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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 08:41:48 | 显示全部楼层
Milled the angled sides which I marked yesterday. The rest will be turned in the lathe when the balance weights are fixed to the crankshaft.
Made myself an extension for a 5.5mm slot drill (photo 3). Used a piece of 10mm silver steel, drilled and reamed 6mm (for the slot drill shaft), cleaned the bore and slot drill shaft with surgical spirit and supergluedthe slot drill in the shaft. I will let it cure till tomorrow and test it out. Still not sure if this will actually work out. We'll find out tomorrow.

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 楼主| 发表于 2014-4-25 08:42:21 | 显示全部楼层
Today I tried using the extended 5.5 slot drill that I made yesterday. Used a piece of scrap mild steel, drilled a 3mm hole, drilled with a 5mm drill to a 2mm depth and then counterbored with the 5.5mm slot drill. I am happy to report that the extension worked and the glue held fast.
I drilled 5mm to a 2mm depth to give the slot drill less work to do.
Now I will make a similar extension for a centredrill.
When I am finished with these extensions I intend to try and remove the 5.5mm slot drill from the extension. If I heat it up do you think I will be able to pull out the slot drill? What do you think?

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 楼主| 发表于 2014-4-25 08:43:31 | 显示全部楼层
Yesterday I made an extension for a centre drill (photo 1).
Today I drilled and counterbored the crank shaft webs. I put a piece of brass between the webs and clamped the crankshaft in the vice using an engineer's square to align it upright (photo 2). Using a wiggler aligned the spindle to the marked hole and then using the extended centre drill started the hole (photo 3). As you can see it was a tight fit. Drilled the hole 3mm with a long series drill. Then using a 5mm drill drilled 1.5mm depth. After that used the extended slot drill and counterbored to a depth of 2mm (photo 4). Another tight fit.
Made the other 3 holes using the same procedure.

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 楼主| 发表于 2014-4-25 08:44:22 | 显示全部楼层
Cleaned up the holes and counterbores and decided to give the balance weights a trial fit.
OMG there is something wrong here.
No way the connecting rod is going to pass between the balance weights. The balance weights should end up flush with the webs but for some reason they were not. Started checking dimensions of the webs and balance weights. Everything seemed correct (or so I thought). Measured again a couple of times but could not find what was wrong. Lit up a cigar and it was finished in record time. Panic was starting to take over. I was convinced that there was a wrong dimension on the plans. Finally, after 30 minutes, I found MY mistake. I misread the diagram of the slot of the balance weight.
Thank God it's a fixable mistake. All I need to do is make the slot deeper. So next time, I will have to re-millthe slots and hopefully keep the same width of the slot.

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 楼主| 发表于 2014-4-25 08:44:57 | 显示全部楼层
Now that looks much better (photo 1) and there is enough space for the conrod to pass between the balance weights.
Marked for the holes in the balance weights with a transfer punch. Drilled and tapped the holes 3mm. Setup the crankshaft with the balance weights on the lathe (photo 2) to trim the sides of the balance weights and webs at the same time.

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 楼主| 发表于 2014-4-25 08:46:43 | 显示全部楼层
I am not good at being a tourist. I just go there to get the job done. Infact next week I have a two week stint in Paris and it's going to be the same story. Go to the sim and back to the hotel.
Well, this evening I finished cleaning up the crankshaft and balance weights and polished the journals. Oiled the journals, put the crank in the crankcase, and gave it a 15 minute run in the lathe. Turns nicely. My first crankshaft is finished. 22 days to make!!

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 楼主| 发表于 2014-4-25 08:47:38 | 显示全部楼层
As I will be going abroad in a weeks time, I don't intend to start working on any major component and leave it half finished. Instead I might do small things and maybe some planning on how to proceed. One thing I will do for sure is clean up the garage and put many tools in place, which I started doing this morning.
Another thing I did this morning was have a second look at how to bolt the two crankcase halves together. At the moment I am using Allen head bolts which I find convenient when assembling and disassembling the crankcase, but on an old engine as this one (1960 era) they look out of place. So my initial plan was to use studs and nuts instead. Well this morning I thought, how would hex head bolts look? So I put an Allen head bolt, a hex head bolt and a stud and nut in the crankcase (see photo) to compare the three solutions together. The big bolt above the stud is the oil drain plug. Looking at it, I am now leaning on using hex head bolts which will also match the oil drain plug. What do you think guys?

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 楼主| 发表于 2014-4-25 08:49:41 | 显示全部楼层
Today I made a 4mm stud from 4mm bar stock BMS (photo 1). It really looked good (photo 2). I tried it out and it was obvious this was not going to work well. I was having problems aligning both crankcase castings when the stud was used. So that method didn't work as well as I had hoped.
Next, I used 4mm threaded rod. Did not look as good as the first stud I made (photo 3) but it worked well.

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 楼主| 发表于 2014-4-25 08:51:14 | 显示全部楼层
And this is how it looks with all the studs in place. Used a spring washer under each nut.

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 楼主| 发表于 2014-4-25 08:53:13 | 显示全部楼层
As I said in an earlier post, this week I would be doing only minor things on the Kiwi. Next week I will be away from the island for about a forthnight and as such I don't want to start any major component and leave it half finished.
What I did today is I took the cast iron that came with the kit for the cylinder liner and I roughed the OD to remove the hard surface. Westbury recommends doing this and then letting it rest for a while to remove internal stresses. I did this using an insert tool to get through the hard surface. Strangely enough, the surface did not seem that hard. When this was done, I sprayed it with WD40 and repacked it in the box. It's going to have a lot of time to 'rest'.

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