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Read my ramblings
about the build of the
6" Scale Mc
Laren Road Loco
Part one
of the 6" Scale Mc Laren Road Loco build diary
Introduction
When we were children back in the early
sixties Dad bought my brother Rodney and I a part built twin cylinder
freelance 1” traction engine. We did not have the required tools
or experience to complete the engine. Dad was told of an engineer
who could help us by completing the engine. This was completed with
the help of an engineer from Staunton on Wye named Jack Phillips.
My Father contacted Jack by letter and a meeting was arranged.
We arranged to meet Jack by the post
box at Staunton on Wye, Jack told us it would be easier if he took
us to his house. Indeed it was we walked across two fields and several
hedges until we came upon a remote cottage, Jacks Home. What an amazing
place, all of the lathes milling and drilling and grinding was powered
by foot using specially made treadle units. There was no electric.
Jack showed us a beautiful one-inch scale showman’s engine he
was building. We left the engine with Jack for several weeks. When
we collected it Jack demonstrated the engine running, again foot power
was used on an old car foot pump. Jack’s other talents were
enormous, he would repair piano accordions radio’s etc. He could
also play the accordion and a small pedal powered church organ that
he had in his living room.
Following the completion of the engine
by Jack the family was hooked on steam engineering. Both my brother
and I would often attend the Ross on Wye steam engine rally with the
engine. It was around 11/2” scale and would pull a couple of
adults. We would take it in turns driving the engine around the rally
field at the ages of 12 and 13. Other times at the rally I would assist
a small stationary engine steam show presented by a welsh man named
Bob Page. Bob would let me oil the stationary engines etc and put
coal on the vertical boiler. He was such a kind man.
Dad bought a Myford lathe in the late sixties and started building
a 5” Simplex locomotive to a design from Martin Evans that was
featured in the “Model Engineer” at that time. Some time
later Rod started building a 31/2” Rob Roy Caledonian tank engine.
Both Dad and Rod went on to complete their engines. Dad later built
a 5-inch GWR Manor locomotive and a four inch Foster Traction engine.
Rod later built a three-inch and four-inch traction engine followed
by a couple of railway engines. His latest engine was the excellent
six-inch Burrell Scenic Showman’s engine called Snapdragon.
Old Glory did a fine article on this in the mid 1990s.
Snapdragon
(built by Rod)
During my teenage years I would often
steer a Steam tractor owned by the late Derrick Hackett who had a
large collection of steam tractors at Ross on Wye. Dai Morgan the
undertaker from Pontrialas would drive the engine and I would steer.
Several times we went from Ross on Wye to the Bromyard Gala and back
towing the typical green living van to sleep in because it was a two-day
event. I recall the travelling speed was around ten miles an hour.
Collecting water en route was interesting, as was the ploughman’s
lunch at the pub on the way.
Steering a full size tractor was quite
hard but also interesting. The tendency to over steer is hard to conquer,
eventually after much prompting by Dai I found that playing with the
slack in the steering chain was enough to keep us on the road. After
a while you tended to loose concentration, Dai told me that it was
easy for him to notice because the chimney would start weaving from
side to side. He usually gave a gentle prod with his elbow to cure
the steering problems. These days were very memorable, I was fortunate
to have such experience.
I believe the engine I drove was an ex
Herefordshire council Aveling and Porter road loco. Maybe someone
could verify this. Also where is the engine now? I know it survived
into preservation. It would be nice to see the engine again. I recall
the road speed was about 10 miles per hour.
Amendment to Diary,
Thanks to the kind e mail I received from Mr Hedwin Jones I now know
more information about the Aveling Traction Engine I used to drive.
Mr Stuart Gray now owns it and I believe the engine is based in Hitchin
Hertfordshire.
Reproduced with courtesy of Steam-up.co.uk
is the following photo and information for the engine.

1920 Aveling & Porter 4 nhp Colonial Steam Tractor
- Clementine
Aveling & Porter Steam Ltd
1920 Aveling & Porter 4 nhp Colonial Steam Tractor - Clementine
Works No. 9225. Reg. No. CJ 4160
The colonial tractor was a class of engine built by several engine
manufacturers to satisfy a demand in the Colonies for road haulage
tractors of a heavier than normal construction and with the ability
to burn a wider range of fuels than the engines made for the home
market. This road tractor was new to Hereford County Council and was
one of three similar engines supplied to them; all three of which
are preserved and regularly seen at rallies today. Clementine was
used on council business until 1939, hauling road building materials,
etc. From 1939 until the mid 1950s she was used commercially, primarily
for threshing, in Herefordshire but was then laid-up until sold for
preservation under the name "Hereford Belle". Following
an early attempt at a showman's conversion she was restored to her
original condltion and is now presented as an authentic example of
a very popular engine, particularly liked by those who had the fortune
to drive them. By traction engine standards these steam tractors are
fast on the road, travelling at about 12 m.p.h. on the level, and
were advertised, rather optimistically, as capable of pulling a load
of about 10 tons.
My first attempt at model engineering
was a 3” traction engine to the design of HR Plastow. This model
was later completed by Rod. Eventually in the early eighties I managed
to set up my own workshop and built a 71/4 “ 0-6-0 Holmside
tank engine. This was the first engine I had built and completed and
was extremely happy to own my own steam locomotive. I bought the copper
boiler and fittings, which allowed quick build time of nine months
from, start to finish.

Holmside 7-1/4” Tank Locomotive
(By Colin Dix 1983)
The second engine that I built was a
5” Royal Scot Rebuilt painted in LMS 1946 black livery with
red and straw coloured lining. This locomotive won a Sliver medal
and the Crebin memorial cup at the 1989 Alexandria Palace model engineering
Exhibition. This was an extremely rewarding model to build, I got
a great deal of satisfaction during the construction and completion
of the model.

5” Gauge
Royal Scott Locomotiv
(By
Colin Dix 1988)
A period of ten years passed with my
departure from this type of engineering due to work and travel commitments.
I decided to build a Road Locomotive, the bigger the engine the better
it would be in my opinion. I have young children and grandchildren
who I would love to see driving such an engine and getting the same
pleasure as Rod and I did at such an early age. A large engine would
allow us all to ride on it maybe?
Mc Laren Build Diary
I contacted Alf Franklin and Wayne Bell
at Franklin and Bell the boiler makers in Gloucester. Alf and Wayne
had built 4” Foster boilers for dad and I. Alf and Wayne pointed
me in the right direction and I made contact with Mick Beadle at Double
B designs. Dealing with Mick was interesting, after discussing the
vital statistics of their half scale Maclaren road locomotive Mick
kindly sent me some drawings completely free of charge and without
commitment. I had left England to work in Asia before they had arrived,
the drawings were hand carried out to Japan by a colleague of mine.
Several weeks of drooling over the drawings
resulted in me placing an order with Double B Designs for enough materials
to stand the engine on its wheels including the smokebox and chimney.
Adding the tender to this would let me see in advance how wonderfully
large the engine will be.
Mick delivered the materials to my home
on 17 December, building work commenced the next day. The front and
rear wheel rims were welded and the hubs machined. In parallel with
my work the pre-prepared boiler kit was being assembled at Franklin
and Bell in Gloucester. During the Christmas holiday the front and
rear hubs were faced ready for slotting the spoke recess.
Full size traction engine wheels were
usually built by casting the iron hub over the spoke and rim assembly.
This used to allow the hub to be bored and finished to complete the
wheel. This is not practical in model engineering and the wheels are
generally made up from several parts. The Rims are rolled from strip
and welded, the tee rings are usually strip rolled on edge. All this
is then assembled by welding the tee rings in the outer rim.

Welded Rims Hubs & Rims
I wanted to fit rubber tyres to the engine
to allow quiet running on the roads. I had a 40 mm layer of rubber
vulcanised to all four of the rims. This was only rough trimmed after
vulcanising. More about the final finish of this later
The hubs on the Mc Laren are made up
from three parts, outer cover, inner hub and inner cover. Double B
care has been taken to follow how the full size wheel will look when
completed. The front inner hubs and covers are machined at an angle
to allow the spokes to point directly at the tee ring without bending
the spoke where it leaves the hubs.
These front hubs were machined on a large
centre lathe with a long cross slide. This allowed me to set the compound
slide to the cutting angle and cut both the inner hubs and covers
with the same angular setting. The hubs were machined with the lathe
running backwards, the cover plates were done running forward. This
used quite a lot of travel, as you would expect. The castings provided
by Double B Designs were of excellent quality and were easily machined.
The slots for the spokes were also cut at the same angle, this was
done in a large milling machine using a rotary table packed up at
the correct angle. I was glad when the final slot was cut due to the
fear of the whole setup moving.

Front Hub on Angled rotary
table
The horn plates were drilled ready to
accept the boiler using a large universal milling machine. Dummy rivets
were added to the horns to recreate the effect of a fully riveted
boiler. The belly tank mountings and ash pan brackets were added.
The Boiler was completed and tested by early march. I had the large
inner-outer firebox stays machined accurately to the boiler tube.
The horn plates are the mountings for the three rotating shafts and
need to be as accurate as possible.

Completed and Tested Boiler
(With Tony Bell, Wayne Bell,
Alf Franklin, John Gage)
Fitting the horn plates to the boiler
was quite a task. The boiler was packed up on a flat table and the
plates accurately located to drill and tap the threaded holes into
the firebox stays. When this was done I noticed the horn plates were
not flat! How would I straighten a piece of 8 mm plate nearly one
metre square?
My method of straightening them was quite
unique. I had a Nuffield 4/65 tractor parked in my back yard which
I believed weighed around two tons. I placed the horn plates onto
a large block and a trolley jack below the tractor tow bar and used
the tow bar as a cantilever. I found that after jacking up the plate
until both wheels of the tractor were off the ground I did not have
enough weight to completely straighten them. Eventually I got them
straightened by standing on the back end of the tractor and bouncing
the tractor up and down, all balancing on a trolley jack! Hell what
a task!
Laser cut parts for the tender sides
and belly tank was obtained. Again the design of the tender follows
the original very accurately. The brake shaft is supported by a casting,
which has flanges that attach to the tender sides. This casting was
nicely cored out to allow the shaft to pass through. The inner and
outer flanges are machined to fit the width of the tender.
tender brake shaft.
The Coal tubs were made up from rolled
components and a laser cut disc. I think the bottom of the tub on
the original was a dished plate pressed from steel. To re-create this
effect I welded the laser cut disc into a rolled section of 40 x 6
mild steel. The weld was dressed with an angle grinder then the disc
was placed into a centre lathe and the outer diameter and radius was
cut. This base was a nice fit into the steel cylinders that make up
the tubs. Lots of 3/16” and ¼” rivets attach the
base and reinforcing ring to the tubs.

Rollings for
Tubs

Complete Coal Tubs
One needs to be fairly athletic to build
an engine of this size, every single part of it is large and heavy.
While assembling the rear wheels I had to turn them over on the workbench,
It took all the strength of my neibour Trevor and I to turn the wheel
over, even then I thought it was very dangerous due to the weight.

Rear wheel during assembly with one side of
spokes fitted
Additional weight is then added when
the outer covers are added along with the massive final drive gears.
Bending the spokes for the wheels was done in a fly-press with a home
made jig. This allowed me to get all the spokes bent to the correct
angle with the same radii on each bend. Taking care during the build
is essential when you are expecting a first class representation of
the full size engine. And of course you want the wheel to run nicely!
There are casting available for the
gears, all casting are truly authentic in appearance. To make these
into a set of gears is simply a matter of turning the casting to the
finished size and get your local gear-cutting engineer cut them. Five
of the gears have 1-7/8” squares cut into them. This is to allow
them to slide on shafts for engaging the required gear. The squares
were cut with wire spark erosion.

Second Shaft With 2nd &
3rd sliding Gears
Spark erosion produces a highly accurate
cut to which the squares on the shafts could be matched. The Mc Laren
has three speeds, High, Medium and Low. To shift the gears into mesh
the gearshift is done with three rack and pinions. Most gear cutting
engineering company’s like to cut gear racks with teeth continuously
along the length. For the racks in this engine we only need 6 and
seven teeth. Also only five and six teeth on the pinions. Double B
cut the rack and pinion gears for me and saved me a great deal of
trouble.
The Mc Laren is a three-shaft engine.
This is the number of rotating shafts to the final drive on the rear
wheels. Three shaft engines rotate backwards to travel forward. The
three bearing housings, Crankshaft, second and third all needed line
boring to allow for any misalignment of the hornplates. I could not
find an adjustable reamer that was long enough for the jobs so I improvised
and tried a boring bar driven with a powerful electric hand drill.
I prepared tapered cones to locate the boring shaft centrally within
the pre-bored bearing housings. After all I only need to take out
30 thou. I found this worked quite well as long as light cuts were
taken. The shape of the cutter was important too. The cutter was a
nice radiused tool that cut smoothly without digging in.

Improvised in-line Boring Bar
The Mother of all Crankshafts
When I started the build in December
2002 Mick Beadle (from Double B) told me they were still working to
complete the detailing, casting patterns and design of this model.
It looked like a mammoth task to accomplice, especially with me travelling
to work abroad some ten times or more, and usually for two to three
weeks at a time each year.
During the build period I managed to
catch up and be in front of the design team at Double B. I used to
call Mick from Asia and ask what new castings were released. When
patterns were ready Mick would soon have me a set of castings. On
my return the castings would be machined and fitted to the engine
in double quick time. Mick would often joke with me by saying “I
will be glad when you go away again so I can get some peace and quiet”.
Unfortunately Mick passed away in 2002.
Double B Designs still continued with the design of the fabulous “6
Mc Laren. By January 2002, the only major components I needed to complete
the engine were the Cylinder Block and Crankshaft. Terry Baxter from
Double B gave a delivery date for the cylinder for Easter 2003. I
though it would be nice to have the crank fitted with the flywheel,
drive gears, eccentric’s etc in preparation. So the mother of
all tasks was about to start. I decided to cut the Crank from Solid.

The late Mick Beadle during
one of his delivery visit’s
The choice of steel for the crank had
to be En40b. En40b is Chrome Vanadium Nitriding steel that has core
strength of 55-65 Tons per square inch. Additionally the Nitriding
process adds a surface hardening of superior quality. Most Competition
or Racing engines used in Motor Sport use this material due to its
quality.
The steel as a billet was 220 mm diameter
(9 inches) by 1456 mm (37 inches) long and weighed a calculated 281
Kgs. This was far too heavy for me to machine. I decided to get the
billet supplied and machined by a local Company in the Forest of Dean
called JM Grail Engineering.
Grails used CNC machining to reduce the
billet to the form shown below in the photo of the part mounted in
the improvised bandsaw.
The profiled crank billet was still a two-man task to carry it or
lift it into the boot of the car. En40b is really tough steel to machine.
I decided that standing by a milling machine to reduce the two centre
parts to form the crank webs and crank pins would not be a good use
of my time. So I decided to try and improvise my 4-inch hobby band
saw to allow it to cut of the large lumps of surplus metal. The top
lift part of the saw was removed and mounted onto a large frame that
allowed me to stand the crank vertically and saw chunks of metal away.

Surplus metal removal with improvised
bandsaw
This proved to be very successful. It
allowed me to continue with other workshop tasks allowing the saw
to slowly cut away on it’s own. Removing the excess metal took
two whole days with the bandsaw. I later found out that this was a
good investment in saving milling cutters etc.
One item on a crankshaft that can cause
concern is how to form the crank pins and hold the metal for machining.
To allow the correct orientation of the crank pins I had arranged
two full diameter flanges each end of the billet with four one inch
holes positioned at 90 degrees to the centre. (See fig 1). These would
be used as reference for the crank webs and later to form the crank
pins. The billet was mounted in the milling machine vice and positioned
in preparation for machining.
The first task was to machine the crankshaft
webs. These are at 90 degrees on this engine with the Low-pressure
crank pin leading in forward gear. This was my first attempt at machining
En40b. Wow this was tough stuff to cut. The milling cutter used was
a replaceable insert Tungsten Carbide cutter. I soon found that the
life of the cutter was quite short, even with copious amounts of cutting
fluid.

Cutting Crank webs with milling machine
I decided that I should leave the crank
pins and shaft diameters 3mm (“1/8) oversize at this stage because
of the risk of distortion due to the inherent stresses in the material.
After completely roughing out the crank the billet was sent for stress
relieving. The billet was supported inside a large oven and heated
to 550 centigrade for four hours. Followed by slow natural cooling.

Crank mounted
to machine the crankpins
My nice shiny billet was as black as
coal. To machine the crank pins I used a large rotary table mounted
on it’s side on the bed of the milling machine to bolt one end
of the crank (flange). The other end was supported using a ball bearing
race (one inch bore) mounded in a steel support on an angle plate.
This allowed me to rotate and mill the crank pins and finish the inner
face of the crank webs. This was an interesting job, it was nice to
see the crank pins slowly appear in the webs. I left the crank pins
ten thousands of an inch oversize for grinding. The crankshaft was
removed from the mill and re-mounted in preparation for machining
the other crank pin.
Removal of Large redundant Flanges
after machining
Following the machining of the crankpins
the large flanges at each end of the crank was no longer required.
These were cut off using the bandsaw. The ends of the crank were machined
clean following this.
The crankshaft was delivered to Moss Engineering at Ledbury. Mr. Moss
the proprietor has had many years of refurbishing combustion engine
components. He was quite intrigued to find a new crankshaft for a
half size traction engine. The crank pins were finish ground to two
inches diameter using a standard crankshaft-grinding machine.
The final details of the crank were added,
this was various diameters to locate the eccentrics, drive gears and
flywheel along with a “1-7/8 square for bottom gear on the off
side. The square was draw filled to allow a good fit on the pre-machined
low gear. All of these shaft diameters were left 0.012 thou oversize
for finish grinding. The shaft was finish ground to size by CRI Grinding
in Gloucester. To complete the crankshaft I added three keyway’s
to the shaft. These are used for the Medium and High Gear sprocket.
Both of these were cut including the slot for the Flywheel Key.
To sum up the work in weight of metal
removed, the stock bar was 281 Kgs (618 lbs.) The finished crank weighs
only 27.3 Kgs (60.2 lbs.) or about 1/2 CWT. Well in reality were talking
about the weight of ten bags of spuds converted into swarf or just
surplus chunks. I now have my crankshaft ready to fit the valve gear
eccentric’s. Drive gears, balance weight and flywheel. More
of that later!

Partially completed crank ready
for Grinding
August 2003 progress update!
A lot of water has passed under the bridge
recently and not much progress has happened following the completion
of the crankshaft. However I have recieved the cylinder block casting
and now it is machined. I still have to machine the slide valves and
make the exhaust pipe flange to complete this assembly.
The block was machined using the Kearn's
boring machine at Allen's workshop. The black was mounted on its side
and the casting was adjusted until it was square and perpendicular
to the table. The first operation was to machine the top surface.
Following the machining of the top surface the cylinder was mounted
on this nicely machined surface. This allowed the block to be securely
clamped to the table and set up to allow machining on the two cylinder
bores, the boiler mounting radius and the front face to mount the
trunk guides and front covers. This is a good way of ensuring all
the bores are inline!

Cylinder mounted during machining
(Apoligies for the mess of tools,
this is a busy operation, note the WD40, do you know this is an excellant
lubrication for threading cast iron. It prevents tearing of the material
as the thread is produced!)
In this photo the bores and boiler mounting
radius has been machined. The table on the Kearn's will rotate and
index accurately. The table is moved after this operation to allow
the slide valve faces to be machined along with the front cover face.
The holes for mounting the trunk guides were added using calculated
cordinates, moving the table until the the digital Readout indicated
the correct position then drill the holes etc. This allowed all holes
to be in the correct position without marking out errors.
Following the machining of the block
all of the holes had to be threaded and studs made for all of the
many positions used. This is 32 off for the valve covers, 32 for the
cylinder covers and 12 for the glands. I like to have a nice coarse
thread in the cast iron for strength and a finer thread for the fastner.
For this I used M6, M8 & M10 for the studs that were threaded
into the cast iron. M8 will quite easily take a 5/16 UNF thread, likewise
M10 will turn down and allow 3/8" UNF. I used this policy for
the cylinder block.

Cylinder top view showing partially
manufactured studs with M10 thread, 3/8UNF to be added later
In this view you can see how the trunk
guides have flanges cut away to allow them to sit at the cylinder
centres. The top horizontal urfaces need covering with a sheet steel
to represent the lagging. The safety valve chimney mounting studs
were spotfaced to allow the nuts to sit square to the mounting surface
and not bind on the casting draft.

Cylinder with Trunk guides
The Trunk guides were a tough job to
machine, I mounted the trunk guides in a pair of vee blocks to machine
them. This seemed a nice idea, the trunks were supplied with the sides
that are hollow section filled in to a thickness of around 1/8".
This was done to support the pattern for stability. Anyway, when this
is machined clear the trunk guides are quite vunerable to distortion
from any external clamping forces. I completly machined the trunk
guides only to find that after releasing them from the worktable they
had moved and ther nice fit I had for the crossheads was now a poor
fit by several thousands of an inch. I rectified this problem by machining
the crossheas to allow a circular brass slipper that can be adjusted
with shims just like the full size engines. this can be seen in the
following photo.

Crosshead with Bronze slipper
fitted!
The trunk guides needed boring slightly
oversize to allow the new arrangement to work. I had to ensure this
time that the trunk guides were perfectly square and surported without
distortion. To do this I machined a split clamp that would clamp on
the free end of the trunk guide where the conrod comes out. This would
allow me to clamp the end of the guide and apply a completly circular
force to support the end while I passed the cutter through. The cylinder
cover end was mounted on an angle plate that had a machined locating
boss. This boring machine was centred on this boss using a Dial Test
Indicater. The trunk was fitted over this then surported with the
clamp. A light cut was machined out of the casting to allow the bronze
slippered crosshead to fit snugly. Later lubrication grooves were
cut into the bronze slippers to allow the oil to collect to provide
good lubrication.
Two Photo's showing the trunk guides
remounted as described above to re machine the bores without causing
mechanical distortion by clamping. In the right hand photo one can
see the angle plate has been lightly faced after mounting to allow
the trunk to be perpendicular to the boring bar, the centring pad
is just visible too.

Front View of the cylinder block
assembly

Bits 'n' pieces waiting to be
fitted or machined, Big End Bronze, Front Wheel Cover, Slide valves,
Rear cylinder covers, Boiler clacks and Crossheads
The conecting rods were machined from
solid. The stock material was 3" En8 round bar. The tapered profile
was turned and the corner radii was produced using HSS radius tools.
The bar was 18" inches long, After turning the bar was mounted
in the mill to machine the flat sections and cut out the pocket for
the little end bearing.

Partially turned blank for Conrod
I decided to add adjustable small end
bearings to my conrods. This entailed making three parts comprising
of a Phospher bronze bush, adjusting block and wedge. The phospher
bronze bush was machined out to allow the adjusting block to fit snugly.

Completed Conrod with adjustable
little end bearing
These two parts and the adjusting wedge
were pressed into the little end. The conrod little end bronze was
then bored out to fit the crosshead pin. The next job to be done is
to make the pistons and straps for the conrods. This will allow the
cylinder block to be positioned onto the boiler in its final resting
place.

Crank Fited to the Engine with
balance weight, eccentrics and drive gears
When I thought the crank was complete
I tried to fit the low gear to the 1-7/8" square. I found the
square to be some twenty though oversize. This was a pain as I had
already fitted the balance weight and eccentrics to the shaft. Well
Ihad to machine this small amount away to allow the Low pressure eccentrics
to fit over the square. The completed crank was mounted into the cente
lathe to machine off the excess. As you can imagine it don't take
long for the boy to come out in us and see how well the balance weight
works? I managed to run the crank at 1000 RPM without any noticable
vibration during machining. Nice one from Mick Beadle and Bill Kiddell
for getting the design right. Only my lack of courage and the need
to complete the task prevented me from testing it faster!

More bits, Valve rod's and eccentrics
etc including the wayshaft bracket!
The eccntric valve rods were also cut
from solid bar. I used En32b case harding steel for the valve rods.
This material is nice and easy to machine but will case harden to
a really tough surface that will be hard wearing and last for many
years without refurbishment. This is another case of starting with
a 2.5 inch bar and machining most of the material away until you have
the complete part.

Wire Spark Erroded Expansion
link
Terry Baxter at Double B Designs supplied
the wire spark erroded exspansion links. This is a very accurate process
that cuts parts to finished dimensions without any additional work.
In the photo the link looks quite small. In fact it is cut from 3/4"
steel plate and is over seven inches long!

Lifting Arms for the valve gear
I considered turning the lifting arms
for the valve gear using specially ground form tools. Then would I
get the centres right? This could cause a problem with unequal valve
timing. I decided to have the turned profile machined with a CNC lathe.
This would make all three identical and allow me to machine the flats,
drillholes and add Keyways to complete them. I insisted that the turned
section should be left attached to the stock bar with a square face.
I could use an edge finder on the milling machine to determin the
correct centres in the spherical turnings. When complete the end view
would be presented concentric and looking good! The lifting arms were
made from En32b. The ends will be case hardned after the valve gear
is trial assembled. The keyway slots had to be accurately positioned.
If one link lifted more than the other this would cause uneven valve
timing. I trusted this process to the expert services onf a company
in Malvern.

Boiler Clack Valve
The boiler clack valves were supplied
as bronze castings. These castings were gripped using a four jaw chuck
to perform the various machining operations. The supply to the boiler
is through a 7/16" valve seat. The valve is actually a 9/16"
diameter stainless steel ball. A tapered shut of cock is also a feature
on this part. To cut the seat I machined the two stainless cock plugs
and a piece of silver steel without moving the angle setting of the
compound slide on the lathe. This method allow you to get the angle
on the finished part the same as the tapered hole you will machine
later. To make the silver steel part in to a D bit is quite simple,
half of the tapered section is machined away. A small relief is added
to the cutting edge then the part is hardened and tempered to a nice
straw colour.

View showing Low Gear assembly
with Rack and Pinnion
This article
is under continual development. Call back later to see how the engine
is progressing!
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