Brian Turners Stunt engine build, final pictures

The parts for the Engine are now finished. All that is needed is for the chroming to return from the Ukraine. This might be a month or so yet so Brian will have to wait to see how it performes.

I have added a link to the last installments:-

The drawings]

First set of pictures]

Second set of pictures]

Third set of pictures]

The spinner

Needle valve assy. The fuel pipe has to be at right angles as the offset of the venturi puts it too close to the side of the cowl to bend the fuel tube without kinking.

The silencer manifold is a tricky bit as it is a mass of different angles. Shown here in the dividing head offset from the vertical to machine the flange. The cutter is a woodruff cutter and is used to machine the area under the flange.

Back in the lathe to machine the oring grooves and part off. From here on the manifold is finished to the final shape by hand.

Finished to final shape - 75mins hand work from the finished machined piece.

This is the trial assembly of the needle valve assy and the silencer manifold.

Machining the back plate. The turning has already been done in the lathe. the bore has been machined to the maximum round diameter and now this inside round is opened up to the "D" shape in the dividing head. Also in this setup the flange is machined and the holes drilled. The extra material used to hold the backplate in the chuck will become the new cylinder head once the finished backplate is parted off.

The back plate set up in the dividing head to machine the backplate mounting lugs to the final round shape. Another of Brian's simple fixtures make this a straightforward operation in the dividing head.

Using the dividing head for this machining doesn't leave very much room under the head of the miller but Brian prefers the dividing head to the rotary table for this operation and the dividing head is a full size one.

Finished backplate showing the cutout for the piston. Brian has made a considerable effort to reduce the crankcase volume to improve the pumping of the engine. During the development of the Stalker he has been using he did some back-to-back testing that showed a real benefit from this.

Outside of the backplate. You can see the transition of the turned to the milled parts of the inside shaping.

That is so cool. Thanks so much for posting these pictures. It's facinating to see how this is done. Convinces me that I'll just continue to buy engines from custom engine makers. I'm a neophyte machinist and this takes a master. That's certain.

Very cool.


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Some days it seems like a coin toss between George Orwell and Monty Python...

That is just freakin awesome!! and to do it the old way with out CNC makes it that much more impressive! Just awesome!
Thanks for posting
Dwayne

Uh,,,,,you wouldnt by chance need someone to test that motor would ya?

I got a real nice stunter that jewel would snuggle into real nice!

That motor is just awesome!!!

Thank you for providing those pictures for all of us to see!
A real exercise in mastery of machine tools.
Forgive me for asking, but why the *Ukraine* for chroming???
Surely there must be *someone* in the USA that can do it!?
Thanks
DAT

The Ukraine is nearer

>The Ukraine is nearer
Sorry - - - My stupid mistake! I didn't realize you were in the UK!
My apologies.
DAT

Hi Dennis

Actually there is more to it than that. Brian has built up some very good contacts amongst the teamrace engine building competitiorsin and around Russia and he nows just what to expect from the guy he sends the cylinders to.
I plan to get a good set of pictures on the finishing of the cylinder when it returns and also how the piston fit is done. Brian has explained it to me but without pictures....

Mike, I am really looking forward to hearing the details of the piston fitting as that is probably the most important detail in setting up an engine.

Charlie

WOW!

Chris Sterner

Another reply
With all the stunt engines out there right now, OS LA series, Brodak .40 and there are others, I'd pay big bucks for this one!!!!!
Dwayne

I assume that the build was for the "fun of it" rather than there was no commercial product that would meet the need?
The workmanship looks outstanding. Hope it runs as good as it looks!
Do you get extra points for BOM (Build Your Own Motor)? Great job!

Richard

This has got to be one of the most amazing things I have ever seen in stunt Right up there with Gene Schaeffers flying.

The design and machining are truly artful. Brian might want to take another hack at the backplate, tho...I made some backplates, and cut an arched groove for the piston to come down INTO. I know he could figure out a way to do it. I didn't do it that way, wouldn't know how, but might be able to figure it out.

One thing that puzzles me, is that glowplug shield. What's that for? I figured the Ukranian's used them to make their available glowplugs work? With our choices in the West, I don't see the need, but could be wrong. I do like the way BT designed the shield, tho. Too many folks only design stuff that's hard to make. Designing stuff that's easy to make is way harder to do. Good show!

We're getting a new Swiss Wire EDM at work, and they asked me to run it. I don't know if that's a good thing. Maybe they think I'm not too good at running the 13 month old Milltronics MB-19? I'm still learning how to program it, but they were the cheapskates that wouldn't buy any training. In return, I got many months of frustration. Steve

Steve Helmick
Renton, Washington
USA

Hi Steve
I know that Brian thought about the method of grooving the backplate to allow just the piston skirt to to clear because we had a borrowed Russian combat engine apart and discussed the benefits of that approach. I think that in the end the tiny calculated improvement in crankcase compression didn't justify the increase in complexity.
The glowplug shield seems to improve the quality of the running. It seems to smooth out the combustion and makes the needle setting less critical. I will get a bit more detail from Brian on the notes he took when he was doing the testing. We did wonder if it protects the plug from any droplets of fuel that may result from the very rich setting we generally use for these engines.
Good luck with the EDM machine. I have had quite a few parts made using that process for my day job.
Brian is a little way back from that sort of technology:-

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Absolutely excellent, beautiful work, we're watching for run tests now!

Randy Ryan <><
AMA 8500
SAM 36
BO all my own M's

Randy - How is your stunt engine coming along? Got a little catching up to do now? [photo not recovered: devil.gif]