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Setup from Hell.

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  • Setup from Hell.

    Got a small 4 cylinder block in to do some work on, it's a French cyclecar made between the war years, hardy something to get excited about but because of this it's the only one left.

    In a bit of a sorry state and the block has cracked / corroded away between No 3 bore and one of the valve seats so it's been sent in to be specialist welded.

    They have made a nice job of this, very old fashioned firm, only two old guys still there, they heated the block up over about 4 hours and gas welded it with cast iron rods whilst still red hot and then buried in hot ashes for two days to cool. Weld came out mint, good penetration and soft as butter, files just like a piece of continually cast Durabar.



    The idea was to lob it on the bed of the POS Bridgy and pick the bore up and valve seat and clean up.

    Nooooooooooo ???????

    Too tall to fit, when the bed is right down the block is just level with the bottom of the spindle with no tooling fitted.

    Sooooooooooo ?????

    Glue it to the bed by it's arse end and get the bore parallel to the bed with lining bars, DRO's, dial gauges and three cups of coffee and a bacon sandwich [ with mushrooms and black pudding ].

    Then stuff the right angled attachment onto the spindle and clock this up parallel to the bed, as measured with a test bar, DRO's, dial gauges and a cup - a - soup [ galvanised iron flavour ] { note to self - self - wash cups again before May }



    Thennnnnnnnnnnnn.
    Get the centre of the boring bar central into the cylinder but only sweeping round 3/4 of a circle because of the weld.
    Take very fine cuts and remove the weld until it just touched the bore.

    Reset up on the valve guide as a central point and bore this out and re-cut the seat all from the same setting. Blue the valve seat and just tweak one way a gnats left bollock so it blued up all round.




    First lick through with the honing stones to see how it's looking, actually looks worse than it is, very slight feel to it on the transition.
    A bit of a buff up with a flap wheel and a re-hone should get this a bit better.

    Hopefuly this will have saved another one from the knackers yard.

    I must admit that the setting up was a pain, started at 2:00pm and this is where it is when i knocked off the go down the pub at 5:00 [ short day today, have to take grandkids shoplifting round Asda on a Wednesday ]

    Hardest one pound seven shillings and sixpence I have earn't for a long while.

    .
    .

    Sir John , Earl of Bligeport & Sudspumpwater. MBE [ Motor Bike Engineer ] Nottingham England.




  • #2
    John, a writeup on the setup using the lining bars, etc and getting everything lined up would be greatly appreciated and could be used for many things, like boring steam cylinder castings on a steam locomotive!
    Good work.

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    • #3
      Fannytastic job, i wouldent even dare try at the moment, how the hell can you go to ASDA on a Thursday without a visit to the watering hole, you need chain mail ankle guards to prevent trolly rash!
      Well done sir John
      regards
      mark

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      • #4
        I would not have even attempted that project with HSM machines. Leave it to Sir John to figure out how to get it done.

        Amazing.

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        • #5
          Originally posted by John Stevenson
          The idea was to lob it on the bed of the POS Bridgy and pick the bore up and valve seat and clean up.
          John, if I had a nickel for every time you've posted a project on your POS Bridgy...

          Nice job! I just found the rare right-angle attachment for my Excello, so I'm hoping to play around with it this weekend.
          "Twenty years from now you will be more disappointed by the things that you didn't do than by the ones you did."

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          • #6
            For a fellow who doesn't like Bridgeports all that much, you seem to do rather well. That looks like a super job! The weld shows a lot of ability, too. A parent metal weld on cast iron is a real specialty.

            Nice work!

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            • #7
              For a fellow who doesn't like Bridgeports all that much, you seem to do rather well.
              Well, ANYONE could do it on a good mill.

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              • #8
                I'm just gobsmacked you did not use your Blake coax indicator for all the critical alignments!

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                • #9
                  Originally posted by dp
                  I'm just gobsmacked you did not use your Blake coax indicator for all the critical alignments!
                  I'd though about it but I don't think there was enough weld protruding to get a proper reading.

                  .
                  .

                  Sir John , Earl of Bligeport & Sudspumpwater. MBE [ Motor Bike Engineer ] Nottingham England.



                  Comment


                  • #10
                    Nice job! looking at your work makes me feel like someone cutting iron with a hatchet, looks great!

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                    • #11
                      Nice job John and don't you just love those angle head attachments. I have been putting off getting one for years. This year may be the time I get one.
                      It's only ink and paper

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                      • #12
                        Kids, this is what it is all about, what separates the men from the boys, be it a labor of love or just another day at the office.
                        Determination and perseverance with the need to press on no matter how daunting the task at hand...
                        The imagination to see the final result when others say it can't be done.
                        To laugh at the hands of defeat!
                        Failure is not an option!!
                        To boldly go where no man has gone before!!!
                        Sir John, this Bud's for you!!!!

                        Steve

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                        • #13
                          You left a broken stud in there
                          Peter - novice home machinist, modern motorcycle enthusiast.

                          Denford Viceroy 280 Synchro (11 x 24)
                          Herbert 0V adapted to R8 by 'Sir John'.
                          Monarch 10EE 1942

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                          • #14
                            Very nice work Sir John. Rework like that is always a challenge and the customer never seems to appreciate how much really goes into it.

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                            • #15
                              Nice job as per usual,what's Black Pudding?

                              Some new brand of gasket glue?
                              I just need one more tool,just one!

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