Thanks for the comments Bazyle. Corrosion doesn't worry me because the cylinders aren't likely ever to get wet!
If, in the next year, I can get to the stage of having a rolling chassis running on air (see http://www.youtube.com/watch?v=0tQRtnREiCg) I shall think my life has been worthwhile. Whether I ever build a boiler is another matter.
Now, I'll come clean here. If you have the latest issue of ME, read the letter from Eddie Jenner. He sounds lke he could be my twin brother.
Many years ago I bought the parts for a Gauge 1 loco "The Project". More recently, but still quite a lot of years ago, bought the parts for a horizontal mill engine called "Tina". I haven't started on either of them and the reason is the same – I'm scared of machining the castings and ruining them. At the moment they have a value – I could sell them. If I ruin them they won't have a value and I don't like that idea.
At the last model engineering show I attended I told a man from SMEE about this. He couldn't help because, frankly, he couldn't comprehend the problem. He didn't lack confidence – I do.
So I would prefer to make something that doesn't need expensive castings and the two questions are:
1. Can I machine a cylinder block from a solid block of metal.
2. If I used aluminium (because it is cheap and readily available) would it work on air – at least for a while.
If I can get the thing working on air I think I would have the confidence to do it again properly. Time isn't an issue. Not getting it badly wrong and giving up in despair is very much an issue. Screwing up a cheap block of aluminium doesn't count as getting it wrong. Junking a £200 casting definitely does.
Regards,
Brian.