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Everything posted by Asciidv

  1. I suppose you should see how well it sits in the cone of the flywheel. If it is proud by a long way then 'thinning down' on a lathe is an option, but I doubt if any of us have turned leather before. Be the first and tell us all how easy/difficult/impossible it was!
  2. For a moment looking at the machined part photo I wondered whether the cracks were self inflicted by the way the part was held in the lathe chuck with expansion forces coming into play. However you can see the old cracks quite clearly in the pre-machining picture!
  3. I had the pleasure of seeing and handling these tanks in real life yesterday ( and stopping Steve from making further progress ). They are beautifully made, very light, without an ounce of aluminium anywhere in excess. They reproduce the originals to the last detail, even though it would have been a lot easier to cut a few corners and miss off some of the more trickier features. All from wooden patterns made in the traditional way. Just superb!
  4. Steve, if you have access to a buffing wheel, then these buffing compounds with grit makes short work of turning a rough casting into a smooth finish. I normally use the 80 grit followed by the 120 grit.
  5. I might be inclined to put a blow torch on them, melt the solder and then just tap the remains of the tubes out. A job for your under cover black smithing facility, where there is plenty of fresh air as we wouldn’t like you to catch ‘fume fever’.!
  6. "One concern though, was that several of the big-end bolts look a bit iffy. I think we shall have to make some replacements but what sort of steel should we use?" EN24T Disappointed that you are not going to punch out the gills yourself! Why is it not possible to re-use the existing tube plates?
  7. Frank's Dennis was actually built in 1916, but that is splitting hairs. Well done Brian for setting the record straight!
  8. Unless you have tried to make something like these you cannot appreciate how beautifully made they are. You can see how the thread stops in exactly the same place on each one before it flares into the hex head. The flare is just perfect too.
  9. I love the bit of old blue rope! I am sure all of us have a bit just the same that has done similar duty, either lifting or holding down precious parts. The milling machine looks just the job, something that you needed years ago.
  10. The Polyoxybenzylmethylenglycolanhydride (Bakelite to you and me) knob terminals on the magneto have a melting point of 150C. Not particularly high when in close proximity to the exhaust.
  11. Steve, is your engine running hotter because of the modern petrol? It would be interesting to have an exhaust gas temperature probe in place and try different petrols.
  12. Even the 'return' on the bottom tank seems to have come out well. The work Steve produces is just amazing. We are very fortunate to be able to look at these pages and see the exquisite skill and craftmanship coming out from a shed in a back garden.
  13. Andy, it is probably a 15 horse motor, so a VFD at that rating would be very expensive. Anyway, I believe that Australia is a big place, so you wouldn’t hear the noise of a generator...
  14. Ben, when I have had cast wheels rubbered the tyre bands were not removed but were wound in situ on the wheel and then the whole wheel put into the autoclave. When you had your tyre bands re-rubbered could they accept the tyre band directly or did it have to be mounted on a donor cast wheel? I am under the impression that the conditions for vulcanisation would always be too severe for a wooden wheel.
  15. Andy the profile of the spokes is actually quite complex.
  16. More pictures showing wheel construction. The spokes are not quite parallel sided.
  17. Andy, I am thinking of going to a traditional wheelwright for final assembly but as he makes all his spokes by hand it seems an unnecessary waste of time and money. The same goes for the felloes. Rather than mucking up my VMC with wood dust I am now tending towards commercial CNC routing job shops who have hard wood experience. I need 24 spokes and if Steven joins in that would be 48 spokes.
  18. Maybe rough the spokes on a bandsaw and just use this for finishing. I wouldn’t like to snap it as this price!
  19. Steven, the spokes are parallel at 4 inches wide with the wheel being just over 6 inches wide. I am just preparing some fully dimensioned drawings for you. It did cross. my mind whether CNC routers can run with 4” long cutting tools as one would make short work of the spokes?
  20. One of the great mysteries of these components is that I am convinced that the brake drum was drilled for the coach bolts using the hub as the template and then kept as a pair. The drilling of the hub (even allowing for the difficulty in picking up the true centre of the holes due to the fretting) does not seem up to the usual Dennis precision. When I made an aluminium plate template from one side hub there was no way in which it was going align with the holes in the opposite side hub. More Wheel pictures can be found on this ED810 Flikr page: https://www.flickr.com/gp/asciidv/R9638M
  21. This is one of the actual wheels. At some time the original full width hoop has been removed and two new bands were fitted at either edge of the wheel these bands were then screwed into the wooden wheel. The wheel with the bands was then inserted into the tyre. As it was slack and not a press fit the bands were then edge welded to the hoop of the tyre. To make extra sure that everything was going to hold together coach bolts were then put through the felloes into the actual tyre band and the nuts countersunk into the rubber! All of this was done at least 50 years ago. So the plan being is to have new wheels made with the correct size hoop for a tight press fit into the tyre hoop.
  22. These are pictures of my hubs. The wooden wheel is clamped between the hub which dogs into the drive shaft and the brake drum. On my machine both the holes in the hub and the brake drum had fretted oval so they were drilled out and oversize coach bolts made and fitted
  23. For those following this thread and wonder what it will end up looking like, here is a link to my own similar Dennis; 1914 Dennis 'N' Type You may wonder why there is a preponderance to wheel pictures. This was because Steven is interested in having new wooden wheels made to make his machine authentic.
  24. Ben, I normally use the dry film resist material rather than relying on toner transfer. It certainly is quite tough and allows for long etching times if you need deep etches. I also have had good success with the brass chemical blacking solutions as an alternative to black paint. It will never flake off!
  25. Andy, do you have any facility to grind the balls after they have been turned? I noticed that your lathe has variable speed but the sound from it did not seem to be synchronised with ball diameter only to the start and end of each cutting cycle?
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