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  1. #61
    Join Date
    Oct 2016
    Location
    Melbourne
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    321

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    Quote Originally Posted by shedhappens View Post
    I have one of those diesel engines here for a future project, it needs a fuel leak repair and a clean out as it has been sitting for a while.
    I could get it going and you could test it to see if one of these is suitable for your needs.
    Personally i think you need to keep the weight down and the diesel engines have quite a heavy power to weight ratio.

    I was thinking about the generators that i built last night whike laying in bed, slowley my memory started coming back about what i was trying to achieve. I was trying to reduce fuel consumption so as the batterys charged and the load became less the engine revs would decrese, so by the time the batterys were close to full charge the engine would be running at close to idle and this is why i need the 1:2 belt ratio on my early prototypes.
    Running your engine 1:1 with an alternator should work fine at 3600 rpm, direction of rotation might be a problem and hp?

    I dont want be the bad guy here but i think someone needs to tell you, you can mig weld an axle if you are making a letter box.....
    But not an axle that you are staking your life on at 300 kph....
    High carbon steels in critical situations need preheating, low hydrogen rods, controlled cooling and to be done by a competent experienced welder with precision alignment jig.
    I think you need to take on board the sugestion that OXX made about cutting and resplining, the only thing that i might add to that is to get the ends proffessionaly anealed before cutting the splines then after they are get it rehardened.

    Cheers, shed
    Hi Shed,
    Yeah i was thinking of the weight as well, once i finish off most of the structural work will get back on getting the test stand set up and the engine and we will find out what needs to be done to get the best results. You not the bad guy mate, i had other people tell me about welding axles ect, ect my budget is low and can only do DIY stuff and this trike will not be going 300 kph and i never seen a trike go 300 kph, they are for cruising only. LOL i maybe only able to ride it on a short stretch of road, and if i can get a dyno power run we could get an idea of what it can do. There is a lot of unknowns with this project, the engine may run to hot or could grenade itself, the gearbox may not be suitable , ect , ect This trike will be heavy as i will need some type of birth shield around the engine, so if it grenade itself i wont have bits of debris entering my body so may use 3/8 stainless steel plates.

    Cheers,
    Mark.

  2. #62
    Join Date
    Mar 2014
    Location
    South of Adelaide
    Posts
    901

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    Quote Originally Posted by shedhappens View Post
    I dont want be the bad guy here but i think someone needs to tell you, you can mig weld an axle if you are making a letter box.....
    But not an axle that you are staking your life on at 300 kph....
    High carbon steels in critical situations need preheating, low hydrogen rods, controlled cooling and to be done by a competent experienced welder with precision alignment jig.
    Mig is low hydrogen. At work we regularly mig weld high carbon steels, its not some dark art.

  3. #63
    Join Date
    Apr 2012
    Location
    Healesville
    Posts
    1,774

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    Quote Originally Posted by Turbine Builder View Post
    Hi Shed,
    my budget is low and can only do DIY stuff and this trike will not be going 300 kph and i never seen a trike go 300 kph,
    Mark.
    No worries Mark, pity, I was hoping to see you break the sound barrier.

    Quote Originally Posted by snapatap View Post
    Mig is low hydrogen. At work we regularly mig weld high carbon steels, its not some dark art.
    G/day snapa, yeah I mig it also but if the welded part is to be expected to withstand extreme loads and mortal safety is also a concern then it needs to be done properly.
    At this link you will find a list alloy steels, the axle is likely made out of one of these, in the PDF files to the right you will find the welding requirements and fillers https://www.voestalpine.com/highperf...n/alloy-steel/ then another complexity could be if the axle has been carbonized.

    I wonder if voestalpine and voldermort are related?

    cheers, shed

  4. #64
    Join Date
    Oct 2016
    Location
    Melbourne
    Posts
    321

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    I got a lot done today, finished off one side of the steel structure. I flip it over as i forgot to leave room for the 1/2 inch bolt when i welded the cross section on the structure.

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  5. #65
    Join Date
    Oct 2016
    Location
    Melbourne
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    321

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    Finished off one other side of the steel structure, weld in a couple of round stock in each end of the structure and drill 1/2 inch holes to bolt onto the plate.

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  6. #66
    Join Date
    Oct 2016
    Location
    Melbourne
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    321

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    I won't weld in this cross tube as i am waiting for a very important part for the gearbox that's coming from Canada, should be here next week.

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  7. #67
    Join Date
    Oct 2016
    Location
    Melbourne
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    321

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    The NGV arrive from Canada, wasn't cheap but i need to have it as i don't have one for the other Boeing gearbox and this one is not butchered up like the other NGV. I can still use it just have to make up the other parts that will fit onto it. As yo can see there is a bleed air duct will hook up a gate valve, this will help on start up of the engine as i can destroy the engine in ~ 10 seconds. I may not need it but it reassurance for me.

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  8. #68
    Join Date
    Oct 2016
    Location
    Melbourne
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    Here is the NGV fitted to the gearbox, as you can see in the photos it's getting a bit cramped with this type of set up.
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  9. #69
    Join Date
    Oct 2016
    Location
    Melbourne
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    321

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    Cut out the steel gusset and weleded in a new one. And yes i am overkill on this structure build Bit of a fiddly job to do, i found out the gearbox is off centre a bit i can make a new base plate or mill slots in the holes and centre up the gearbox that way, also the steel structure that bolts onto the side of the gearbox will need to be modified as well .

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  10. #70
    Join Date
    Oct 2016
    Location
    Melbourne
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    321

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    lots of welding and grinding i have been doing, at last got most of the work done on the diff, had to grind my crappy Welds and re weld . I welded on some Steel gussets on the two long diff perches just to give it a bit more strength. Tack weld a nut for the vent tube and sealed up with JB weld. Cut off the square tubes on the frame will redo the side structure supports for the gearbox with rectangle tubes and use shoulder bolts to hold everything together. The two steel tabs on the side of the frame i will weld a tube in between the them they a quite solid and will help in strengthening the frame.

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  11. #71
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    Oct 2016
    Location
    Melbourne
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    321

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    Got some work done on the steel structure on the rear end of the frame, gave it some paint and welded in more Steel gussets.

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  12. #72
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    Oct 2016
    Location
    Melbourne
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    321

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    Got some V clamps , looks like i may have to pull the bigger clamp apart and cut it to size. The one that is closest to the size was ~25 mm short if i use this clamp i think it may leak.

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  13. #73
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    Oct 2016
    Location
    Melbourne
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    321

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    Got 16 mm thick plate to machine up the two v band flanges and got a scrap piece of ss tube will have a go at making a concentric reducer.

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  14. #74
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    Oct 2016
    Location
    Melbourne
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    Time for a update, redone the side support structure for the gearbox welded in solid round steel stock inside the tubes and steel gussets plates and drill to size for shoulder bolts, nice and strong support for the gearbox now.

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  15. #75
    Join Date
    Oct 2016
    Location
    Melbourne
    Posts
    321

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