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International Waters Gallery


Another pit box idea


pit box 006.jpg

6 files, last one added on Jul 22, 2006
Album viewed 102 times

precision cable collet assembly


cable_collet_clamps_058.jpg

58 files, last one added on Sep 27, 2007
Album viewed 286 times

26 albums on 3 page(s) 3

Random files - Jim Allen's Gallery
Deep-Groove Ball Bearing 057.jpg
Carbon fiber cowling in place on the hull505 viewsThe solid carbon fiber rod does not go completly into the high modulus sponson tube, but ends 1.750 in from the inside of the sponson. This allows the sponson tube to shear off easily in the event of a collision. After milling out the damaged tube in a jig, new tubes are glued in; also done in a jig. Jim Allen
dynamometer 040.jpg
.156 thick & .125 thick rotors707 viewsThe .156 thick rotor is on the left. Again, it is relieved in the center to keep everything centered. With holes going through the rotor there are a total of 24 holes. Jim Allen
Deep-Groove Ball Bearing 014.jpg
823 viewsThe sleeve, which fits over the crankshaft, fastens both inner races of both bearings mechanically to the crankshaft. The front end seal is machined onto that same sleeve. Crankshaft endplay is set at .003 to .004 with machined spring steel shim washers to be shown. Even at elevated running temperatures, the end play remains the same, because all parts; the crankshaft; the sleeve; the shims; the front end; & the bearing races; ARE ALL MADE OF STEEL! This system also works with all metal bearings, but CERAMICS WILL RUN FASTER, LONGER!Jim Allen
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bell valve assembly1372 viewsThis induction system gives a large increase in hp; removes excess drag from the bottom end; stuffs the cranklcase to the maxuim & allowes the connecting rod to be guided in the upper end. The total clearance between the ID of the bell valve & the OD of the back end it rotates around is .0001. Notice there is no rubbing between the valve and the back end in any of the photo's. These valves have been used for hundereds of hours of engine testing. The only part to be replaced was the ball bearing which has been replaced with a ceramic hybrid.Jim Allen
Engine building 002.jpg
Some liner samples795 viewsMany liner designs; different angles on tops & sides of windows; different aluminum & brass materials; different lip sizes & thicknesses; different window shapes; different window geometries; different number of windows; many different timings; many different tapers; & many different fits have been tested before arriving at the final design. This does not mean that there is nothing better! The final setup uses ABC technology; a .100 thick liner wall; a full head dia .200 thick lip & eight, 8-32 head bolts passing through the liner lip; which mechanically fastens the liner lip to the crankcase. In fact, the liner lip, the crankcase, the head button & the head, are all the same diameter. These features, when applied to ABC or AAC setups, prevented liner blow out at the top; keep the liner round at the top & stablized the liner at the top when heated during running conditions. Upper liner cooling was also greatly improved with this liner lip design, which allowed very high compression ratio's to be used. All of these things increased the engines HP a significant amount.





















Jim Allen
cable_collet_clamps_009.jpg
331 viewsA Brown & Sharp .00005 indicator tells me exactly how far I have moved the compound to bring the taper to the correct number.Jim Allen
crankcase, crankshaft, & piston fixtures 002.jpg
Crankcase boring fixture747 viewsThe two large threaded holes ingage the lathe draw bar when mounting the fixture to the face plate. The third smaller counterbored clearance hole fastens the fixture to the rotary table (located with the same two .3752 dowel pins) for profilling the outside of the crankcase.Jim Allen
cable_collet_clamps_029.jpg
350 viewsThis is the tapered collets internal seat & clamp. It also fastens to the flywheel face with two 6-32 bolts. It is located with a very tigh fit (.0002 interference) on the steel stub on the flywheel's face.Jim Allen
Deep-Groove Ball Bearing 017.jpg
845 viewsThis picture shows machined spring steel shims made using the same method used to make crankcase shims or head shims. On the left is the crankshaft sleeve that sits between both inner races with the correct thickness shim to give .003 to .004 end play. Jim Allen
cable_collet_clamps_052.jpg
597 viewsThe collet holding fixture is made of #316 stainless steel & is not hardened. Jim Allen

Last additions - Jim Allen's Gallery
cable_collet_clamps_058.jpg
996 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
cable_collet_clamps_057.jpg
710 viewsThese spring steel washers will prevent any galling of the clamping nut, even when it is tightened with great force.Jim AllenSep 27, 2007
cable_collet_clamps_056.jpg
726 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
cable_collet_clamps_055.jpg
517 viewsJim AllenSep 27, 2007
cable_collet_clamps_054.jpg
631 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
cable_collet_clamps_053.jpg
644 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
cable_collet_clamps_052.jpg
597 viewsThe collet holding fixture is made of #316 stainless steel & is not hardened. Jim AllenSep 27, 2007
cable_collet_clamps_051.jpg
574 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
cable_collet_clamps_050.jpg
688 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
cable_collet_clamps_049.jpg
998 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