MEG steam Wendy Reconstuction

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skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Ok Wendy fans got the top blocks of the cylinders made today, there a little large yet for machining but there in place, will mount the rotary table tomorrow to machine a notch in them and then there off to the welder.

Thats it for now
Matt
Attachments
INBOARD SIDE
INBOARD SIDE
OUTBOARD SIDE
OUTBOARD SIDE
PORT FACE
PORT FACE
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Bill Shields
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Re: MEG steam Wendy Reconstuction

Post by Bill Shields »

Looks really nice...well thought out

Question

Is the finished valve port face going to be steel?
Too many things going on to bother listing them.
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

The plan at the moment is that they will be steel with a cast iron valve, maybe bronze. But I have an option that i could put a cast iron plate on top of this and have it ground, the old stationary engines did this so a worn surface could be renewed on the ports could be changed might look at that.
Matt
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Hi Wendy fans
I set up the rotary table today and machined a groove in the end of the cylinders so they can be welded, i got one done today and that will be it until next weekend
Matt
Attachments
SETTING UP ROTARY TABLE TO CUT WELD GROOVE
SETTING UP ROTARY TABLE TO CUT WELD GROOVE
FINISHED GROOVE
FINISHED GROOVE
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Bill Shields
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Re: MEG steam Wendy Reconstuction

Post by Bill Shields »

Like the valve plate idea.

Used phosphor bronze plate for my valve surface since it silver solders well.

Doubt I will live long enough to see it wear out.
Too many things going on to bother listing them.
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Hi Bill
I'm kind of fawned of the plate idea myself makes porting easier, how thick is you plate.
Matt
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Bill Shields
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Re: MEG steam Wendy Reconstuction

Post by Bill Shields »

Well...1/4"....but then the plate is silver soldered into the cylinder assy as one piece...

Construct is a bit different than yours but the plate concept holds true.

Look closely at the bottom of the valve chest. The dark strip is phos bronze which is actually a structural part of the assy silver soldered into place, thereby sealing the passages from each other
20201230_122113.jpg
The entire assembly is silver soldered steel & phos bronze sandwich with a bronze liner slipped into the cyl bore, sealed with o-rings as needed. It will eventually rust into place, but has a lot of wall to allow for eventual rebore by the next owner's grandson.

I do not have your welding skills (not in my wildest dreams even 40 years ago when eyes were good and hands did not shake could I have done what I see you doing).

I would take hat off if not worried about sunburn on bald head
Too many things going on to bother listing them.
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Hello Wendy fans:
I got the cylinder blocks off to the welder, so I turned to the wheels, I set up spindle to mount the wheels on the rotary and started cutting the spokes down at the outer rim, i got all four done to this point and set up to start the inner cut but had to call it quits for the day (Life got in the way)
Well, that's about it for now
Matt
Attachments
SETT UP TO MACHINE OUTER RIM STEP ONE
SETT UP TO MACHINE OUTER RIM STEP ONE
FIRST ONE DOWN THREE TO GO
FIRST ONE DOWN THREE TO GO
ALL DONE READY FOR STEP TWO
ALL DONE READY FOR STEP TWO
SETTING UP TO CUT INNER HUB AT SPOKE STEP TWO
SETTING UP TO CUT INNER HUB AT SPOKE STEP TWO
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Hi Wendy fans:
Not much to report this week. I did get the cylinders back from welding and now i have lots of mill work on them.

Matt
Attachments
Cylinder weld 1
Cylinder weld 1
Cylinder weld 2
Cylinder weld 2
Cylinder weld 3
Cylinder weld 3
Last edited by rmac on Thu Aug 04, 2022 2:02 pm, edited 1 time in total.
Reason: Photo Orientation
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Hello Wendy fans:
I finished machining the spokes as far as I can for now, need to get the crank pin hole drilled so I can cut the top of the hub around the pin for the spoke, the next step is to use a die grinder and shape the spokes, round them off and smooth everything together. I used a 1/2" ball end mill around the outer ring and inner hub this will match the radius cut on the sides of the spoke, so they just need smoothed out. Next, I'm going to start machining the cylinders
Thats it for now
Matt
Attachments
FIRST WHEEL STEP TWO
FIRST WHEEL STEP TWO
STEP TWO DONE
STEP TWO DONE
REMOVING MATERIAL BETWEEN THE RADIUS CUTS
REMOVING MATERIAL BETWEEN THE RADIUS CUTS
STEP THREE DONE
STEP THREE DONE
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Hi Wendy fans:
Made some progress on the cylinders yesterday and today. I machined the valve face first with a fly cutter, I had to make two passes because of the width but it is going to get a surface plate on it, so the finish is not super critical. But I can have it ground if needed. I found that I was off by about 0.30 degrees from the valve surface to the side that mounts them to the frame, so I started buy re-shimming and cutting the top. Then i took down the set up and cleaned the mill for set up two. I clamped a 90-degree plate to the table and mounted the cylinder block to it, I squared it up with the cylinder wall then checked the plate that was going to be milled both read 0.00 degrees after adding some shims to hold it there I clamped it in place, the left side was straight forward but the right was a fun mess, nightmare came to mind. but it worked very well and there starting to look like proper cylinder blocks. Next week all get the second one done and start the third side.

Thats it for now.
Matt
Attachments
cylinder set up to mill
cylinder set up to mill
first cylinder port face almost done
first cylinder port face almost done
port face shimmed to recut
port face shimmed to recut
squaring up to cylinder pipe
squaring up to cylinder pipe
checking the face to machine
checking the face to machine
set up left side
set up left side
skyloop440
Posts: 126
Joined: Wed Mar 13, 2019 5:23 pm
Location: colorado

Re: MEG steam Wendy Reconstuction

Post by skyloop440 »

Hers a few more pictures
Matt
Attachments
right side clamp
right side clamp
final cut
final cut
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