Concept To Completion No 4771

[JasonBModerator @jasonb]

Now that the latest edition has finally been added to the forum pages and given the fish and chip quality of the paper currently being used I thought I would post a few more photos to go with part 1 of my article.

The initial “Concept” sentto me via FB Mesenger

My CAD design done in Alibre

What’s inside

Flywheel half pattern straight off the CNC

Test cut for the coverplate engraving done in Melamine faced MDF

Test cut in the actual pattern material 6mm perspex/lexan type material.

Turning the pattern using masking tape and superglue method to hold it

Completed coverplate pattern

[JasonBModerator @jasonb]

The completed crankcase and flywheel patterns

What came back from the Foundry plus several flywheels that may come in handy

Some initial lathe work, boring out for the ball races and coverplate recess

And the one on the other side

Jig to locate crankcase on the rotary table which was my poor man’s 4th axis

 

 

[JasonBModerator @jasonb]

Remaining machining all done on the CNC

Flywheel turned on the manual lathe

The three parts complete

Couple of videos that were linked in the article

[Ches Green UKParticipant @chesgreenuk]

Wonderful design and manufacture. Thanks for sharing.

Ches

[John HaineParticipant @johnhaine32865]

Thanks for posting these Jason.  As a matter of interest, do you log how long you actually spend on an engine?  Your productivity puts us to shame!

[JasonBModerator @jasonb]

No. Best I can do is look at the date of the first photo I take and the last one, that gives me an idea of how long it took but not really the time. Even then it is hard to include time thinking about doing the next bit and not just the actual workshop time.

For example the V twin Kelsey I’m posting about at the moment had the first cut made on 7th November. I took the photos and video of the finished and painted engine yesterday. Currently I try and get 1 to 1.5hrs done on most  weekday afternoons and a bit more at the weekends

[Nigel Graham 2Participant @nigelgraham2]

Impressive work!

[Author]

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