Making small gaskets for model IC engines.

[Andrew TinsleyParticipant @andrewtinsley63637]

I often repair model aero engines. My Achilles heel is making the small replacement gaskets that are often needed. My usual method is to trace the outline and cut the material with a scalpel and drill any holes with either a pin vice or an Archimedean drill.

I find this to be quite awkward and time consuming. The results are hardly good looking! Does anyone have any better suggestions? The main problem is that the gaskets are usually one, or at most, two off. This makes a punch tool a non starter. Some sort of CNC method is hardly warranted and could be quite expensive, although I don’t mind spending a reasonable amount on a cost effective solution.

Andrew.

[Roderick JenkinsParticipant @roderickjenkins93242]

It might be worth looking at small laser engraver/ cutters, there seems to be quite a few available between £100 and £200.  I would look very closely at the thickness of materials that can cut.

Rod

[Andrew TinsleyParticipant @andrewtinsley63637]

Thanks for that suggestion Rod. The cost for the cutters seems reasonable I assume you need some sort of CAD to input the design to the cutter, if so, that will bump up the cost and include a learning curve?

Andrew.

[John HinkleyParticipant @johnhinkley26699]

Andrew,

Have you considered 3D printing the gaskets?  Apparently, TPU is suitable for low-temperature areas like the inlet and crankcase and a carbon reinforced filament could be drafted in for the exhaust, etc.

John

 

[old martParticipant @oldmart]

I used to have some of those tools used for carving lino which fitted into a holder. They were different shapes with cutting edges at the ends.

I checked on ebay serching “lino cutters” and they still exist.

[Speedy Builder5Participant @speedybuilder5]

Have you seen this ?  Set yourself up and advertise your services on this site ???

https://store.creality.com/uk/products/creality-falcon-a1-enclosed-laser-engraver-cutter

[FulmenParticipant @fulmen]

An old method is to use the mating surfaces as the cutter. Fix the gasket to the part using weak glue or tape, then tap the circumference with a rubber mallet or similar to cut the gasket. With a little practice you can get a quite decent result with little effort.

[Andrew Tinsley]

On Andrew Tinsley Said:

I assume you need some sort of CAD to input the design to the cutter, if so, that will bump up the cost and include a learning curve?

Andrew.

Yes, just like a 3D printer if you want anything that is not available as a download you need to be able to produce a CAD file to get what you want. Need not cost anything but you will need to learn though flat gaskets should not be too complicated.

Myself I tend to use  aliquid gasket on my IC and stationary engines.

For thin paper like you get on model aero engines then holding the paper on the actual metal part and drawing a needle file backwards over the edge is quite an effcetive way to cut to the required shape, I do that for masking when painting. Similar to Fulmen’s method but won’t bruise the diecast alloy

As for hole you might want to consider one of the small punch & die sets that the plastic model guys use, they work much like a hole punch for filing A4 paper but have a range of small sizes. Loads on the web if you google but this sort of thing which you could even make.

[noel shelleyParticipant @noelshelley55608]

Start with silver steel rod. drill a hole of the size of the hole you need for the bolt then turn the od to a longish taper to meet the hole. Harden and temper then grind the end to a good cutting edge. Mark out gasket paper and use cutter on a block of lead or hard wood to make your holes. Just twist and press down. Tapping out gaskets with a small hammer for the main shape.  Noel.

[Andrew TinsleyParticipant @andrewtinsley63637]

Thanks for all the suggestions, there are some methods that look effective. I will give them a trial and see if I can speed up and improve the quality of my gasket making.

3D printing is something I don’t wish to get involved with, too time consuming and I have little enough spare time!

Andrew.

[Trevor Drabble 1Participant @trevordrabble1]

Maun Industries Ltd are an English Company who make a range of punches and styles from 1 mm diameter upwards.  I have no connection with the company other than a very satisfied user of a number of their pliers .

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