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Stuart No. 1 Build Progress

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Mark Gould 107/11/2018 11:09:42
82 forum posts
42 photos

Dad and I have started our Stuart No.1. We started with the easy parts. Here's our progress so far. 

Edited By Mark Gould 1 on 07/11/2018 11:27:42

Mark Gould 107/11/2018 11:14:01
82 forum posts
42 photos

Sorry guys, I am struggling with photos in my album, they're all rotated incorrectly. Bear with me while I sort it out.

Mark Gould 107/11/2018 11:39:50
82 forum posts
42 photos

Here is our lathe, a Super 7 rebuilt to new here in the Netherlands by a MyFord specialist.

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...and our small milling machine, an Emco FB-2.

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And then the first machining on our new Stuart No. 1:

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3404607/11/2018 11:47:19
374 forum posts
2 photos

All looks well set up and good to see progress on the no 1.

Bill

mechman4807/11/2018 13:49:12
avatar
2329 forum posts
375 photos

Looking good Mark; I like the lighting set up on your mill, I assume it's an 'angel eye' off eBay. is it powered off a 12v 'wall wart'? would be nice to see more pics of lighting set up.

George.

Mark Gould 107/11/2018 15:11:39
82 forum posts
42 photos

George,

It is a LED ring that attaches via magnets to the bottom of the milling head, around the spindle. I bought it on eBay but to be honest I am going to replace it with a larger diameter ring. This ring has an internal diameter which is 2mm larger than the spindle thickness and so the light is concentrated around the spindle. A collet/drill chuck or shell mill actually blocks the light from getting to the cutting surface.

I am going to get a larger one with a 100mm diameter (€8 on Banggood) to see whether it clears the tool. Keep you posted.

Mark

mechman4807/11/2018 15:37:13
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2329 forum posts
375 photos
Posted by Mark Gould 1 on 07/11/2018 15:11:39:

George,

It is a LED ring that attaches via magnets to the bottom of the milling head, around the spindle. I bought it on eBay but to be honest I am going to replace it with a larger diameter ring. This ring has an internal diameter which is 2mm larger than the spindle thickness and so the light is concentrated around the spindle. A collet/drill chuck or shell mill actually blocks the light from getting to the cutting surface.

I am going to get a larger one with a 100mm diameter (€8 on Banggood) to see whether it clears the tool. Keep you posted.

Mark

Much appreciated. My mill measured up at 80 mill but 100 mm looks a more promising size.

Geo.

Mark Gould 109/12/2018 18:49:35
82 forum posts
42 photos

Progress and Failure.

Our engine is progressing steadily but it hasn't been plain sailing. We managed to get the lower bearings into the sole-plate. Just need a skim across the top to make the top surface exactly level.

The upper halves were a different matter. We thought some, pondered a bit and then thought some more and then buggered them up. I have no idea how or where we made the mistake but it all went wrong when we got the 2 halves into the 4 jaw. I have ordered 2 more top halves from Stuart.

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Here I am milling to mating surfaces of the top bearing halves to be able to super glue them together.

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Failure. The radius is off centre. We could possibly salvage the parts but getting one side correct and placing the incorrectly turned faces on the inside of the engine but that would reduce the crankshaft bearing area so we decided to make 2 new ones.

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Mark Gould 110/01/2019 19:12:33
82 forum posts
42 photos

My Dad and I have made slow but steady progress on the No.1. The main bearings are complete and we have drilled and reamed the holes for the crankshaft. I was a little worried about this operation as it is quite important to get it right and we didn't want to ruin the main bearings.

Anyway, here are some pics. Sorry they are rotated. I have tried and tried but am unable to post them the right way up. I managed a few weeks ago but have forgotten how I did it. Most infuriating.

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Edited By Mark Gould 1 on 10/01/2019 19:18:51

JasonB10/01/2019 19:15:16
avatar
Moderator
15171 forum posts
1548 photos

Looks good so far.

Samsaranda10/01/2019 19:24:38
avatar
644 forum posts
4 photos

Nice work Mark, why does everyone’s workshop always look much tidier than mine?

Dave W

Mark Gould 120/03/2019 17:34:58
82 forum posts
42 photos

Progress is slow. The workshop is at my folks place which is 50km from me and with work in the way our days spent machining have been few and far between. I hope to step it up a bit soon.

Today we finished machining a simple but time consuming bit. Not even sure what it's called but it still needs a bit of light filing and sanding but the basic shape is there. It takes a lot of time if you're a newbie and this took quite a while! It tapers by 2mm from end to end, not clear on the pics. 

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Edited By Mark Gould 1 on 20/03/2019 17:35:59

Mark Gould 105/04/2019 09:44:04
82 forum posts
42 photos

Almost completed the next component. This also took quite a lot of time as we kept having to take it out, measure, put it back, find zero etc. It still needs a general deburring but the fit in the standard is excellent.

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mechman4805/04/2019 10:24:26
avatar
2329 forum posts
375 photos

Looking good Mark. As Dave W. commented... ditto.

George.

Mark Gould 120/04/2019 16:29:06
82 forum posts
42 photos

Got a bit more done. The con rod bearing and the slide valve. The con rod bearing is actually 2 parts super glued together for the machining. They turned out nice although this gun metal is very “bitey” to drill into!

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