Table of Contents
Tasks
- Inventor model (.ipt)
- Fusion 360
- 3D Printer
- Inventor part prints (.dwg)
- PDF booklet
- Machine prototype
- Modifications
- Tolerances
- Metal grades
- Order of operations
- Parts List
- Assembly directions
- Expected time to complete
- Equipment list
- Surface treatment
- Operating Steam Engine
- air
- steam
- Feedback and Reviews and Testimonials
- YouTube - mrpete222 Lyle Peterson
- Pictures
- Videos
- Wiki page
- Pattern making
- Sand casting
- CNC Machining - G-Codes
- Sales and Marketing
- CSN
- Danny K - Amazon
Boy's Model Steam Engine
Inventor Files
- C:\Users\JeffJourneyJensen\journeyeducation.org\Jensen - Documents\JeffJensen\GISEngineering\Inventor\projects\Designs\GeneralNotes
- C:\GISE\GIS Engineering\GISE - Documents\ProjectsMechanical\Inventor\Designs\SteamEngine01-Adam
Parts
- 00-Assembly-Ethan.iam
- 01-UprightStand.ipt
- 02-PistonCaseAltaA.ipt
- 03-PistonHeadAltA-sw.ipt
- 04-PistonRodAltA.ipt
- 05-EyeNut91705A500_Eye Nut-Style Hangers.ipt
- 06-Flywheel-3in.ipt
- 07-FloatingPin-Bushing-sw.ipt
- 08-CrankCaseBolt-sw.ipt
- 08A-WasherFender-sw.ipt - McMaster 1/4" Fender Washer
- 08B-JamNut-sw.ipt - McMaster 1/4" Jam Nut
- 08C-Spring-sw.ipt - McMaster Compression Spring 3/4" length, inner diameter 5/16"
- 09-LockNut (not used)
- 10-CrankDiscAltA.ipt
- 11-CrankPin
- 12-PistonCaseLid (not used)
- 13-PostExtension (not used)
- 14-Brace.ipt
- 15-Spring (not used)
- 16-CrankShaft.ipt
- 17-PistonCylinderCap (not used)
Simple Little Wobbler Engine
Required Tools (not included)
- Drill Press
- Metal Drill Bits
- Air Compressor
- File
- Screw driver
- Layout fluid (dykem or sharpie marker)
- Digital Calipers
- Tap Wrench
Parts List
- Hardware - Piston Chest Valve Bolt
- 1/4" x 2" 20TPI Hex Bolt - Lowes \$1.08 for two
- Hex bolt 1/4“-20 length 3” (too long?)
- Binding Barrels 10-24, length 1/2“ (McMaster-Carr \$1.10 each)
- Aluminum Binding Post from Home Depot
- Jam nut 1/4”-20
- Nut 1/4“-20
- (2) Washers 1/4”
- 7/16“ External Retaining Ring
- Compression Spring (Everbilt $5.38 Spring Assortment Kit (84-pack) at Home Depot, Harbor Freight $4.50 Assorted Spring set 200 pc, MSC $3.27 for 1/4" spring, ACE Hardward Assorted Springs $10, Lowes \$4.18 Hillman Springs
- C-560 5/16” x 3/4“ compression spring from McFadden-Dale Industrial Hardware
- 1/4 x1/2 compression spring C-510 does NOT fit #10 bolt, use 5/16” instead
-
- Hardware - Piston Chest Cover
- (4) Cap screws
- 1mm (0.005“) PTFE roll (ePlastics $2.86 ft
- brown paper bag lightly oiled (The Home Machinist forum - Gasket thickness for steam chest & cylinders)
- Hardware - Compress Air
- Clear Vinyl Tubing 3/16 in ID x 5/16 in OD
- 3/16” Hose x 1/4“ Male NPT Brass Hose Barb
- Fastenal \$3.14 each
- 1/4 in Female Steel Industrial Plug
- Harbor Freight - SKU #63548 \$1.39 each
- Hose Clamps
- Home Depot 1/4 in to 3/8 in Hose Clamps \$7.69 for 12
- Aluminum Tubing - 3/16”
06-Flywheel
- Shepherd 2 in Cast Iron Caster \$4 Home Depot
- 3" Cast Iron Casters \$25 for set of 4 from Amazon
-
7/16 Hole
- Drill 7/16“ (0.4375”) diameter
- Shars 7/16" Reamer \$10.35
Custom Mandrel
- Home Depot - Hex Flat Head Socket Cap Screw \$1.51 each
-
Mandrel - Inside Grip or Expanding or Arbors
01-Frame - Upright Stand
Frame Design
- Clearance Hole
- hole should be 1/32“ larger diameter than bolt used
Frame Materials
- Aluminum Roll Flashing
- 10 in x 10 ft Aluminum Roll Valley Flashing \$10 at Home Depot
- Glue Aluminum to Wood
- JB Weld
- 3M Marine Adhesive Sealant 5200
- Gorilla Glue - foams up, kinda messy but good bond
- Titebond II - not that good
- Max Bond Crazy Glue - terrible
- Degreaser and cleaner
- Recommended Aluminum (6061-T6511) Flat Size (based on availability, Curtis Steel Co. - Jim Pennington 702-952-3000)
- 3/8” x 1-1/4“ x 12' \$24.50
- 3/8” x 1-1/2“ x 12' \$39.50
- 1/2” x 1-1/4“ x 12' \$29.85
- 1/2” x 1-1/2“ x 12' \$48.00
- Pacific Steel Aluminum Flat Sizes Pacific Steel Handbook
03-Piston Head
- Clinching Nut (a.k.a. Press-Fit Nut)
- Walmart - Self-Clinching Nuts 1/4-20TPI, \$19.49 for 100
- Female Threaded Round Standoff
- McMaster-Carr - Round Standoffs OD 1/2”, 1/4“-20TPI
03-Piston Case
- Material - Aluminum
- Size 1” x 3/4“ bars, 1”x1“ should work also
03-Crank Disc and Pin
-
- Material - Aluminum
- 1.25” diameter
- 3/8“ ID Lowe's Fender Washer \$0.26
- 1.5” diameter
-
- 2.0“ diameter
- 1/2” ID Lowe's Fender Washer \$0.29 each
04-Cylinder
- 3/4“ aluminum square
- Bore is off-center
04-PistonRod
1/4-inch threaded rod
- Curtis Steel - $7 for 10-ft, 1/4”-20TPI threaded rod
- Home Depot - 1/4" Threaded Rod - 36" \$2.50 each
05-Connecting Rod
- Eye Nut Style Hangers
- 0.25-in square bar or Square Key Stock
Corner Rounding End Mill
06-Air Port Pipe
- Round Aluminum Tube 0.25in x 12in length \$1.53 K&S 8106 from Amazon
08-Crank Case Bolt - Threaded Rod
- 1/4“-20 fully threaded studs (coarse standard thread)
- \$0.60 for 3” length Lowes item#3024613
- \$1.93 for 3“ length Bolt Depot
- 5/16” x 3“ threaded hex bolt with 1/2” socket size
- $0.75 each Lowes item#214122
- Shoulder Axle Bolt from The Hillman Group
Extension
- a.k.a. Binding Barrel, Bolt Sleeve, Bushing Sleeve
- Extension for Low-Profile Binding Barrels \$1.10 McMaster-Carr
- 8/32 x 1/2" Aluminum Binding Post Extensions \$0.98 each The Hillman Group
- Extension Posts 12x5mm \$0.25 each from Amazon - Hotop
Jam Nut
- $0.25 1/4“-20 TPI jam nut Lowes item#137162
Lock Nut
- $0.13 1/4”-20 TPI lock nut Lowes item#63403
Cut Threaded Rod and Studs
- Use Uniburr to deburr the end of the cut rod
- Deburring External Chamfering Tool \$15 from Amazon
16-CrankShaft
Material
- Option 1 - Aluminum Round - 1/2“ diameter
- concern the set screw will easily mar and create burrs in the workpiece
- Option 2 - Hot or Cold Drawn Rounds
- 7/16” diameter would be ideal, but wonder if turning to remove the outer scaling will make the diameter to small
- Hot-rolled $12 for 20-ft length
- Cold-rolled (1018) $17 for 20-ft length
- 1/2“ diameter
- Hot-rolled $13.50 for 20-ft length
- Cold-rolled (1018) $22.50 for 20-ft length
Grooving Tool
- Kennametal Top Notch Groove and Turn Inserts - NG2031LK - 5967744 - appears I need right hand
- Banggood 2mm wide MGEHR1616-2
17-PistonCylinderCap
- 5/8”-18 UNF length 1/2“ UNF set screw
Bottom Tap
Set Screw
- McMaster-Carr 5/8"-18 length 5/8" UNF cost \$6.89 for 5
- tap size 37/64”
- McMaster-Carr 1/2"-20 length 1/2" UNF cost \$8.39 for 10 (recommend using UNF instead of UNC) (don't use diameter two small)
- Hollow (don't use these)
- McMaster-Carr 1/2"-20 length 1/4" UNF cost \$9.25 for 10
- McMaster-Carr 1/2"-13 length 1/4" UNC cost \$9.25 for 10
- Harbor Freight - SAE Tap & Die Set \$90 has both 1/2-20 and 1/2-13 taps
- Harbor Freight - SAE & Metric Tap and Die Set \$40 has 1/2-20 and 1/2-13 taps
08-Brace
- 1/2“ x 0.065 x 20' Hot Rolled Tubing-Round (ASTM A513) \$15
- flatten both ends of tub
- drill hole
- bend at 45deg
- mount to side of upright stand
- mount to wooden plate
Materials
- Piston Rings and O-Rings
- Compression Springs
- Creeya 225pcs compression springs \$17.50 Amazon
- Ball Bearings
- Miniature Ball Bearings \$2.37 each
- Circlips - Snap Ring - E-Clips
- Snap Ring Pliers \$16
Engine Balance
Furnace
- Pressure Cooker
- Ade Swash - Model Engineer, swashade@gmail.com
Equipment
- Drill Bits
- Reamers
- Engine Cylinder Hone Set
- Gearwrench Hone Set \$28 from Home Depot
- Vise
- Loctite 635 Retaining Compound
- Layout
- Layout Fluid
- Sharpie Marker
- Dykem Blue 8oz \$17
- Scribe
-
- Center Finder
Machines
Vertical Mill
- Central Machinery - 9 Speed Vertical Milling Machine \$2500 Harbor Freight
Max Novo Machines
- MM-D320PRO High Precision Mini Lathe - need DRO, ideal for Industry Schools
DRO
Vendors
- Titan Metals
- Curtis Steel
-
- Rods, Tubing and Flat Bars
- Material: Aluminum, Brass, Copper, Stainless Steel
-
- jefferyjjensen, account# 7592905 NormalOne
Machining Equipment - Guy
Lathe
Mill
Shop Fox
Quick Change Tool Post Set
- Grizzly G5689 \$380
- AXA 250-101 (AXA) Tool Holder (1/2” shank size)
- Note BXA is 250-201 (5/8“ shank size) and CXA is 250-301 (3/4” shank size)
Autodesk Inventor Setup
Content Center
- Location of Libraries - C:\ProgramData\Autodesk\Inventor 2023\Content Center\Libraries
- Folder Options - C:\Users\JeffJourneyJensen\Documents\Inventor\Content Center Files\R2023\ (nothing in the folder)
References
Tubalcain Part 1 of 3
Tubalcain Part 2 of 3
Tubalcain Part 3 of 3
Forums
- The Home Machinist - www.chaski.org/homemachinist username jefferyjjensen NormalOne