mills 1.3cc diesel engine crankshaft bushes mikes-models

9th April 2008 session 1

Whilst waiting for the reamer required for the bushes, I started on the
cylinder liner. I am making a practice one as I did for the crankcase. I made
this decision before mucking it up, honest!

In Ron's article he explains very well the honing procedure. Since I hadn't
any diamond paste [see photo 1 below] I searched on eBay and was very
surprised at the cost of the paste in the UK. Some retailers selling it for as
much as Ł8 per grade stored in a syringe! I bought mine from Hong Kong
for Łx including shipping to the UK and two packets containg 12 syringes,
arrived just yesterday.

So armed with this new resource I will start the Mills project again next
Monday [the 14th April 2008] body permitting.

26th April 2008 session 2

After another long lay off I finally got back to re comencing the cylinder liner
rebuild! I decided to make the cylinder liner from the start and ignoring the
'practice' one made earlier.

The first task was to chuck the 1" diameter steel bar which I turned down to
the required diameter, leaving a flange. I then reversed the bar and turned
down waht will be the top of the liner.

After centre drilling and opening out with three drills I carried on and bored
the liner to the required .406" and the boring was achieved slowly, but to
exactly 0.406 which was very pleasing. I used my new set of bore gauges,
which proved very valuable, certainly making the task easier than before
[please see photo] and thats as far as I have gone to date,

4th May 2008 session 3

It was just a short session today where I spent most of the
time in setting up the milling machine and vertex for the
milling of the cylinder liner. I didn't get as far as I wanted
because concentration seemed to be going and it was
getting close to critical work.

After getting the Vertex secured squarley to the mill bed
and ensuring the liner was parallel, I started to cut the 4
flats required. I decided that I would do it in two passes.
The first to get them near the 0.0750 required and bringing
to final size on the second pass.

It was when checking the sizes I was surprised that one set were near to size
whilst the second set was 50 thou out! This shouldn't have happened and the
cause I tracked down to not tightening the ER25 collett up, the mill cutter
slipping down. So as a little calcualtion will be required to bring the flats not
only to size but also central. So I decided to leave it untill
tomorrow.....again. The set up on the milling table is shown by the photo's
on the left.