution... significant offset, and excavation |
|
|
|
|
|
|
|
|
|
|
|
|
The IP liner in the lathe, the HP liner ready for the mill |
|
|
|
|
|
|
|
|
|
|
|
|
|
The HP liner just finished in the mill |
|
|
|
|
|
|
|
|
|
|
|
|
The IP valve liner. Filing the ports square for both liners took all day, 3 hours to make the filing buttons and 2 hours filing. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Side on 11.5.03 Note the revised reversing wheel and the three tallow pots for secondary lubrication |
|
|
|
|
|
|
|
|
|
|
|
|
The reversing wheel
12 turns from ahead to astern via a two start left hand 5/8" acme thread. A bronze and brass fabrication |
|
|
|
|
|
|
|
|
|
|
|
|
The piston valve liners prior to shrinking in place. Set up under the mill quill just in case some pressure was required |
|
|
|
|
|
|
|
|
|
|
|
|
|
The IP piston valve liner in place.
0.0005" interference, cylinder block heated up to 150 degrees C.
This gave 0.004" clearance and they "fell" in. |
|
|
|
|
|
|
|
|
|
|
|
|
Progress at 19 August 2003
The engine has been disassembled, degreased and painted. Reassembly and final fitting is underway |
|
|
|
|
|
|
|
|
|
|
|
|
The Feed , Auxiliary and Air Pumps |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The finished engine sees the light of day for the first time, omly 16 stairs to go |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
How the engine, boiler and engineer will fit in the boat |
|
|
|
|
|
|
|
|
|
