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International Waters Gallery

chrome tank 017.jpg
1379 viewsA completely finished liner; piston & rod. Notice that the head bolts go through the liner lip, not outside the liner lip. This allows the head bolts to be tightened without bending the liner in the critical upper area. The head bolts are tightened with an Armstrong torque wrench to 20 in. lbs. each. There is no loss of piston fit & the 8 bolts seal the head with no leaking! Notice the very high finish of the chrome. Also notice that the connecting rod is guided between the piston bosses (.005 in total clearance) & not in the bottom end as found in ALL PRODUCTION MOTORS. The rotational speed is much lower in the upper end compared to the bottom end. This liner & piston have not been run yet. Jim Allen
connecting rod 029.jpg
1276 viewsSome engine pieces to be explained in the future. The sample dog bone crankshaft pictured definitely makes less hp. than the full dics crank used at the present. The full hard O-1 tool steel front end uses ceramic bearings with the crankshaft fastened to both inner races. This front end type runs faster & longer than any aluminum set up! The 2024 T-351 aluminum crankcase is one piece with 5 transfer ports cut from the inside. All parts are machined to less than .0001 tolerance & squareness! Jim Allen
connecting rod 032.jpg
997 viewsThis dedicated fixture is used to grind crank pin holes in through hardened crankshafts. The crank pins used are full hard M-2 steel & are a .0012 to .0014 press fit. The press fitting operation is done with a fixture to insure alignment when starting the crank pin in the ground hole. The crankshafts are made of AISI S-7 shock resisting tool steel; tensile strength is 285,00 p/si; yield strength is 220,000 p/si; hardness is 53 rockwell Rc; with a Charpy impact value of 219 ft lbs. This fixture could also be used to grind a one piece crankshafts crank pin; including the induction valve driver. The crank throw of this fixture is fixed at .9020.
A fixture like this assures that every crank is exactly the same!
Jim Allen
crankcase, crankshaft, & piston fixtures 001.jpg
Crankcase boring fixture934 viewsThe four locating pins, located on the top of the fixture on the right, engage the four crankcase mounting holes with a tight fit. Then the block of metal, which has mounting lugs already machined, is clamped for all machining operations. While in this fixture; the cylinder bore & face; the front end bore & face; the back end face; the 8-32 threaded holes for the front & back end; the 8-32 threaded holes for the head; the exhaust outlet; the 8-32 threaded holes for the exhaust header; profiling of the crankcase outside & the cutting of the transfers is done, completing the crankcase. The fixture is located with two 3/8 inch dowel pins, located on the left, when used in either position for boring.Jim Allen
crankcase, crankshaft, & piston fixtures 002.jpg
Crankcase boring fixture754 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
crankcase, crankshaft, & piston fixtures 003.jpg
Crankcase boring fixture rear view678 viewsJim Allen
crankcase, crankshaft, & piston fixtures 004.jpg
Draw bar extension screwed into the bottom of the crankcase boring fixture915 viewsThis precision machined piece, which is threaded on both ends, allows the crankcase boring fixture to be securely mounted to its aluminum base plate. Two 3/8 inch dowel pins insure the correct location for boring the cylinder or crankshaft bores. Jim Allen
crankcase, crankshaft, & piston fixtures 005.jpg
Precision face plate731 viewsThis 10 in face plate has been carefully machined while mounted in the lathe. It is mounted with a D-4 camlock nose & has repeat accuracy of .0001 over its entire surface. A 1 in thick precision ground plate is screwed & pinned to the face plate. The brass weight counter-balances the crankcase boring fixture when it is in position for boring the front end bore.Jim Allen
crankcase, crankshaft, & piston fixtures 006.jpg
Precision face plate with crankcase boring fixture mounted1153 viewsWhen mounted in this position, the front end bore is done. Rotating the fixture 90 deg allows the cylinder bore to be done. When doing the cylinder bore the brass weight is not used. Custom made, .750 in dia, carbide tipped, boring bars are used to bore the crank shaft & cylinder bores.Jim Allen
crankcase, crankshaft, & piston fixtures 007.jpg
Side view of the entire assembly942 viewsIf the base of the fixture is square, then the two bores (cylinder & crankshaft) must also be square to one another. If the dowel pin locations are the same distance from the center of both bores, on both bases, then the two bores are in line with each other also. Di-axis offset is easily set up with this fixture by moving the dowel pin location on the cylinder base. Jim Allen
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