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3 cyl Pip engine

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David Kenyon 218/01/2019 20:34:48
167 forum posts
136 photos


Back to the lathe the fan is parted off then I had to make a fixture to hold it
onto the rotary table.

Now I can mill out the back of the fan to create the passage for the air/fuel to pass through.

p1040822 (medium).jpg

David Kenyon 218/01/2019 20:36:18
167 forum posts
136 photos


With the drive pin and bearings fitted I can then balance the fan by putting small
off cuts of steel rod into the holes drilled opposite. These will be fixed into place
with Loctite.

p1040857 (medium).jpg

David Kenyon 220/01/2019 16:41:02
167 forum posts
136 photos


Picture showing how the diffuser is driven from the crankshaft big end. p1040860 (medium).jpg

David Kenyon 220/01/2019 16:44:31
167 forum posts
136 photos


Balancing the engine,
I bought a little 'jewlers scale' off E Bay so I could weigh each part.


Rather than explain I will just re print the chart from the plans with the weights
filled in.

Ian Skeldon 220/01/2019 17:03:32
331 forum posts
27 photos

David I bow to your ingenuity and machining skills, not to mention your patience.

Edited By Ian Skeldon 2 on 20/01/2019 17:04:33

David Kenyon 221/01/2019 20:01:58
167 forum posts
136 photos
Posted by Ian Skeldon 2 on 20/01/2019 17:03:32:

David I bow to your ingenuity and machining skills,

Please don't , I really am a novice when it comes to Engineering.

The 'PIP' plans come with substantial build notes which explain each step of the build , I am just good at following instructions.

David Kenyon 221/01/2019 20:34:24
167 forum posts
136 photos

Master rod total weight 100% 6.86g

Master rod upper half 43% 2.95g

Master rod lower half 57% 3.91g

2 Slave rods total 100% 4.49g

2 Slave rods upper half 50% 2.245g

2 Slave rods lower half 50% 2.245g

Reciprocating parts

3 Pistons 12.42g

6 Piston rings 1.17g

3 Wrist pins 6.22g

3 Small end bearing 1.97g

1 Master rod upper half 2.95g

2 Slave rods upper half 2.245g

Total Reciprocating parts [ 26.975 ]

Rotating parts

1 Big end bearing 4.08g

2 Knuckle pins 2.59g

2 Small end bearings 1.51g

1 Master rod lower half 3.91g

2 Slave rods lower half 2.245g

Total Rotating parts [ 14.335 ]

David Kenyon 221/01/2019 20:34:43
167 forum posts
136 photos

Weight to be balanced

1/2 x reciprocating parts 13.378g

1 x rotating parts 14.335g

Total to be balanced 27.822g

David Kenyon 221/01/2019 20:36:57
167 forum posts
136 photos


I then turned a bob weight to 27.82 gramsp1040847 (medium).jpg

David Kenyon 221/01/2019 20:39:20
167 forum posts
136 photos


With the bob weight placed on the crank pin the counterweight falls to the bottom
as it is heavier


I then slowly turned down the counterweight testing between cuts until the crank
can be placed in any position balanced.

p1040852 (medium).jpg

David Kenyon 223/01/2019 21:26:16
167 forum posts
136 photos


I am now ready to build up the engine.
First I fit the 'ring gear' held by 8 M2 screwsp1040862 (medium).jpg

David Kenyon 223/01/2019 21:27:43
167 forum posts
136 photos

I turned an Alloy tube to hold the camshaft in placep1040899 (medium).jpg

David Kenyon 223/01/2019 21:28:53
167 forum posts
136 photos


This tube is pushed up through the bottom bearing and the cam is dropped in lining
up the gears with the centre punch marks which are top / bottom dead centrep1040902 (medium).jpg

David Kenyon 223/01/2019 21:30:25
167 forum posts
136 photos

The Cam followers in their bushes are pressed into place from the outside.
p1040898 (medium).jpg

David Kenyon 223/01/2019 21:31:28
167 forum posts
136 photos


The second main bearing plus its carrier is then pressed into place, this will
be held in place by three of the cylinder mounting bolts.
I cannot now see the camshaft so I have run some sticky tape around the outside
of the cam followers so they press against the cam and hold it steady. p1040903 (medium).jpg

David Kenyon 223/01/2019 21:32:47
167 forum posts
136 photos


The crankshaft can now be placed into the end of the alloy tube and slowly pushed
through so the tube is replaced by the crank. The crank pin is held at TDC and hopefully
it will engage with the cam still held at TDC by the taped followers. p1040904 (medium).jpg

David Kenyon 223/01/2019 21:33:50
167 forum posts
136 photos


Master con rod is placed onto the crank pin and the big end bearing screwed into place. p1040930 (medium).jpg

David Kenyon 223/01/2019 21:34:37
167 forum posts
136 photos

Piston is then fixed by the gudgeon pin and the rings carefully fitted
p1040934 (medium).jpg

David Kenyon 223/01/2019 21:35:28
167 forum posts
136 photos


Broken rings already , good job I made spares p1040937 (medium).jpg

David Kenyon 223/01/2019 21:35:57
167 forum posts
136 photos

p1040936 (medium).jpg

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