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  1. #16
    Join Date
    Aug 2011
    Location
    Melbourne
    Posts
    3,969

    Default

    Hi Don,

    I'm a bit late reading this thread but I have thoroughly enjoyed reading your posts. Your techniques employed and attention to detail are to be admired. Boy do I have a lot yet to learn!

    Nice work Don.

    Simon
    Girl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.

  2. #17
    Join Date
    Feb 2012
    Location
    Willunga
    Posts
    109

    Default

    Hi Don

    This is really impressive, makes the 040 steam loco I am making seem... well steam powered.

    Regards

    Ian

  3. #18
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    24

    Default

    G'Day All,
    Thanks again to all that have sent likes etc.

    I have fabricated the pivot head for the front of the roller & after grit blasting it should look like a casting. It has been fabricated from six pieces of shaped materials & then silver soldered together. My MAPP gas torch was at it limits to keep enough heat into the assembly to allow a reasonable flow of the silver solder. The bearing housing was turned with a 12˚ taper over the height with the other pieces being cut & shaped by hand. The last image painted with aching primer to see if it would look like a casting.

    DSCF4643.jpgDSCF4645.jpgDSCF4647.jpgDSCF4650.jpg

    The drawing called for the chassis rails to be made from 25 x 16 x 385 channel. Fat chance of buying that! So, the two rails have been mill from 25 x 25 black bar. Also, 19 x 10 channel is required as well as 10 x10 angle. Both of these will be milled.

    DSCF4685.jpgDSCF4684.jpg

    The rear axle block was also to be fabricated, but after the heating problems for the pivot head it was machined from a 75 X 75 X 75 piece of mild that has been lurking under the bench for years. The block will be fitted with two bronze plain bearings & will be riveted to the chassis rails.

    DSCF4665.jpgDSCF4678.jpgDSCF4683.jpg

    Currently turning the rear rollers from 150 x 64 solid stock. The rollers were to be fabricated also but, are well beyond my heating capacity.

    This is a photo of the real deal that started it all.
    Aveling Barford DX8 roller.jpg

    Regards,
    Don.

  4. #19
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    24

    Default

    G'Day All,
    Finally back in the shed after the summer heat has subsided, just too hot to do any work since last November.
    I have recently finished the two rear rollers, apart from the reamed holes that will house the drive pins.
    The time required, as it turned out (no pun intended) to complete, took much longer that I had anticipated. The lack of suitable tooling for this job being the main cause. I would have liked to have had a number of face grooving tools but, at a couple of hundred each the cost was too high. The bulk of the material was removed by plunging a ground HSS tool to a depth of around 5mm & increasing the diameter with successive cuts until a carbide boring bar could be then used to remove the excess material. The inner face being tapered at 11˚only compounded the problem. After 3 wheelie bins of swarf, the turning was complete. The rollers are 149 x 65 wide. The roller that has the stepped centre spigot is the roller that will eventually house the differential centre.

    DSCN0577.jpgDSCN0578.jpgDSCN0579.jpgDSCF4726.jpg

    The front rollers are being turned at present & are presenting the same problems with regard to relieving the centres.
    Regards,
    Don.

  5. #20
    Join Date
    Oct 2017
    Location
    Lismore, NSW
    Posts
    24

    Default Aveling Roller continued

    G'Day All,
    Finally, back in the shed after the summer heat & other interruptions. I have finished both the front rollers, again turned from solid stock (150 x 56) black MS. As the rollers are only ever to be rotating at a very low RPM, I have made the inboard & outboard bushes from 6061 T4 aluminium.

    18.11.2018 Finished Frint Rollers..jpg

    The steering fork has taken about 20hrs to finish & required a lot of milling using a 5 mm end mill for most of the milling with the inner radiused corners of the relieved section completed with a 5 bullnosed end mill. I was trying to make the steering fork look like it has been cast & by using a mounted point in a dramel to rough up the surfaces of the relief, I think that it will have a cast look after the outer surfaces have been grit blasted.
    The folk started as a 170 x 30 piece of black MS that was turned to 168 x 25.5. The blank was marked out & set up in the mill on a rotary table & the inner diameter of 150 was milled to form with a 5 end mill using 2mm deep cuts.

    11.02 2019 Steering Fork proir to milling.jpg11.02.2019 Milling fork from blank..jpg11.02.2019 Fork after cut from blank..jpg

    Once this was completed, the folk blank was set up on an angle plate to mill the 12 grooves for the pivot trunnions that are to be silver soldered in position.

    14.02.2019 Set up to mill steering folk ends..jpg

    The fork blank was then clamped to a piece of 12mm plate that was bolted to the rotary table. This was to allow the relieving of centre section of the folk.

    25.02.2019 First relief groove milled.jpg
    Shown here is the smaller diameter of the relief. When this groove was to depth the blank was repositioned to mill the large diameter of the relief.

    Below is the fork after the relieving had been completed on both sides of the fork.

    13.03.2019 Fork relieving finished..jpg

    The trunnions were held in position during the brazing with a piece of 6 rod, threaded at both ends so that a couple of nuts could be tightened to hold all the parts together. This rod also doubled as a clamping bar for the milling of the taper that runs down to the pivot trunnions.
    Below is the fork with trunnions brazed in position & the body of the fork being milled to a taper of 4˚, both sides.

    22.03.2019 Milling tapered fork profile..jpg

    And, the finished fork.

    25.03 2019 Finished Steering Folk. (1).jpg25.03 2019 Finished Steering Folk..jpg

    As can be seen there has been a lot of effort to complete the steering fork, but I think that it was worth the effort. As I am not a welder, fabrication was not a consideration.
    The forecarrige that connects the steering fork to the roller axle is now being made.
    Regards,
    Don.

  6. #21
    Join Date
    Jul 2016
    Location
    Melbourne
    Age
    31
    Posts
    1,000

    Default

    Have to admire those results, that fork is lovely.

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