Another Internal Combustion Engine

[rdean]

Well I made it back and I had a good time but I did miss the shop.

This is the start of the cylinder head with a routed name tag.


I have never tried this method on aluminum but I have used it many times in wood.
I mix up 2 part epoxy and add some black power coat pigment.
Stir it all up and spread it over the area making sure you get the all air bubbles out.


I'm going to let it cure overnight and then cut the excess off the top in the mill.


Thanks for looking
Ray

 

[rwm]

That's gonna look great! I have done the same thing using black automotive touch up paint. It is easy to apply with the tiny brush it comes with and sticks well to the metal.

 

[rdean]

Well I cut the top of the epoxy off today and was disappointed. It just didn't stick well on the slick aluminum so I picked it all off and started over.
Robert I took your advice and had my wife paint in the letters.
It turned out quite well I think.


I had some time so I cut out some head gaskets.


I just had to install the head to see if I had any compression. That lead to finding my exhaust valve was not sealing.
Something to fix later.

Thanks for looking
Ray

 

[extropic]

Please describe what's going on in the gasket cutting picture.
Vacuum chuck holding the stock?
CNC drawing the circle?
The utility blade follows the spindle motion (like a caster)?
What is that thing with all the nomenclature? Brand name or link please.

 

[rwm]

Well I cut the top of the epoxy off today and was disappointed. It just didn't stick well on the slick aluminum so I picked it all off and started over.
Robert I took your advice and had my wife paint in the letters.
It turned out quite well I think.
View attachment 510130

Yes that looks great! I'm glad your wife has a steady hand. You can do it just like epoxy too. Fill in the letters and let it flow over the edges then machine it off. The stuff shrinks as it dries so it leave a nice concavity to the letters.

 

[rdean]

The gasket material is held on a vacuum table to keep it in place.
This is a very simple job for the software that can cut intricate designs and square corners. I use Aspire software for the cad and Mach3 for the cam part.
Donek Tools is the brand name of the cutter.

Thanks for asking.

Ray

 

[rdean]

This is the head mounted on the engine.
What do you think?
Do you like the name?


It has proven to be abundantly clear to me that the flywheels I made are way too small. I have a pair of 8" round cast iron slugs from McMaster Carr with the certification papers to be free of voids and hard spots. Cost me some $$$ but the other were just too small for this long stroke engine.
Out of the box they weighted right at 11 pounds each and at this roughed in stage they are at 6lbs 12oz and there is still more to be taken off later.


Now to clean up the lathe and the rest of the shop.
They did machine nicely though.


Thanks for looking
Ray

 

[Chris Hamel]

Engine is really looking good.

 

[rdean]

Thanks Chris

I made up a couple of taper lock bushings and taped the holes in the flywheels.


I just can't have plain solid flywheels so over to the CNC mill for some bling.
Drew up some curves, added some width, and hoped for the best.
I think it came out fine.


First one cut out but a lot of work left to clean it up nice and pretty.


The other flywheel will be the mirror image of this one so the pattern goes the same direction on either side.

Thanks for looking
Ray

 

[Chris Hamel]

Flywheels look great. How did you decide on 5 spokes?