International Waters Community

International Waters Gallery

deep groove ball bearing test fixture

Deep-Groove Ball Bearing 001.jpg

13 files, last one added on Sep 06, 2005
Album viewed 188 times

SG gas & SG 80 carbon fiber cowls

Deep-Groove Ball Bearing 057.jpg

8 files, last one added on Sep 16, 2005
Album viewed 102 times

the high price paid for engine building

Engine building 013.jpg

16 files, last one added on Oct 21, 2005
Album viewed 217 times

tuned pipes

Engine building 017.jpg

9 files, last one added on Oct 21, 2005
Album viewed 132 times

boat hardware

Engine building 027.jpg

6 files, last one added on Oct 22, 2005
Album viewed 100 times

machine tools & tooling


31 files, last one added on Nov 20, 2005
Album viewed 277 times

hot wire cutter

Deep-Groove Ball Bearing 066.jpg

6 files, last one added on Nov 24, 2005
Album viewed 81 times

Paul Bugl's hanger piston details

.15 bell valve 006.jpg

3 files, last one added on Jul 16, 2005
Album viewed 106 times

Spray Painting Equipment

paint spraying equipment 010.jpg

10 files, last one added on Mar 02, 2006
Album viewed 77 times

One more way to make a fuel tank

gas tank 017.jpg

17 files, last one added on May 03, 2006
Album viewed 152 times

laping tool, K-67 liners & pistons

liners & pistons 013.jpg

14 files, last one added on Jun 25, 2006
Album viewed 163 times

piston relief areas

piston cut-away 001~1.jpg

6 files, last one added on Jul 19, 2006
Album viewed 118 times

26 albums on 3 page(s) 2

Random files - Jim Allen's Gallery
272 viewsThis compound has been zeroed with an indicator so that its movement is parallel to the lathe carriage movement. It also has its way surfaces ground to give very smooth movement. Accurate rough setting of compound angles can be easily done. Jim Allen
universal crank pin grinding fixture1226 viewsThis fixture is square within .0002 in both axes for a distance of 6 in's. It can be used to grind any crankshaft crank pin hole or any crank pin at any crankshaft throw dimension for split or cantilevered type crankshafts. When used for split cranks, the final assembly is done in a die set. This assures precise alignment of both halves with little effort. Jim Allen
torque cradle 010.jpg
Fan shroud rear view656 viewsThis view shows how the fan shroud is fastened to the rear shaft bearing support. Also notice the rear main shaft bearing mount. Both mounts are aligled bored together. They are doweled pinned & keyed to the 1.000 in thick Blanchard ground base plate.Jim Allen
piston cut-away 001.jpg
machined aluminum piston & steel connecting rod673 viewsNotice the large amount of piston skirt left after cutting the reliefs for the main transfers. This allows pistons to be re-mounted in the lathe if re-cutting for fitting is necessary. Pistons with the entire skirt relieved showed no HP increase as a result of not blocking the boost ports at BDC. A larger skirt area also helps to control piston movements in the axis opposite the wrist pin & crank pin. Also notice in this & the previous photo the relief in the connecting rods bottom end. Two staggered oil slots & the fact that the rod runs in a groove in the crankcase provide ample lubrication. One oil slot is used in the upper end & all slots are .156 long on ODs X .032 wide. ALL INSIDE CORNERS EVERY WHERE HAVE A RADIUS!!Jim Allen
liners & pistons 006.jpg
Lapping tool & liner639 viewsThis liner is smaller by .0008 at the top (.9613) as can be seen by its position on the same lap that was used before.Jim Allen
Deep-Groove Ball Bearing 050.jpg
1557 viewsThe gear ratio is 1 to1 in this setup. The torque & HP are doubled & the rpm's stay the same (minus any gear loses). Properly designed spur gears typically have efficiencies greater then 98% (Dudley"s Gear Handbook; 2nd edition; chapter 12). At the center output shaft the HP is 14.6; the torque 460.8 in oz; & the rpm 32,000. Total weight of the pictured unit is 5 lb 12 ozs. The flywheel has been removed from the center gear for clarity of the gear mesh. Both motors rotate clockwise with custom made inverted drum valves & the propeller shaft rotates counter clockwise allowing the use of available left hand propellers. Full blade area 2170 propellers, with 7.125+ inches average pitch, are being used with this setup! Jim Allen
dynamometer 007.jpg
front view of torque arm & load cell808 viewsThe load cell is mounted on a very rigid one piece machined base. Jim Allen
dynamometer 039.jpg
.156 thick rotor734 viewsThis rotor is the same as the .125 thick rotor mounted in a previous picture. Notice its center has been relieved .015 deep on both sides in order to keep it centered inside the dyno housing & also keep the .250 thick clamping hubs in the same position. By using pockets, rather than holes, & alternating pocket locations from side to side, (the reason for the two dowel pin locations) a total of 48 pockets can be machined in the rotor faces. With a .125 thick rotor mounted, the clearance from the rotor face to the housing inside face is .0312 in. With a .1562 thick rotor mounted, the clearance is .0156 in. Jim Allen
torque cradle 006.jpg
Dynamax fan1039 viewsAt present, a Dynamax fan is used as the loading device. The load is varied by closing off the front of the shroud with different size air intake restrictors. A new loading device is being machined from aluminum to allow safe operation at 40,000 rpm. Also, a new load cell will be added, to make torque readings easy. At present, the pointer & scale indicate the torque amount.Jim Allen
liners & pistons 012.jpg
Machined pistons & K-67 stock piston700 viewsThe four pistons on the left are machined from RSP Technology 30 % silicon alluminum alloy # RSA 444. Diamond tooling including drills, end mills, boring bars, & lathe tool bits make it possible to achieve a very smooth finish. The piston on the right is a stock piston.Jim Allen

Last additions - Jim Allen's Gallery
787 viewsCompleted pieces are all interchangeable & after mounting to the flywheel are within +-.0002 concentricity 1.000 in from the split collets face. The same type of a flanged piece with six mounting holes is made when I set up ball and pin universals for solid shaft applications. When using the solid shaft method the thrust is driven up the entire shaft into the engine by using hardened thrust washers between the ball ends & there sloted ends. Jim AllenSep 27, 2007
658 viewsThese spring steel washers will prevent any galling of the clamping nut, even when it is tightened with great force.Jim AllenSep 27, 2007
676 viewsMachine an arbor; fasten pieces securely; machine the OD with carbide. Finished washers have no burs on the OD or ID & are very precise.Jim AllenSep 27, 2007
466 viewsJim AllenSep 27, 2007
581 viewsAfter clamping .010 thick spring steel pieces between two aluminum pieces, they are machined square to a convienent size. Boring with carbide gives a clean hole without burs. Jim AllenSep 27, 2007
589 viewsThis photo shows the locking nut being singled pointed internally. This piece does not have to be hardened because it will ride against the spring steel washer when tightening the split collet. It is made of #316 stainless steel.Jim AllenSep 27, 2007
545 viewsThe collet holding fixture is made of #316 stainless steel & is not hardened. Jim AllenSep 27, 2007
523 viewsThe split collets are ground internally while being held in the fixture directly above them. External grinding was proved to be un-necessary.Jim AllenSep 27, 2007
635 viewsThis photo shows the back ends of the split collets being ground square to their ID's. This is done in a Suburban Tool Master-Grind. (+-.00005 spindle runout) The split collets are wrung onto a hardened indicated gage pin for this operation.Jim AllenSep 27, 2007
935 viewsTwo 6-32 SHCS, a precisely machined steel hub on the flywheel face (.5002 OD) & a flange on the tapered sleeve which has a 1.125 in OD (.5000 ID), ensures positive location of the tapered sleeve each time it is mounted. The hub is #316 stainless steel & is shrunk into the flywheel before final machining. Notice the six bolt hole pattern used on the tapered sleeve's flange. This feature allows automatic positioning of the propeller to a horizontal position if the engine should stop suddenly at wide open throttle & prevents the hull from diving! It is used on solid drive shaft setups.Jim AllenSep 27, 2007