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Hit & Miss Gas Engine Discussion

Wisconsin T-Head Restoration Log


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  #81  
Old 03-02-2012, 03:48:17 PM
tharper tharper is offline
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Default Re: Wisconsin T-Head Restoration Log

Today I got the first manifold fitting machined and cleaned-up. This connects to the carburetor via a cast iron piece which contains the butterfly valve for the governor. When the governor kicks in it chokes the engine.

It was counterbored to recieve the 1-3/4" O.D. brass tubing which connects the various pieces.



Here is a photo of the original set-up. You can see the governor butterfly valve as well as the adjacent elbow/tees. The tube to the right contains the control shaft to the governor. The carburetor is a Stromberg M4 (which Iam in need of!)



Its really, really satisfying taking these pieces from measurements and photos to drawings, to pattern to casting to finished piece.
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  #82  
Old 03-02-2012, 05:40:00 PM
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Default Re: Wisconsin T-Head Restoration Log

Oooo shiny. Looks great
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  #83  
Old 03-02-2012, 05:56:59 PM
Tencubed Tencubed is offline
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Default Re: Wisconsin T-Head Restoration Log

Been a member a short time and just found this rebuild thread. What a fascinating read. Wonderful workmanship and real talent.

Looking forward to the next installment.

Mike
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  #84  
Old 03-02-2012, 06:49:28 PM
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Default Re: Wisconsin T-Head Restoration Log

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Oooo shiny. Looks great
Ray,
you know the rountine...get it all nice and shiney then the fun..... watch it get all sloppered-up with gas and oil while its running!
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  #85  
Old 03-02-2012, 11:17:01 PM
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Default Re: Wisconsin T-Head Restoration Log

Of course if that didn't happen where would the fun be
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  #86  
Old 03-17-2012, 09:16:31 AM
tharper tharper is offline
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Default Re: Wisconsin T-Head Restoration Log

Foundry 101 continued.........

This morning I got an E-mail from Peter Grant at the Odd Duck Foundry - yesterday he poured the rest of my intake manifold fittings .....and sent photos

Here are the patterns in the bottom half (Drag) of the form
ready to have the top half (Cope) fitted and rammed-up. The Cope will be removed and the cores placed



the cope has been rammed-up, the patterns removed and the gates and vents cut.


Here the sand cores are in place. Peter powdered them with Plumbago to facilitate release and give a smoother finish. He placed a chaplet (a small piece of a bronze sprue under the elbow to keep the core from shifting.



Fresh, warm, bronze castings! Ready to be cleaned, machined and polished!


One of the flanged elbows failed to fill out so Peter will pour that again today. Can't wait!

T.
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  #87  
Old 03-17-2012, 09:24:17 AM
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Default Re: Wisconsin T-Head Restoration Log

Yesterday I couldn't resist bolting on the new oil pump drive casting (Part No. B1B) just to see how it would look.

It still needs cleaning-up and some machining on the stem and thrust bearing but it sure looks better than the blank space that was there!

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  #88  
Old 03-17-2012, 09:14:11 PM
tharper tharper is offline
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Photo Re: Wisconsin T-Head Restoration Log

Ok, yes you can tell Iam pretty pleased about this....

Peter even created one of my classic staged photos with the patterns and drawings After I get these all polished-up and assembled Peter will be sending Peter photos for the Odd Duck Foundry website

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  #89  
Old 03-18-2012, 04:23:28 AM
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Default Re: Wisconsin T-Head Restoration Log

What brass/bronze are the castings.
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  #90  
Old 03-18-2012, 07:48:10 AM
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Default Re: Wisconsin T-Head Restoration Log

Hello Ray,

The oil pump drive housing is new 660 bronze.

For the intake fittings (being non-critical) we used a whole bunch of scrapped heavy bronze water fittings - most of which appear to have never been installed. - whatever the bronze alloy (220?) it matches in color almost exact the original intake on Don's Lombard.
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  #91  
Old 03-18-2012, 10:14:15 AM
OddDuck OddDuck is offline
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Default Re: Wisconsin T-Head Restoration Log

You could kind of say that it is going to have that "pre-antiqued" look to them. The patina they have right out of the sand is similar to that which you would get if it was out in the woods for fifty years or so. Hmm, maybe I shouldn't have wire-brushed them.
Yes, scrap plumbing fittings, and I'd say they weren't real high in zinc, I didn't get much off-gassing and it poured quite nicely.
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  #92  
Old 03-18-2012, 04:34:14 PM
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Default Re: Wisconsin T-Head Restoration Log

Peter,
after I get done with them they will be mighty fine engine Bling
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  #93  
Old 03-21-2012, 02:06:37 PM
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For todays adventure......... I created two patterns for some cast iron pieces. Fortunatly there are not a lot of cast iron pieces missing or needing replacement.

Earlier we had turned new grey cast iron valve guides (part No. 027X) from round stock and pressed on the collars. This worked well but was a lot of work and waste of material.

Even though I have a complete set of new guides I decided to make a pattern so the next person who decides to take on one of these beasts can work from castings.

The other pattern is for a new oil strainer cover.
(Part No. F4F) As you can see its quite a bit diffrent than the cover that came with the engine.

Apparently they had a problem with the original design breaking so Lacroix's mechanics retrofitted a cover sourced from some other engine. I have seen this on one other ex-Lacroix Lombard engine as well.

Now we can cast one that is an exact copy of the original as issued by the factory.

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  #94  
Old 03-21-2012, 05:46:04 PM
OddDuck OddDuck is offline
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Default Re: Wisconsin T-Head Restoration Log

Oohh! Fresh new patterns to get all dirty! Bring 'em with you the next time you're up and we'll give 'em a try.
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  #95  
Old 03-21-2012, 08:39:06 PM
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Default Re: Wisconsin T-Head Restoration Log

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Oohh! Fresh new patterns to get all dirty! Bring 'em with you the next time you're up and we'll give 'em a try.
Can't come up there empty handed!
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  #96  
Old 03-28-2012, 09:14:01 AM
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Default Re: Wisconsin T-Head Restoration Log

With the intake manifold casting done I have switched my focus to the patterns for the Top Water Manifold. Similar to the intake manifold these are separate bronze castings with 1-1/2" O.D. brass pipe silver soldered to the fittings and rubber hose connectors.

As usual for me I start with a good set of drawings - here is the overall assembly:



Here is a photo of the front fitting (A18A) on Don's Lombard.



Now its off to the lathe!
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  #97  
Old 03-28-2012, 05:06:27 PM
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Default Re: Wisconsin T-Head Restoration Log

Terry, any way that maybe you could just make new core boxes for the elbow patterns that you already have? 1 1/2" isn't that far off from 1 3/4" to look that much different. Repurpose the elbow patterns you already have made and proven. That way all you would have to do as far as a new pattern would be the end piece.
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  #98  
Old 03-28-2012, 05:24:00 PM
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Default Re: Wisconsin T-Head Restoration Log

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Originally Posted by OddDuck View Post
Terry, any way that maybe you could just make new core boxes for the elbow patterns that you already have? 1 1/2" isn't that far off from 1 3/4" to look that much different. Repurpose the elbow patterns you already have made and proven. That way all you would have to do as far as a new pattern would be the end piece.
Pete,

I.........Can't...............it's that type A+++++++ thing... others might not notice but I would and it would drive me nuts!

I would have to do some serious reconfiguring of the patterns to make it work and I want to keep those correct in case they need to be used by others.

Besides..... I already have a good start on them!

Hang onto those fittings I will be up soon!

T.
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Old 03-28-2012, 05:29:06 PM
OddDuck OddDuck is offline
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Default Re: Wisconsin T-Head Restoration Log

Gotcha, you're gonna need to build on an addition to house all your patterns before too long...
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Old 04-13-2012, 08:45:58 PM
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Default Re: Wisconsin T-Head Restoration Log

Today.... I took a road trip back to the Odd Duck Foundry in Orrington, ME. to pick-up the rest of the intake manifold castings, drop off a new pattern and core box and continue my education in Foundry 101.

When we arrived Peter had the flasks all set to cast two pairs of aluminum valve shrouds. When I got the engine Don had given me a set of 10 pairs that he had cast many years ago. He also loaned me the pattern amd core box so I could have the missing sets cast.

The only lubrication to the valve stems is via a light oil mist from the crankcase via oil holes drilled through the lifters. The shrouds serve to contain it and protect the valves and guides from dirt etc.

Peter used "dry sand" cores for these castings. This is nothing more than green sand rammed-up in the core boxes with a wire reinforcement. They are more fragile than the sodium silicate/sand cores he usually uses but they worked great for this application.

Here is one pair of shrouds ready to have the sprues cut.


Next... Peter cranked-up the heat for a cast iron melt. We decided to try out my patterns for the valve guides and oil strainer cover.

Here is a view of the drag and cope after the patterns have been pulled and the gates, shrinkbob, and vents added.


And..... here are the castings right out of the sand. The valve guide is on the left and the oil strainer cover on the right.




Nice to know the old Chevy engine Peter broke-up has gone to good use!
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