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发动机建造 Kiwi Mk2(绝对精华)

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 楼主| 发表于 2014-4-25 08:23:00 | 显示全部楼层
Chain drilled and hacksawed the other side for the other journal (photo 1). This time milled the outside of the webs (photo 2). Put it in the lathe but instead of between centres, I held the part in a collet and the other side with a live centre (photo 3). Same as the other side I had to change the live centre to a half dead centre for the final 8mm cut. And this is how it looks after lathe work was finished (photo 4).

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 楼主| 发表于 2014-4-25 08:23:30 | 显示全部楼层
Crankshaft is not finished yet. I threaded the ends of the shaft 8mm fine (1mm pitch) with a die. The plans do not specify the lenght of the threads so I made them short and will increase as required at a later stage. The top and bottom of the webs need to be rounded off but I intend to do that when the bronze counterweights are in place. Also I need to drill the oil passageways. I will be drilling them 2.5mm and then tapping 3mm. Yesterday I went shopping for a long series 2.5mm drill which I could not find so I settled for an extra long version. Hope I do not break it in the hole.

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 楼主| 发表于 2014-4-25 08:25:28 | 显示全部楼层
This evening I fitted the crankshaft in the crankcase and tried to turn it by hand. It was binding at a particular angle. Took the crankshaft out, put it in the collet which was still fitted to the lathe and started the lathe. There was a slight wobble at the end which was confirmed with a DTI. I suspect that the brass packing I put between the webs was too tight. Lesson learnt.
Using the DTI and a plastic hammer the crankshaft was trued. Tested again in the crankcase and it was much better. Gave it some running in on the lathe (photo).

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 楼主| 发表于 2014-4-25 08:27:04 | 显示全部楼层
This morning I was thinking of drilling the oil passageways in the crank but as I know that I work slowly and this afternoon I have to go to work I decided not to do the passageways.
I wanted to do something simple and decided to do the hole for the breather assembly in the rear crankcase. Marked the hole, fixed the casting to the angle plate and drilled and tapped for 6mm fine. As the surface in the area is round and tapered, I counterbored with an endmill 10mm so that the body of the breather will seat on a flat surface. Et voila finished. At least I did something today. This maching thing has become addictive. I need to do something, even if I sit down in front of the plans and plan something, at least I will not get withdrawal symptoms.

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 楼主| 发表于 2014-4-25 08:32:17 | 显示全部楼层
Started work on the four oil passageways holes in the crank but only managed to finish three of them.
Drilled and tapped 3mm the first hole through web, from the top of the web to the crank centreline (photo1). Set up to drill the second hole through the crankpin (photo 2). Used a wiggler to align the spindle with the hole mark (photo 3) and drilled till it broke into hole 1. Tapped 3mm. Also used a jewel screwdriver in hole one to see when I break into the hole. I got this idea from someone on the forum but can't remember who it was. SORRY. Good thing I had the extra long drill for this operation (photo 4).

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 楼主| 发表于 2014-4-25 08:33:24 | 显示全部楼层
Hole 3 was drilled in the crankpin until it broke into hole 2. Used the same screw driver to know when I reached hole 2. Next time I will do the forth long hole in the crank to meet hole 1.

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Fourth hole finished and tapped 3mm. Used a steady rest to support the crankshaft. Started the hole using a normal size 2.5mm drill then continued with the long drill. I need to get me some 3mm grub screws to plug the holes that were tapped. One more hole needed in the crankshaft. This will be the oil feed hole but will do it at the same time when drilling the crankcase.

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 楼主| 发表于 2014-4-25 08:35:27 | 显示全部楼层
Made the oil inlet hole in the front crankcase casting. Held the casting in a vice and milled flat the boss of the oil inlet. Drilled through a 2.5mm hole and then drilled and tapped 5mm.
Next the oil inlet hole on the crankshaft which should meet the previously drilled hole in the crankcase. With the crankcase still in the vice, inserted the crankshaft and positioned it at TDC. With a transfer punch through the crankcase 2.5mm hole marked the crankshaft. Drilled a 2.5mm hole in the crankshaft and filed it with a small round file as per instructions.

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 楼主| 发表于 2014-4-25 08:36:57 | 显示全部楼层
Started work on the bronze counterweights for the crankshaft. The bronze casting came with the kit. Milled the bottom to give me a flat surface and then milled the top.

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 楼主| 发表于 2014-4-25 08:38:15 | 显示全部楼层
Continued work on the counterweights. Brought down the thickness of the casting to dimension on the lathe. Then mounted the casting on the milling table (photo 2). Used a 12mm endmill and milled the slot to the required depth of 3.175mm.

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 楼主| 发表于 2014-4-25 08:40:35 | 显示全部楼层
Did some more work on the balance weights. Hacksawed the casting so that I could separate both balance weights. Milled the flat at the top on both weights and then marked them so that next time I will mill the 15 deg. sides.

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