International Waters Community

International Waters Gallery

Another pit box idea

pit box 006.jpg

6 files, last one added on Jul 22, 2006
Album viewed 42 times

precision cable collet assembly


58 files, last one added on Sep 27, 2007
Album viewed 180 times

26 albums on 3 page(s) 3

Random files - Jim Allen's Gallery
Deep-Groove Ball Bearing 006.jpg
362 viewsIn this picture the bearing has been rotated 90 degrees while the anvil was locked. The red mark is at the three o'clock position. The anvil is then released & another reading is taken. Notice the indicator is now reading .0008 while the pressure pad is applying pressure.Jim Allen
389 viewsThe first four sections of the tuned pipe fitted together.Jim Allen
Engine building 027.jpg
Kalfus rudder mechanism479 viewsThis unique mechanism allowed a straight line movement of the .1875 hard steel rod on the right hand side to move the rudder. This rod was guided by the horizontal piece (on the right) seen in the picture & a bushing mounted in the transom. As the rod is moved for & aft, the crossover clamping piece moves the rudder through the two pivots seen on the left. Notice that the rod is always pulling to activate right rudder. All parts, including the pivot screws, are made of full hard O-1 tool steel. Jim Allen
liners & pistons 007.jpg
Lapping tool & liner533 viewsNotice the position of the liner in relation to the top end of the lap. The liner's ID at the top is .9621. Compare this photo with the next photo of the same lap inside a .9613 ID liner.Jim Allen
Engine building 001.jpg
Some of the many machined pistons762 viewsMore than 50 piston types & over 100 pistons have been tested. Materials include; A-390; Mahle-138; Dispal-250; & RSP-444. Some pistons were set up in ABC setups & some in AAC setups. No particular setup gave a significant increase in HP & piston scuffing was not eliminated with increasing amounts of silicon in pistons. Piston scuffing was eliminated with the correct amount of taper & finish on the liner ID; plus the correct amount of taper on the piston top. Liners must be ground, not honed, & tapers on both must be done very precisely. No lapping of any kind is ever done to any piston or liner! This method works even when running the motor at very lean settings.Jim Allen
gas tank 014.jpg
Welded & soldered center section356 viewsThe baffle positioner on the left is now inserted, to position the baffle for welding. After welding it is also soldered.Jim Allen
torque cradle loading devices 011.jpg
Five loading devices735 viewsFive loading devices will allow one thousand rpm increments from 32,000 to 36,00 rpm. This will be accomplished by reducing the diameter of each blade. Jim Allen
connecting rod 016.jpg
830 viewsSide view of the connecting rod mounted on the fixture after all milling is completed. All machined edges on the connecting rods are smoothed. After tempering all connecting rods are sand blasted.Jim Allen
pit box 001.jpg
Pit box420 viewsThis pit box contains all the necessary items to start the engine. There is no battery for an electric starter because the engine is started with a pull chord. In the photo beneath the box are some typical pull chords made of 1/8 dia nylon & kevlar braided ropes. The glow plug cables are very fine stranded 12 gage copper wire. Their ends are staggered to prevent accidental contact & a insulator is connected between them during transport. This is necessary because the glow plug battery is a 10 amp hour nickel cadium wet cell. It easily lights any glow plug used, including a Novi Rossi # 9. The aliminum plate holds various types of glow plugs including tappered seat & standard types.Jim Allen
331 viewsThe middle sections of a 30,000 rpm pipe machined from 1018 cold rolled steel bar stock. All sections have .020 thick walls except the head pipe which has a .040 thick wall. Where the sections overlap at the joints, the pipes wall thickness is .010 for each piece.The entire unit is silver soldered in the lathe while rotating slowly. All joints are tinned first, then assembled & silver soldered.Jim Allen

Last additions - Jim Allen's Gallery
659 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
559 viewsThese spring steel washers will prevent any galling of the clamping nut, even when it is tightened with great force.Jim AllenSep 27, 2007
579 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
377 viewsJim AllenSep 27, 2007
482 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
492 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
453 viewsThe collet holding fixture is made of #316 stainless steel & is not hardened. Jim AllenSep 27, 2007
435 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
541 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
801 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