Machining base without a lathe part 2

[cease232]

Disclaimer- Title is a little misleading because I used a wood lathe.

I had to step away from saws for a minute to spend money on other things. Well I was visiting family in New Mexico and my cousin had an 044 sitting out in his field. It was sun bleached white and covered in powdery sawdust. Could start but wouldn’t stay running. Offered to fix it but he said I could have it. I paid him a fair price and shipped the saw home to Oregon. Once I tore into it I found a pretty low hour saw that had been neglected. Probably ran lightly for a few seasons and when it stopped working was tossed aside. Well since I had it apart and needed an excuse to procrastinate other projects I decided to experiment.

I recently bought a cross vise at a yard sale for 10$. I clamped the vise to the bed of my wood lathe and clamped a router into the cross vise. Turned down a piece of alder to 50mm and mounted up the cylinder. Chucked a 3/8 endmill into my router and thats it.

Squish was right about .030 so I was shooting for removing .010

Finish looked pretty rough but a couple spins on a sheet of 220 grit sand paper on a cast iron surface and it turned out pretty nice.

Squish ended up dead on .020 on both sides of the piston.

Thanks for reading. Some of you may remember my other thread.
http://opeforum.com/threads/machining-base-without-a-lathe.3989/
Jeremiah.

 

[Mkinslow]

That's cool bud,welcome back

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[Ronie]

Like MKinslow said, very cool.

 

[Intoxsawcated]

That's pretty crafty, good job! I especially like how you were "shooting for removing .010". Glad it worked out.

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[cease232]

That's pretty crafty, good job! I especially like how you were "shooting for removing .010". Glad it worked out.

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To be honest I tested it first on a scored Hyway cylinder I pulled off a previous purchase so I was fairly certain it would work out. Didn’t wanna ruin a good cylinder.


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[Xr650jkallen]

Innovative for sure. I'd say you could probably play with rpms and get the cut quality even better. Most likely the routers rpm.

 

[cease232]

I didn’t time it before but the timing is now
Ex-102
Tr-119
In-70
Gonna do a little grinding and see how she runs.


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[thesawincanada]

I’ve marked the base all around and used a belt sander to take the base down.

 

[Al Smith]

That looks a lot better than a method done with a router from an outspoken personality who once became a real troll of web forums .Since gone missing after removal from about every forum concerning chainsaws or several other interests .
That said it looks like it works .With a router I'd bet the aluminum just flies because of the speed of rotation .

 

[cease232]

That looks a lot better than a method done with a router from an outspoken personality who once became a real troll of web forums .Since gone missing after removal from about every forum concerning chainsaws or several other interests .
That said it looks like it works .With a router I'd bet the aluminum just flies because of the speed of rotation .

I’m not aware of said person ever using a router, I believe he was using a belt sander.
Bolted it up last night with a new OEM gasket and it passed vac and pressure. Need to go get a carb kit before I can test it in some wood.


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[Al Smith]

My reference was to a guy in California on a web forum no longer in operation .Shall we just say his method was not too realistic .
However on the subject a very resourceful guy on Ontario used a table top milling machine before he owned a lathe and had very nice looking work .After he got a lathe I sent him enough carbide tooling to last him for years .

 

[Al Smith]

I'm certainly not trying to poke fun with people working with what they have to work with .Probably 40 years ago I reamed a brass bushing for a track roller for a bull dozer using an x-y table on a drill press .Holding the cutting tool in the vise with an expanding arbor in the press to hold the bushing .Took forever but it worked .

 

[Deets066]

I’ve marked the base all around and used a belt sander to take the base down.

Don’t do that

 

[thesawincanada]

It works flawless but you have to take your time and take a little at a time off

 

[Deets066]

It works flawless but you have to take your time and take a little at a time off

Flawless? You can sand a jug perfectly flat within .001”?

 

[thesawincanada]

You finish up by sanding on a flat steel plate with fine sandpaper. Cleaning and checking squish. As you go. Guy on you tube did a 4 cylinder engine head the same way.

 

[thesawincanada]

I’ve done a ms 360, ms 440 and ms 260. I’ve done it to my saws. Haven’t done for my customers

 

[Deets066]

You finish up by sanding on a flat steel plate with fine sandpaper. Cleaning and checking squish. As you go. Guy on you tube did a 4 cylinder engine head the same way.

Even if you have surface plate it would be hard to keep even pressure. I guess it’s possible

There used to be a dickbag around here that sanded jug bases for customers saws. It was not uncommon for him to be .020-.030 out.

 

[cease232]

I don’t think I would trust the belt sander method but if it’s your personal saw then to each his own.


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[Deets066]

Sharpie line is a perfect .020”.