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Post by jbodenmann on Aug 25, 2010 2:44:03 GMT
Lets see what's next, the reflector seems logical. As this reflector is set up for an oil burner it has two holes in it, one for the burner to pop up through the bottom, and one for the glass chimney to exit out the top. Even though it's just an electric lamp we must have it looking proper. So we can't use a flashlight reflector because it only has one hole in the middle. And anyway when was the last time you saw a metal flashlight reflector. Plastic....oh please! So we will have to make one. .062" copper, a wood die to spin it on and Bob's your uncle. Attachments:
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Post by jbodenmann on Aug 25, 2010 2:46:22 GMT
The wood spinning die has been mounted to a steel mandrel and is gripped in a collet in the lathe. I always use collets when possible as they have no jaws twirling about to bash your knuckles on like a lathe chuck. Held in the compound rest is a piece of square stock with a ball bearing assembly mounted to the end. The outer race of the ball bearing has an aluminum tire pressed on it. This ball bearing assembly is what is pressed against the spinning disc to make it conform to the die. The copper disc is held to the form die by a brass cup pressed against it with the tailstock and live center. Even though well annealed, the first thing the disc does is go all wiggly and pie crusty as we are trying to shrink the outer edge. So we will have to remove it from the die and straighten out the wigglies. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:04:20 GMT
Straightening out the wigglies is done with our old friend the rawhide mallet. Gently tapping on the inside of the reflector on the steel table. Work around the reflector just enough to get most of the wrinkles out. DO NOT use a metallic hammer. It will put dents in the reflector that will make your hair stand on end later when it's time for polishing. After smoothing things out, re anneal the reflector and go back to spinning. It will go wiggly again, remove it from the die, de wiggle, re anneal, spin some more. Every time you will get closer to having the reflector snuggle up against the die. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:05:21 GMT
Now we are getting somewhere. At this point the reflector has been spun, de wiggled, and annealed five or six times. Just a bit more to go. This is not rocket science, just patience (in my case hammer headed stubbornness), and some mild powers of observation. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:16:39 GMT
Once the reflector is snuggled up against the die it is trimmed with a sharp lathe bit. If you did a good job you will have a hard time getting it off of the die. The objective is now to polish the reflector. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:20:17 GMT
Here a tube has been soft soldered to the back of the reflector. This will allow the reflector to be held and spun for polishing. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:22:57 GMT
The first step of polishing. Spinning the reflector and zooming it with a angle die grinder and a small flexible abrasive wheel.
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Post by jbodenmann on Aug 25, 2010 3:26:18 GMT
This photo should have been in the last post. Oops Attachments:
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Post by jbodenmann on Aug 25, 2010 3:27:59 GMT
A bit more polishing, working with water and finer and finer abrasive paper. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:29:15 GMT
Finally, ready to have the holes cut for the burner and chimney. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:30:37 GMT
Here are some photos of the burner- bulb and chimney holder. A small piece of teflon drilled to accept two pieces of 1/16" tube that will form the socket for the Mag Light bulb. The teflon is threaded to fit into the burner. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:33:57 GMT
Here is the bulb in the socket. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:34:44 GMT
And assembled into the reflector. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:37:02 GMT
Mostly done. Attachments:
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Post by jbodenmann on Aug 25, 2010 3:38:26 GMT
Just a few more Attachments:
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Post by jbodenmann on Aug 25, 2010 3:40:06 GMT
Mounted on the engine. No shortage of things to do. Attachments:
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Post by Deleted on Aug 25, 2010 9:38:42 GMT
Gobsmacked is the only word I can come up with about this build  - attention to detail is staggering and I am overawed by your skill. Am following the thread in amazement - many congratulations on work so far JB.  |
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Post by jbodenmann on Sept 13, 2010 1:34:26 GMT
Hello My Friends Having a delightful time here making little bits for the American. Also thank you very much for the kind compliments. Here is some progress. The tender water outlets have received some attention. Here is the bottom bit. There is an O ring seat inside that the plug will press against. Later I will show you how to make ribbed engine tender hoses that will slip on the barbs and connect to the engine. Attachments:
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Post by jbodenmann on Sept 13, 2010 1:36:48 GMT
Here is a photo of the top bit. As the handle is rotated on the curved ramp it will lift the plug off the O ring seat in the bottom of the tank allowing the water to flow to the crosshead pumps.
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Post by jbodenmann on Sept 13, 2010 1:40:33 GMT
Here are some shots of the wood brake beams, the brake shoe holders, retainer keys and brake shoes. Early equipment like this has a wonderful profusion of square head nuts and bolts, and ogee washers holding all the wood pieces together. Attachments:
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- attention to detail is staggering and I am overawed by your skill. Am following the thread in amazement - many congratulations on work so far JB. 
