Author Topic: Southern Cross ETB diesel engine  (Read 3039 times)

glort

  • Hero Member
  • *****
  • Posts: 2936
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #75 on: April 07, 2019, 12:05:36 PM »

Wow!

So far from finished but already looks great and the attention to detail is very evident.
If this is what you do with Crook hands, can't wait so see what you can do when they are good again.

I had a similar thing last year when I bought a pulley for my plough engine.  Told the guy the correct metric size, got the imperial closest..... which didn't fit.
Took it back ( Only 15 KM for me each way) and he told me " It's close enough, should fit".  I think the manager came in just in time to hear me ask " Are you an idiot or just trying to take the piss? I told you the correct size, do you have it or not? "
Manager got me the right one which lesson learned, I confirmed with my own verniers before moving from the counter. Had I a brain I would have taken them the first time and checked.

Can't trust anyone these days to have any knowledge of the game they are in or to give you the right thing.

The Pics are very inspirations thanks but I look forward to the Vid of it running.

ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #76 on: April 07, 2019, 02:13:22 PM »
Thanks mate, the day of reckoning for my left hand is this Friday, hoping things will work out OK. I have a mate who I hope will be continuing the work once I am incapacitated. I will be supervising him!  :laugh:

Bob

ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #77 on: April 10, 2019, 10:03:42 AM »
Well guys the last day to be useful is tomorrow. So I had a good day today, turned up the new pump shaft and bushes. I don`t have access to a milling machine so I can`t cut the slots for woodruff keys, I do have a decent drill press so I chose to drill and fit shear pins as an alternative. I doubt this will cause any problems as this is only going to be a display piece and will never be put to any real work. I think I might use it to filter and dry waste vegetable oil when it is not on display, or even as part of the display.  I have always liked the idea of a diesel engine that makes it`s own fuel, might be an interesting thing to demonstrate at an old engine rally.

Tomorrow I will have to have a bit of a clean up and touch up the paintwork. I`ll also put a couple of coats of clear varnish on any naked steel to prevent it rusting while I`m incapacitated. Anyway a couple of photos to keep you amused.

Bob

ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #78 on: May 08, 2019, 09:43:23 AM »
Hi Guys, while I have been crook, I have had the opportunity to polish a lot of brass and bronze, one handed. Soul destroyingly slow and boring but marginally better than daytime TV. I also managed to bush the small end of the connecting rod and file enough material off the mating surfaces of the big end to bring the clearance down to 3 thou.

The original brass nut on the Marino reciprocating piston pump was beyond repair and all my efforts to source a replacement were unsuccessful. I went to visit one of my neighbors, Ken Inglis, who has the ability to cast aluminium from waste. He provided me with a suitably sized aluminium billet which I was able to turn into the nut shown in the photos below.

I also managed to turn up a new stainless steel piston and wrist pin. I cannot begin to explain how tedious it is trying to work a lathe with only one good hand but I am very happy with the results. Tomorrow I have to got into town to get some gland packing, with a bit of luck I should soon be able to post some pics of the assembled pump.

I still have to find the time and materials to make up new inlet and outlet valves and seals for this old pump but I am hoping that I will have it all done for the local rusty metal rally in August.

Bob

glort

  • Hero Member
  • *****
  • Posts: 2936
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #79 on: May 08, 2019, 10:41:40 AM »

Wow!
Beautiful work as always.
You are a fair Dinkum embarrassment Bob. you can do more with one hand than I can do fully articulated.

It might seem slow  but you are certainly achieving something. I suspect that your regular slow working will result in a far faster build than many of us get with a few hours here and nothing for a month, or 6 , and then a couple of hours there with another long absence method. And lets face it, you are making good use of your recovery time in which no one would expect you to be doing anything!

If you ever need anything simple cast in aluminium that your friend cant do or he is just short of ally, let me know and I'll do something up for you or send you some raw stock.

I was thinking of casting the Mrs a heart in ally and mirror polishing it for mothers Day and having it engraved but walked around today and couldn't find a suitable template. Loads of foam Balls, letters and numbers in every size but not quite the same significance.
Daughter is going to try cut something out from some foam tomorrow for me. If that goes well i'll drag out one of the burners , scare the neighbours and their sheep and do a pour.  If it's not quite finished by Sunday, I can always do it later in the week.  Knowing her she will probably like it rough cast or partially anyway.

If you need any round, or whatever, put your order in now!  :0)

ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #80 on: May 08, 2019, 11:48:20 AM »
Hey Buddy, glad to hear you like what I`ve been up to, difficult to explain the grief I have had from Narelle about doing too much to soon or getting my hand dirty.

Aluminium casting is something I have never tried, I might ask to watch Ken next time he is doing some. If you can`t find a suitable template have you thought of sculpting something out of candle wax?

I have recently been watching a couple of YouTube videos about sand casting and the current trend is to make your patterns using a 3D printer. Looks to produce very good results.

Bob

EdDee

  • Hero Member
  • *****
  • Posts: 744
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #81 on: May 09, 2019, 11:21:13 AM »
Lovely stuff indeed Bob!!

Well done!!

Try sheets of polystyrene expanded foam to make the positive for sand casting.... Works reasonably well too...

(That's if you don't have a 3d thingy to play with...)

Cheers
Ed
12/1 750RPM/9HP Roid 5kVA- WMO Disposal/Electricity & Hot Water Gen
12/1 650RPM/8HP Roid 4.5kVa - Demon Dino
Chinese Yanmar - Silent Runner with AutoStart
Classic Komatsu 1963 Dozer/Fergusson 35 Gold Belly ...
Bikes,Cars,Gunsmithing & Paintball...Oh yes, a 5Ha open air Workshop to play in!

ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #82 on: May 10, 2019, 09:24:36 AM »
Thanks Ed, I like the idea of using polystyrene to form a template for sand casting. I wonder if spray foam or fixing foam would do the same thing.

I don`t have a 3D printer but would be interested in the technology when the price comes down a bit. I read your post about moving the milling machine, I was lucky enough to spend several years operating these wonderful tools and I am hoping to buy one in the near future.

Not much achieved today but I did manage to fit the new piston to the connecting rod and fit the new gland packing, very pleased with how it all looks. Still a little too much play in the big end so I guess I will have to get the file out again.

Bob

EdDee

  • Hero Member
  • *****
  • Posts: 744
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #83 on: May 10, 2019, 09:48:52 AM »
Hi Bob,

It might indeed, but haven't tried it yet...This does present an idea... If you silicon rubber coat a master positive, then peel off carefully, use that silicon mold with spray foam to make multiple foam positives for casting....

Milling machines are the best thing since canned beer....except for my lathe of course...or beer....or rum and coke....or....

You need to build one of these things (see pic below) all the pulleys and wheels etc I cast in ali as blanks and machined them to size (beer cans for the small wheels, coffee tin for the drive wheel mold)... You will hardly touch a file after that...

Incidentally, I did exactly what you are doing a while back... The big end on a Honda 340 petrol if I remember...only thing I did differently was to squash it oval on the fly press while bolted together, then separate and sand the half shell a bit smaller and undersized, re-assemble, then bore to correct spec on the lathe using a face-plate... About 50c worth of raw material costs/electricity, 1hr of hobby time, and a more than happy friend who had his genset up and going again....

Every bit achieved is a step in the right direction!!

Cheers
Ed
12/1 750RPM/9HP Roid 5kVA- WMO Disposal/Electricity & Hot Water Gen
12/1 650RPM/8HP Roid 4.5kVa - Demon Dino
Chinese Yanmar - Silent Runner with AutoStart
Classic Komatsu 1963 Dozer/Fergusson 35 Gold Belly ...
Bikes,Cars,Gunsmithing & Paintball...Oh yes, a 5Ha open air Workshop to play in!

ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #84 on: May 11, 2019, 12:08:20 PM »
Hi Guys, now that the stitches in my hand have been removed I can do a bit more. so today I tackled the pressure bottle that is part of this old pump. It works by moderating the pulsing water pressure from the piston to produce a steady water pressure rather than a pulsing water pressure. The problem was that the base of the unit was flogged out, so I have filed out the worn parts and fitted a new center bush which was soldered in place with plumbers solder. Please see photos. The bottle was polished and sprayed with a varnish, hopefully it will look good and be functional for years to come.

Bob


ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #85 on: May 11, 2019, 12:33:09 PM »
Further to my previous post I now have a question for the forum. This old pump has two brass valves with sealing washers, one for inlet and one for outlet. When I acquired this pump it was in bits and did not have any springs behind the valves. Does anyone know if this unit originally had spring loaded valves or was it all done with gravity and water pressure? Photos attached.

I have calculated the number of piston strokes per minute at between 150 and 200, so I suspect that this pump originally had some sort of stainless steel spring above each valve, very similar to the valve springs used in a pressure washer, the travel on each valve is around 1/4", if anyone has any knowledge on this please share it.

Bob

glort

  • Hero Member
  • *****
  • Posts: 2936
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #86 on: May 11, 2019, 01:32:05 PM »

The polished brasswork is beautiful.
I used to do that with odd bits and pieces with a buffing wheel with an uncle. To keep the brass Nice I found coating it with clear car lacquer  worked very well and preserved the finish of the brass by sealing out the air and contaminants.

Had a padlock on a shed door I polished and lacquered that looked perfect for years.

mikenash

  • Hero Member
  • *****
  • Posts: 638
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #87 on: May 11, 2019, 07:01:28 PM »
Bob, any of those old pumps I have seen have a stainless or brass thin washer that follows the rubber or leather sealing washer and which supports a coil spring. Most I have seen have a tapered thin coil spring made from stainless wire

Traditionally you bought a "service kit" for them when they stopped working every few years

See pic?

Cheers

ajaffa1

  • Hero Member
  • *****
  • Posts: 1292
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #88 on: May 11, 2019, 11:56:30 PM »
Hi Mike, not much chance of getting a service kit for a pump that was made in the 1940`s. I guess I will have to adapt whatever I can find on fleabay. I`m also going to have to rework the original valves, I was thinking to replace the worn shafts with stainless steel.

Any idea what sort of pressure I should expect to get out of this contraption? It would originally have had a pressure gauge which I would like to replace.

Bob

mikenash

  • Hero Member
  • *****
  • Posts: 638
    • View Profile
Re: Southern Cross ETB diesel engine
« Reply #89 on: May 12, 2019, 12:25:31 AM »
Y'know, most rural service towns have a pump shop with some old fart who knows all about these old units - there's still a place here that works on ones similar to your cos people continue to use them because they are positive displacement units.  So if you can find a pump shop and just ask them about springs you might get lucky with a close match

That said, if you look at what's happening when the piston goes back and forth - there's pressure on one side and suction on the other, probably?  If that's the case, the spring isn't withstanding pressure, it's just holding the rubber "valve" in place maybe?

See the springs in the pic?  They're light - maybe anything like that you can find will do?

If it was in good shape maybe it would do six or eight bar?  Maybe 100PSI or a bit better?  Just a guess - no way of knowing really.  Gauges are cheap anyway - put a cheap one on and look around for a good one once you understand the pressure range?

If you have a look on google for some pumps with a similar physical structure, find a pic with a name/ID plate visible, then google the "pump curve"  - that will give you an idea

I will watch with interest.  Cheers