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  1. #31
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    58

    Default

    G'Day All,
    Some more progress on the roller. The exhaust system has been the most frustrating part of the build so far. I used K & S metals, 5/16" x 0.041" wall thickness hard drawn brass tube for the pipe work. I used the formula four times the pipe diameter for the minimum bend radius to make a tube bender to suit. The tube was annealed & packed with fine sand & plugged each end. I had no end of problems trying to get a smooth inner bend surface as the tube continually kinked. This was somewhat overcome by bending to about 15˚, re-annealing & bend another 15˚& so on. The result is not what I wanted but will have to do at present. The tube bent easier at a larger radius, but this was too big for the application as space is at a premium. The finished exhaust system to the tail pipe is shown here. The tail pipe will be left until the canopy is in place.

    IMG_1072.jpg

    The hand brake & transmission control levers & associated components were fiddly & time consuming. The lever positioning quadrants/ratchets were both initially turned into an annular ring fro 3mm ms sheet, mounted on a mandrel & milled to suit the the pawl profiles.

    IMG_1074.jpgIMG_1071.jpg

    The hand brake band is made from a piece of stainless "band-it" strap. It's very flexible & the exact width required. The brake material is a section of thin conveyor belt.

    IMG_1075.jpgIMG_1076.jpg

    Does anyone know where I may be able to buy miniature checker plate, locally? The pattern of standard checker plate is far too large for this application.
    Stay well everyone.
    Regards,
    Don.

  2. #32
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    58

    Default

    G'Day All,
    Thanks to everyone that sent a like to the last post on the rollers progress. It is much appreciated.

    I have hit a bit of a brick wall at present. Having trouble finding a suitable ignition coil. The engine runs fine on a conventional 12V auto coil/condenser & points system.
    My trouble is that I cannot find a supplier in Oz that can supply a coil small enough to fit into the space available. The coil needs to be no bigger than Ø35 mm & no longer than 40 mm. 6 or 12 volts does not matter. I was thinking of using a coil that the old style sparky model aero engines used to use, but cannot find any supplier of those coils either.
    Can anyone offer some advice please.
    Thanks in advance.
    Don.

  3. #33
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,439

    Default

    Hi Don,

    Very nice work there !

    I wonder if one of those camper 12 volt gas hob igniter’s would be any help ? The one on my camper hob sparks very rapidly when you hold the knob down. I've not taken the hob apart, but from memory when fitting it there looked to be two black cubes with wires to the control knobs and a single thick one to the spark probe. All that probe is, is a thing that looks like a pencil lead about 3 or 4 mm from the burner edge.

    HTH.
    Best Regards:
    Baron J.

  4. #34
    Join Date
    Nov 2007
    Location
    Near Rockhampton
    Posts
    270

    Default

    Quote Originally Posted by Don@2480 View Post
    G'Day All,
    Thanks to everyone that sent a like to the last post on the rollers progress. It is much appreciated.

    I have hit a bit of a brick wall at present. Having trouble finding a suitable ignition coil. The engine runs fine on a conventional 12V auto coil/condenser & points system.
    My trouble is that I cannot find a supplier in Oz that can supply a coil small enough to fit into the space available. The coil needs to be no bigger than Ø35 mm & no longer than 40 mm. 6 or 12 volts does not matter. I was thinking of using a coil that the old style sparky model aero engines used to use, but cannot find any supplier of those coils either.
    Can anyone offer some advice please.
    Thanks in advance.
    Don.
    https://www.dlenginesaustralia.com/dlshop/rcexl.html
    Not sure if these are small enough. If not they may be able to suggest something

  5. #35
    Join Date
    Apr 2004
    Location
    Notting Hiĺl (Melb) or Echuca
    Age
    64
    Posts
    179

    Default

    Quote Originally Posted by Don@2480 View Post
    .....

    Having trouble finding a suitable ignition coil. ...

    My trouble is that I cannot find a supplier in Oz that can supply a coil small enough to fit into the space available. The coil needs to be no bigger than Ø35 mm & no longer than 40 mm. 6 or 12 volts does not matter. I was thinking of using a coil that the old style sparky model aero engines used to use, but cannot find any supplier of those coils either.
    Can anyone offer some advice please.
    Thanks in advance.
    Don.
    Hi Don,

    Not sure if it is small enough or would do the job but in my efforts to get a motor bike going I came across this
    20200514_231155.jpg
    Case just 30mm dia if cut off mounting lug and 33mm long ignoring lead/plugs
    From a Honda TRX300 1990 vintage motor bike.
    One gotcha might be that it is a CDI system and expects a good wack on the primary of the coil to do its thing.

    Another random thought - On the gas oven in our home there is a gas flame monitor and electronic igniter on a single electronic board -- the coil used to generate the spark for the igniter is smaller again than the one above and is mounted on the board with a socket for the high voltage wire. https://www.ebay.com/p/1975814970?ii...26094292&rt=nc is an example of the board but the white thing to the top left is bigger than the one in ours. Some effort to drive it would be required.
    Last edited by HavinaGo; 15th May 2020 at 01:07 AM. Reason: Another thought added
    cheers
    David

    ------------------------------------------------
    A society grows great when old men plant trees whose shade they’ll never sit in. (Greek proverb)

  6. #36
    Join Date
    Dec 2007
    Location
    Adelaide
    Posts
    574

    Default

    You've done an excellent job on the roller, back in the mid 50's we were 15km from the CBD and "out in the sticks" and all roads were unpaved dirt, I recall seeing them in my street and surrounding streets when they were being paved. Would a coil from a car coil pack the type that sits on top of the spark plug be any good.

  7. #37
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    58

    Default

    Thanks for the input blokes,
    I have looked into an electronic box as suggested by GuzziJohn & I think that is what will finally finish up as the ignition. My concern with these units is that the ignition is going to fire every rev. (please correct me if I am wrong) which is not what I really wanted.

    I have tried a motor bike coil & after only a couple of seconds all the magic smoke came out of one end of the coil & it was all over. I wired the coil as per instructed by the supplier for a test sparking & turned the switch in the circuit on/off as rapidly as I could & got a good spark each time. Then, poof. Lots of sparks & smoke. All over.

    As space is extremely tight & cannot use an over the plug coil as the smallest I have been able to find is far too big.

    Baron J's suggestion of a gas igniter reminded me that I have some information on these units that have been converted to act a a coil. May yet be worth consideration.

    So, thanks again to all for your combined input.

    Regards,
    Don.

  8. #38
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,439

    Default

    Hi Don,

    Maybe not suitable but worth looking at ! I recently disposed of an old laser printer, actually stripping it for useful parts. It occurred to me that the printer generates very high voltages for the corona wires and drum, around 30 Kv between them. The transformers are very small about 25 mm by 30 mm and maybe 8 mm thick. There are several of them feeding recitfier circuits, providing positive and negative voltages. So putting out maybe 12 - 15 Kv.

    They seem to be driven by a power oscillator using a big FET from a 24 volt DC power rail. Now it would probably work to feed the transformer in the manner of a Kettering ignition.

    Some pictures.

    15-05-2020-001.JPG 15-05-2020-002.JPG

    15-05-2020-003.JPG 15-05-2020-004.JPG
    These are quite small and compact. The high voltage winding is on the top two pairs of pins and the bottom ones have a tap on the winding, so probably feedback of some sort. I did try flashing a 9 volt PP3 battery across but failed to be able to measure a voltage across the output. But you can feel a sting when you do. On the circuit board the two middle pins are joined together. The rectifier diodes on the output are wired as a voltage doubler, so I don't think that the transformer produces the full 15 Kv, probably only about half that.

    HTH.
    Last edited by BaronJ; 15th May 2020 at 09:35 PM. Reason: Edited to add pictures.
    Best Regards:
    Baron J.

  9. #39
    Join Date
    Dec 2007
    Location
    Adelaide
    Posts
    574

    Default

    In the video I can see what looks like valves opening and closing so I'm assuming the roller is a 4 stroke if the points are driven by the camshaft which is what it looks like to me then you should only get a spark every second rev.
    In any case it shouldn't matter - some motor cycles do fire every rev but that is due to the design of the points and coil, on a twin cylinder, I seem to remember on certain Hondas the points were driven by the crank shaft so there was a spark every rev, the one coil fires both cylinders, one of the cylinders had the spark on the exhaust stroke - it did not affect the running of the engine.

  10. #40
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    58

    Default

    G'day Familyguy,
    Yes, it is a four stroke engine. It has 15cc capacity & runs best on 95 octane petrol. Using 91 petrol it "chugs" a bit & 98 it gets very hot.
    Regards,
    Don.

  11. #41
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    58

    Default

    G'Day All,
    After a bit of a break due to illness, I have started on the roller again & have only a few components left to make. As you can see, the canopy roof is to be completed. The tail pipe & the roller scrapers are the only parts left to make.
    Then hopefully, I will be able to try a test run. If the proves to be OK, a competed strip to the individual components for painting.


    18.05.2022 (1).jpg18.05.2022 (2).jpg18.05.2022 (3).jpg18.05.2022.jpg

    The roller dimensions are; 575mm long, 225mm wide, 335mm high & weighs 22.3kg.

    As a side issue. Make sure that you have regular PSA tests. Prostate cancer crept up on me & showed no symptoms. If not for regular checks it would have been too late before detection.

    Regards,
    Don.

  12. #42
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    58

    Default

    G'Day All,
    Finally, have all the components of the model Aveling DX road roller complete.
    There has been 477 individual components made, a lot then fabricated into one assembly.

    IMG_1665 (1).jpg
    Parts missing from the image are; the piston, conrod & sump oil pan. These are in the crankcase.

    The video is the first self powered run.


    Regards,
    Don.

  13. #43
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,439

    Default

    Hi Don,

    Very nice ! Its a good feeling when you have spent hours making something and then seeing it working .
    Best Regards:
    Baron J.

  14. #44
    Join Date
    Dec 2007
    Location
    Adelaide
    Posts
    574

    Default

    Excellent work, you should be proud of the job done - scratch building something like the Aveling or any other working miniature model is a labour of love - I started a miniature V8 engine some years back and got as far as making the block and a cross plane crank, and then other jobs came along and no progress on the engine - maybe seeing your great effort will give me the kick up the butt that I need to restart work on the engine.

  15. #45
    Join Date
    Feb 2014
    Location
    Werribee, Melbourne
    Posts
    177

    Default

    Wow! What a brilliant effort - well done.

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