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Hit & Miss Gas Engine Discussion Meet collectors of hit and miss engines, ask questions about collecting, restoring and showing antique flywheel engines.

Hit & Miss Gas Engine Discussion

1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration


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  #41  
Old 02-28-2015, 06:27:31 AM
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Wayne Grenning Wayne Grenning is offline
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

Two 8" bridgeport "riser-blocks" made off shore were ordered from an import company in California. At about 100 lbs each, the un-impressed UPS driver delivered to my door a couple days later.
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These get locked in the column section of the mill with a crossbar and draw bolts. Here is looking downward and inside the column with my original 7" riser and the two new 8" risers.
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Riser blocks installed.
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Next the chain-falls are cranked up all the way, with only 1/2" to spare, I roll the top section of the mill over to the frame and lower on to it. There is a rabbit fit that is supposed to engage the lower pointing boss of the ram to the machined hole in the bottom. ^$*&^$*^*!!!!
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Last edited by Wayne Grenning; 02-28-2015 at 01:17:58 PM.
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  #42  
Old 02-28-2015, 06:39:44 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

At this point a few expletive comments were uttered deeply expressing my passion for the quality imported goods we are cursed with.

Out with the calipers to see what has gone wrong.
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First to check the diameter of the boss that extends from the bottom of the Bridgeport ram. It measures right at 12.5000, dead Nuts,

Next check the hole in the Chinese riser block.
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Looking at the inside scale. It measures 0.017 undersize!
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Several more expletives later I'm over it and figure out what to do.
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In the 16" lathe the riser block goes!
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With only 1/4" clearance it fits. While in there I check the face run out. Its surprisingly perfect. The bore is opened so that it gives clearance when the ram is assembled on the column.
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  #43  
Old 02-28-2015, 06:45:32 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The machine finally get put together with all it components and a total of 23" of riser blocks. Its one awkward looking machine at this point!
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The adjustable hydraulic table make a perfect working platform. With a few quick checks, it looks like we are back in business - a very interesting solution, resolving the capacity limitations of a machine. The cylinder is trammed in and will be in this position for a several days. There lots of boring, drilling reaming and cutting that will happen here

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  #44  
Old 02-28-2015, 12:28:25 PM
Jerry Toews Jerry Toews is offline
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

AMAZING AND INCREDIBLE!!! Don't get too engrossed in your work and fall off the scaffolding.
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  #45  
Old 02-28-2015, 01:29:17 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

Jerry, I am so glad you are having this project done. I know its a tremendous commitment but this engine is so deserving of the effort. When I would see that engine at your place I would always think I'd love to tear into it to bring it back to life in its original glory. The conversion was rather neat in itself and was a part of engine advancement at the turn of the century. But, having it as it came from the factory is the way it should be. There are only a few folks I can think of that you could entrust this effort to. You picked the best!
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Old 02-28-2015, 02:03:10 PM
Don Selmer Don Selmer is offline
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

Jerry, You know you can sell me that Lavender engine to help fund this project
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  #47  
Old 02-28-2015, 02:34:15 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

Question; Was this engine sold in Pa. at public auction a few years ago? Thanks for putting all this on Smokstak for the rest of us to view.Dick.
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Old 02-28-2015, 02:46:12 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

No Dick, Jerry has owned this engine for a number of years, I'd say close to 30. The engine was brought to the US from the UK by Dan Crist of Quinter, KS. Dan purchased it and a smaller Crossley side crank engine. Dan's interest migrated more toward the large Prairie Tractors and he sold the engines to Jerry to purchase some tractors.
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  #49  
Old 02-28-2015, 02:59:21 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

Just don't back up to scratch your nose or to look at how it's cutting.

You couldn't mean chin quality on the risers could you? How out of square were they besides the bore that was undersized.
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  #50  
Old 02-28-2015, 07:47:11 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

TT - Thanks for the vote of confidence.

Regarding the risers. They were surprisingly within 0.001"

---------- Post added at 06:47 PM ---------- Previous post was at 06:33 PM ----------

Alright, now it gets interesting. There are a whole bunch of little details to be done while the cylinder is in the "stretched" Bridgeport.

The first step is to tram or indicate in the spindle so that it is perfectly perpendicular to the face of the cylinder.
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Next is to verify the four backing plate securing screw holes still have enough integrity to do their job. A tap is threaded in to chase out the years of debris and grime.
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Next a boring 3/4" boring head is mounted in the spindle and the rectangular combustion chamber hole opened to accept cast iron plug that will be made next.
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Eventually the hole is made, with the floor of it as flat as possible by taking lots of little cuts and a controlled depth.
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  #51  
Old 02-28-2015, 07:52:54 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

A three inch bar of Cast Iron is used to make the plug.
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In the lathe it is parted off and the "hockey puck" is faced off on both side to a final size just thicker than the depth of the hole bored into the cylinder. Also the overall diameter is a slight interference fit .
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Next the three hole bolt pattern is drilled and counter bored into it to accept 1/4 x 20 alloy steel socket head cap screws.
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Old 02-28-2015, 07:59:42 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The finished plug.
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A quick dry fit is done to make sure everything fits.
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All parts are completely cleaned and degreased.
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A film of Anaerobic Flange Sealant Equiv. of Locktite 515 or 518, is applied to the contact surfaces.
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Old 02-28-2015, 08:07:50 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The socket head cap screws are tightened to approx 75% of their ultimate strength.
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The bolt on valve and hot tube assembly that was added during its upgrade was held on with two 3/4" studs. The old holes were chased and the threads cleaned.
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Threaded plugs were made in the lathe from a piece of iron Durabar..
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The plugs and holes were cleaned, locktited and firmly tightened.
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Old 02-28-2015, 08:22:36 PM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

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A protective board is put on the cylinder face and the iron bar cut off.
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A light cut is taken on the end of the cylinder to face the insert and the two threaded plugs.
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The area above and below the backing plate mounting area is decked to a depth that removes the circular grooves put there years ago - about a 0.012" cut.
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---------- Post added at 07:22 PM ---------- Previous post was at 07:19 PM ----------

Next texture is applied to the surface - the very first of many steps that will help it blend in to the original surface on the cylinder.
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Old 03-01-2015, 06:16:44 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The slide valve cover and guides are positioned in the proper position on the cylinder. A steel bar, and a deep clamp are used to secure them there.
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The next is a compromise of proper location and visual appearance on exactly just where the two main studs will be positioned. I am using the washer as a guide to locate the visual center of the castings radius.
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Old 03-01-2015, 06:33:40 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The cover, guide and 1st half inch of the cylinder drill fine, then something below that really really does not like drill bits. There appears to be the edge of a web bordered with either silt, sediment or core sand in this inaccessible corner of the water jacket. I dont want to force it as the drill will surely want to wander a little.
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So I break out the die grinder and a carbide ball end burr and "hand- drill the rest of the hole - take time and patience but it works.
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Finally able to get a hole depth of 1' and then they are threaded 7/8 x 14 fine thread.
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Old 03-01-2015, 06:48:22 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The slide valve guides are set up on the other mill where the outer surface can be counterbored to accept the a retaining shoulder that will be machined into the two main studs.
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Temporary fine thread 7/8 bolts will be used to secure the guides for the next steps.
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The guides are bolted to the face of the cylinder and clamped to the fixture plate to ensure perfect position and maintain a parallel relationship between them. The precision square is used as a check to verify proper left/right alignment.
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Old 03-01-2015, 06:58:26 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The temporary bolts are now really tightened.
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In two locations for the top and bottom guides 5/16" fine thread alloy steel socket head cap screws will be used to retain them. Here the holes have been drilled and the counterbore is being plunged for the bolts head.
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The holes in the cylinder face are tapped.
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Next, each guide get a pair of dowel pins to secure it in position.
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Here the hole gets drilled undersize.
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Old 03-01-2015, 07:05:54 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The hole is reamed for a 0.0005" interference between the pin and the guide and cylinder end.
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Next an oversize ream is chosen as the whole length of the hole does not need to be undersize. This way only the last 1/2" of engagement between the pin and the guide are tight. - Setting the height the ream is to go using a gage block..
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Im having the expected problems getting chips out of a small diameter deep hole. Time to modify the blow gun.

Drilling a 1/8" NTP plug to accept a 1/8" brass tube.
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The tube is soldered into the plug.
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Old 03-01-2015, 07:16:38 AM
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Default Re: 1882 Crossley Bros. 3 1/2 HP Piano Base Slide Valve Engine Restoration

The chips are blown clear and the reaming of the hole can be finished
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The guides removed and the two 5/16 fine thread holes are chased with a bottoming tap.
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Everything is prepared and layed out for the next step.
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The cylinder end and contact surface of the guide are cleaned with lacquer to ensure no oil or contaminants and a liberal application of Loctite 518 applied. Although final cure of this stuff happens several minutes after the two parts are mated up it starts to set up within 60 seconds. To minimize the film thickness and ensure a perfect joint once the two surfaces contact, the dowel pins get hammered in and the bolts get tightened. Note: I am not using the locktite as a "sealant", but rather a bonding agent between the two surfaces. A properly prepared bond using this stuff is quite strong.
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