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Scale Model Engineering Steam, gas and hot air model engines, tractors and accessories. Machining and milling castings.

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1/2 scale Aermotor Build


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  #21  
Old 01-07-2017, 06:52:11 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

One piston done out of cast iron as I am making two engines I will make the other out of aluminum just to see if there is any performance differences. The rings were purchased from Star Bolt. I made the piston first to use to check my cylinder bore sleeve for fit as I do not own a bore gauge .The print called for an aluminum piston with no rings and it was a 2 piece build I chose the more traditional method. the connecting rod on the wrist pin is called out at .875 hence the large pocket in the piston
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  #22  
Old 01-08-2017, 06:19:10 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

Aluminum piston is done the aluminum is 4.35 ounces lighter than the cast iron it will be interesting to see if the two will preform noticeably different. Dimensionally they are the same .Maybe some of some of the stackers could give some insight into this
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  #23  
Old 01-10-2017, 08:00:51 PM
Matthew Guy Clarke Matthew Guy Clarke is offline
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Default Re: 1/2 scale Aermotor Build

The shrink, expand of aluminum is greater than cast, so what tolerance did you use. If using an aluminum piston, I machine extra clearence.
I often use .001 on cast, and no ring. But you can scare a piston, with such close tolerance. When casting, aluminum shrinks 3\16" per inch, oposed to casts 1|8" per foot. Bore diameter also comes into play.
Using an aluminum block, then the aluminum piston may fit better at heated running condition. It may all never get hot enough to make any difference. I am not familiar with how an aluminum block ,with cast iron sleeve will expand to fit of piston.

Last edited by Matthew Guy Clarke; 01-10-2017 at 10:04:10 PM.
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  #24  
Old 01-11-2017, 06:12:58 AM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

The engine is an 8 cycle so it fires 1/2 as often as a 4 cycle.I do not expect much heat to be generated.The pistons are at 1.4985 I will fit the sleeves to them.I am a machinist and my boss probably would loan me a bore gauge but in the past I have made my self a set of go no go plugs.Which for my purposes works okay.The prints call the piston out of aluminum no rings at 1.500 and the sleeve at 1.500 granted he laps it to a good fit with the sleeve.I seriously am no fan of turning aluminum at home or at work .
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  #25  
Old 01-14-2017, 05:24:04 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

I have both cast iron cylinder sleeves made and honed to fit pistons.Both were loctited into place with high strength 638 retaining compound. I am now working on the connecting rods I made a fixture this should allow me to do all operations on it without removing it from the fixture. The loctite is good to 300° f should be OK as I have a light press fit as well
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  #26  
Old 01-15-2017, 04:58:46 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

Connecting rods complete now just need to make the grease cap and bearings.
Oh yes and stud and nuts I generally do things like that after the engine is test run then I focus on all the finish and detail work
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  #27  
Old 01-28-2017, 05:53:19 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

Working on the exhaust assembly.I have made a fixture to hang on to it for machining the vavle inserts are installed and I will let the loctite cure over night before drilling and tapping the muffler hole. I made all 4 valves I needed as a 2 piece assembly cold roll steel stem and a stainless head.I first thread them together then silver solder. Then I hold them by the stem center drill the head introduce the live center and turn the 45°s this ensures concentricity.I should be able to wrap up he exhaust bodies tomorrow
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  #28  
Old 01-29-2017, 05:15:10 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

100% done on exhaust assembly with muffler except the proper spring a trip to the hardware store will fix that I could wind one but some times I like the easy way
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  #29  
Old 02-05-2017, 01:30:04 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

Tank complete along with intake valve. I wound the tapered spring on a tapered mandrel with tensioner I made I put the lathe in threading mode at 10 threads per inch and hand turn it
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  #30  
Old 02-17-2017, 08:10:44 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

I have the governor assembly almost done just need to drill and tap the flyball for a thumb screw. I made the the bottom of the flyball hub on the rotary table as it is an eccentric then I silver soldered the tab on to it . The arm is 1/8" crs with a tab soldered on with two bends to clear the fly wheel. The ball is a ball bearing I annealed to soften it for drilling.Next will be the governor arm and latch out assembly and finish the rocker arm. At that point a timer spark plug and a buzz coil and it should run. After I get it going on spark plug I will then move forward on the Igniter and trip assembly.Once it is all running okay on the igniter I will commence with all the finish work nuts, studs, gear guards. crank guard and base, drip oilier, crank oil lids etc
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  #31  
Old 02-26-2017, 08:16:58 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

I have been working on making the square headed nuts and bolts for the bearing blocks they are done Now working on fitting the swing latch out arm. this has turned out to be a real bear but this one looks pretty close once i get the mating piece on the rocker made and installed then I can make the latch out blade and fit it. The second one should go smoother with what I have learned doing this one
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  #32  
Old 03-04-2017, 06:48:20 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

https://www.youtube.com/watch?v=a0RG...ature=youtu.be


Running a bit fast will need a bit of tuning for sure its much easier to working out the timing bugs and the governor on spark plug once it is tuned in then i will work on the igniter. I borrowed the buzz coil of from my Redwing model to experiment on this engine. Funny had to choke up the mixer in take just like my old alamo engine > Still a good Day
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  #33  
Old 03-05-2017, 07:30:35 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

https://www.youtube.com/watch?v=F6J8...ature=youtu.be

Well I got it running quite nice on spark plug. I found it was opening the exhaust valve before the power stroke was complete a bit of grinding and it was fixed. I am now running it on propane and I must say it it runs better than on the aviation fuel I normally use. Now a bit more running to break in the valves and rings then its on to the igniter.I am very happy with this project it has had some very challenging parts and has been very rewarding
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  #34  
Old 03-12-2017, 04:30:28 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

The igniter body is complete now need to make all the accompanying pieces and parts I have decided to concentrate on one model get it running well on igniter then do the other one.I have this one running just the way it should on spark plug this will eliminate a bunch of variable when I start tuning in the igniter
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  #35  
Old 03-19-2017, 04:25:08 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

The igniter is complete and tested I must say it was quite challenging especially getting the springs wound and bent just right to make it work right.
The end of the movable electrode is a bit rough I had welded it to the shank but had to remove it for line up issues.I now have a set screw holding it in place until I prove it out then I will silver solder I wish I had silver soldered in the first place easier to undo than weld. Here is a short video of the first test

https://www.youtube.com/watch?v=8N_E...ature=youtu.be
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  #36  
Old 03-31-2017, 09:08:23 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

I finally got it up and running some what decent on the igniter. It is a very finicky set up I am starting to get a feel for it and I think I can get it going good it sill needs a bit more tuning as in this short video it starts out great and starts to mess up a bit toward the end of the video. A with most of my projects they will run super until a camera is introduced instant camera shy

https://www.youtube.com/watch?v=ATgH...ature=youtu.be
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  #37  
Old 05-26-2017, 10:59:34 AM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

I have not worked on this for a while but we have a show tomorrow in Bernardston Mass and I wanted to bring it even though the finish work still needs to be done.So I made this stand to display it on not like what is suggested in the blue prints but it is what I wanted to do. Before fall I will get it finished up and painted
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  #38  
Old 08-20-2017, 06:12:15 PM
JFleury JFleury is offline
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Default Re: 1/2 scale Aermotor Build

Today I finally got the Aermotor model running just the way it should ran two solid hours without skipping a beat finally shut it down. I made a new igniter springs and a new stationery electrode. The previous electrode was almost pure nickle now I have a piece of drill rod and off and running maybe nickle does not carry low voltage well . Normally I use drill rod but I had the piece of nickle to try the movable electrode is also drill rod.I have also started replacing all the set screws and store bought bolts with shop made ones and have stabilized the timing which on this model is very very fussy.

YouTube Video Link
https://www.youtube.com/watch?v=JL6X...ature=youtu.be
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  #39  
Old 08-20-2017, 09:29:46 PM
Ken K Ken K is offline
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Default Re: 1/2 scale Aermotor Build

Electrodes made from pure 1/16" tungsten work well. Used in welding, so may get short piece from a weld shop.
Ken K
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