Professional Documents
Culture Documents
440
H68
ding
ES.
Work.
etc.
used
THE LIBRARY
OF
THE UNIVERSITY
OF CALIFORNIA
LOS ANGELES
Whit
Emb
Boo
HON.
C
write
Forn
Tick.
Tools
Painting,
g a Room.
and Shoes.
sewing and
ted Boots
Engravings
The
S'gnhe Simpler
Signboard.
Wo<
ng Wood.
GIFT OF
i Spiriting
e-polishing
ors Stains.
and
Pioc<
John S.Preli
Dyn
Diagrams
lanchester
Wire
Dyn;
Smal
and
for
Causes
rmine the
ire Motor.
sir
Dim
Unde
Diagrams.
C<
ront Driver.
Buildmg-a rcear-Kinving saiety. Building landem Safeties. Building Frontdriver Tricycle. Building a Hand Tricycle.
to Make and Fit
Brazing..
Gear Cases.
Wheel Making.
Fittings and Accessories.
ng.
Tyres and Methods
of Fixing them. Enamelling. Repairing.
How
'
Decorative Designs of
and Cork.
Pictures.
Contents.
DAVID McKAY,
HANDICRAFT SERIES
(continued").
and Diagrams.
Appliances used in Glass Blowing. Manipulating Glass Tubing.
Blowing Bulbs and Flasks. Jointing Tubes to Bulbs forming Thistle Funnels,
etc.
Blowing and Etching Glass Fancy Articles ; Embossing and Gilding Flat
Surfaces.
Utilising Broken Glass Apparatus ; Boring Holes in, and Riveting
Glass. Hand-working of Telescope Specula. Turning, Chipping, and Grinding
Contents.
G ass.
How
Make
Systems.
Bamboo
ing Horns.
Dyeing
Skins.
Specimens.
Tailoring:.
Co: tents.
and .Pressing.
Make
Tailors' Requisites
Simple Repairs
Trousers.
How to
How TO
With 160
Comprising
STANDS.
Illustrations.
Contents.
Cameras.
Cameras.
Illuminant for
Contents.
Dissolving View Lanterns.
Single Lanterns.
Conducting a Limelight
Optical Lanterns.
Optical Lantern Accessories.
Lantern Exhibition. Experiments with Optical Lanterns. Painting Lantern
Slides.
Photographic Lantern Slides.
graph Management.
Engraving Metals.
Mechanical Lantern
With Numerous
Introduction and Terms used.
S;ides.
Cinemato-
Illustrations.
Contents.
Engravers' Tools and their Uses.
Elementary Exercises in Engraving. Engraving Plate and Precious Metals.
Engraving Monograms. Transfer Processes of Engraving Metals. Engraving
Name Plates. Engraving Coffin Plates. Engraving Steel Plates. Chasing
and Embossing Metals. Etching Metals.
Basket Work.
Round
DAVID McKAY,
Philadelphia.
HANDICRAFT SERIES
Bookbinding.
With
125, Engravings
(continued).
and Diagrams.
Contents. Bookbinders' Appliances. Folding Printed Book Sheets. Beating and Sewing. Rounding, Backing, and Cover Cutting. Cutting Book Edges.
Account Books,
Cloth-bound Books, Pamphlets, etc.
Covering Books.
Ledgers, etc. Coloring, Sprinkling, and Marbling Book Edges.
Marbling
Book Papers. Gilding Book Edges.
Sprinkling and Tree Marbling Book
Covers. Lettering, Gilding, and Finishing Book Covers. Index.
Including ELEMENTARY ART METAL WORK. With
Irpn
269 tngravings and Diagrams.
Contents. Tools and Materials. Bending and Working Strip Iron. Simple
Exercises in Bent Iron. Floral Ornaments for Bent Iron Work. Candlesticks.
Hall Lanterns. Screens, Grilles, etc. Table Lamps. Suspended Lamps and
Floor Lamps.
Flower Bowls.
Photograph Frames.
Newspaper Rack.
Miscellaneous Examples. Index.
Bent
Work.
and Darkroom.
Contents.
i'ue
Intensification and
Developing and Fixing Negatives.
Exposure.
Portraiture and Picture Composition.
Reduction of Negatives.
Flashlight
Processes of Printing from Negatives.
Photography. Retouching Negatives
Copying and Enlarging.
Stereoscopic
Mounting and Finishing Prints.
Index.
Ferrotype
Photography.
Photography.
Upholstery. With 162 Engravings and Diagrams.
Contents. Upholsterers' Materials. Upholsterers' Tools and Appliances.
Webbing, Springing, Stuffing, and Tufting. Making Seat Cushions and Squabs.
Upholstering an Easy Chair. Upholstering Couches and Sofas. Upholstering
Miscellaneous Upholstery. Mattress Making
Footstools, Fenderettes, etc.
and Repairing. Fancy Upholstery. Renovating and Repairing Upholstered
Furniture. Planning and Laying Carpets and Linoleum. Index.
Plates.
Working.
Harness Making.
With 208
Contents.
Temporary Beehive.
W. B. C." Beehive. Furnishing and
Tiering Bar-Frame Beehive. The
Stocking a Beehive. Observatory Beehive for Permanent Use. Observatory
Beehive for Temporary Use. Inspection Case for Beehives. Hive for RearBee Smoker. Honey Extractors. Wax
ing Queen Bees. Super-Clearers.
Extractors.
DAVID McKAY,
Index.
MOTOR BICYCLE
BUILDING
WITH NUMEROUS ENGRAVINGS AND DIAGRAMS
EDITED BY
PAUL
N.
HASLUOK
\FTS,
ETC. ETC.
PHILADELPHIA
DAVID McKAY,
(510,
PUBLISHER
Engine**
Ubrary
TL
PREFACE.
Handbook
THIS
everyday
use,
form
convenient
for
articles
contributed
by
in
contains,
number
of
Mr. W. Travers
WORK, one
of
weekly journals
The chapter on
it
my
is
coils
ignition
is
on practical
Readers
the
of
fortune to edit.
electrical
who may
desire
details
respecting special
of
subjects.
additional
the
information
x.
in this
WOKK,
subjects,
so that
it
may
a
P.
733510
N.
HASLUCK.
CONTENTS.
CHAPTER
I.
II.
III.
IV.
V.
VI.
VII.
Frame
for
Motor Bicycle
Patterns for
Frame Castings
Making 34-H.P.
Spray
Petrol
Motor
PAGE
...
...
...
47
Motor
97
*
.
10
32
.104
VIII.
....
Spray Carburettor
Index
for
.118
Light-weight Motor
149
15
LIST OF ILLUSTRATIONS.
PAGE
Working Drawing of
13
Motor Bicycle Frame
17
2.
Bottom Bracket
18
Back Fork Crown
3, 4.
5.
End of Back Fork
.19
Crown
20
Rear Engine Lug
6, 7.
21
Front Engine Lug
8, 9.
22
Left-hand Fork End
10, 11.
12.
Top Member of Left22
hand Fork End
22
13.
Back Stay Eye
22
14.
Front Fork End
Patterns for Top and
15, 16.
23
Bottom Head Lugs
24
Seat Lug
17.
24
18.
Rear Part of Seat Lug
25
19.
Lower Horizontal Lug
26
Girder Tube Lugs
20, 21.
27
Front Fork Crown
22, 23.
28
Tube
Lug
24, 25.
Steering
2
26, 27.
Engine Plate
FIG.
1.
42.
43.
46, 47.
48-50.
....
52.
28, 29.
30.
Ball-race
Crank Case
Bracket Lock-nut
Engine Plate Belt .
34.
Tappet-rod Bush
60, 61.
Lever
Connecting Rod
62, 63.
Union Nut
64, 65.
Flywheel
Valve-lift
.67
.
71
73
...
73
75
76
77
38
67.
3S
68.
41
69.
Half-time Shaft
70.
Tappet Rod
....
Position
of
56, 57.
31, 32.
33.
60
61
Section
58, 59.
37
58
59
...
58
63
of Inlet Valve
Spring Washer of Ex63
haust Valve
Plan of Cylinder End
64
of Crank Case
54.
Side Elevation and
Vertical
55.
.
.
53,
...
.
51.
of
Methods
44, 45.
Two
PAGE
FIG.
40, 41.
of
Section
3J-h.p. Petrol Engine
36.
Vertical Section and
66.
Vertical
.
.
.
.
81
81
48
71.
49
72.
Gudgeon Pin
38.
of Engine Cylinder
of Bottom or Open
End of Cylinder
Section of Finished Pis-
55
39.
ton
Section
35,
37.
Plan
Plan
Line
of
XX
Piston
(Fig. 38)
73, 74.
75.
on
.
ways
51
76.
77,
57
79,
...
82
...
.
83
85
86
87
88
LIST OF ILLUSTRATIONS.
PAGE
FIG.
81, 82.
83.
Tube from
.
84,
86,
88.
89.
90.
89
....
Cover Piece
Base Piece
99
Diagram
of
117, 118.
120.
121.
End
of
Coil
.
Diagram
Working
Coils
102.
of Coil
Diagram
nections
101.
.114
Con.115
showing
of
.
123,
Cam Chamber
108.
125.
126.
127.
128.
129.
130.
135
136
137
Piston Ririg Joint
Better Form of Piston
.137
Ring Joint
Piston Ring Bored Ec.138
centrically
124.
Section and Eleva.
Rod
140
and
Crank of
141
Light-weight Motor
.143
Crank Casting
of
Section
Flywheel
.145
and Pulley
146
Exhaust Cam Shaft
.147
Exhaust Cam
Shaft
.147
Ignition Cam
Section and ElevaCarof
tion
Spray
for
burettor
Light.
134.
121
136.
137
151
152
125
154
Throttle Stem
Pattern of Gauze Cone 155
and
Induction Pipe
.156
Union Nut
.
135.
123
weight Motor
Valve Stem Guide of
Spray Carburettor
Section of Carburettor
.
133.
Section of Light-weight
Motor Cylinder
Light-
104, 105.
of
tion of Connecting
Ignition
.117
Section of Light-weight
Motor Crank Case
118
Plan of Light-weight
Motor Crank Case
119
106, 107.
Piston
weight Motor
Gudgeon Pin for Piston
131, 132.
103.
100.
122.
99.
119.
Condenser
.111
Layers
Longitudinal Sectional
Elevation of Trembler 112
Transverse
Sectional
Elevation of Trembler 113
.
98.
94.
97.
96.
95.
93.
Light-
.100
.100
Pattern for Gauze Cone.101
.
.
piece
.102
Bridge Piece
92.
of
Half-plan
Car-
....
burettor
91.
PAGE
FIG.
109.
Plan
of
Union Nut
157
MOTOR BICYCLE
CHAPTER
BUILDING.
I.
handbook,
difficulty
2j in.
w ould be preferable
7
if
a powerful engine
is
fit
amount
of
pattern-making necessary.
The front forks are oval in section, with girder tube* | in. round, swaged down to A in. at
each end. The front fork tube is of l g -in. diameter, and should be stoutly butted at the crown
end to at least No. 13 or No. 14 gauge.
11-
(p. 13) is
12
be to
to do will
as Fig.
1,
down tube;
and 1 ft. 2
14
15
making an ordinary motor cycle according to the instructions given in this book. It
may be mentioned, however, that the diameter- of
the tubes for a tandem motor bicycle with lady's
frame at back will be regulated by the make and
type of fittings used, but the gauges should be as
follows
Bottom front tube, No. 14 down tubes,
No. 18; top and bottom horizontal tubes, No. 20;
head tube, No. 20; bottom bracket connecting
tubes, if |-in. twin, No. 16, if li-in. single tube,
No. 18; rear forks, No. 16; rear stays, No. 20;
front forks, No. 17, with No. 18 girder stays;
steering tube, No. 16, butted 12 at the crown.
Cnater Lea and Co. make several designs of tandem fittings that would be suitable for the pursucceeds in
pose.
16
CHAPTER
II.
and
moulder rapping
shrinkage is made up by
the pattern in the sand, so that as a rule it will
scarcely be worth while to take shrinkage into
consideration. In turning up the body part of
in.
the bracket leave a core-print at each end,
17
-g
and the
the
l|-in.
castings
down
are
Fig. 2.
Bottom Bracket.
may
body
core.
be 2
in.
IS
Fig. 4.
Figs. 3
aad
4.
made on
PATTERNS
FOE,
FRAME CASTINGS.
19
Fig.
5.
End
of
20
tion, Jl
is
in.
made
fa
Fig.
Figs. 6
6.
and
Fig.
7.
7.
member
21
l|-in.
..J-...JI
Fig. 8.
Figs. 8
be
made
piece of
in
two
3^
in.
and
9.
Fipr.
pieces,
by'
9.
1-^
the
in.
in.,
crown
the
same
as
backstay,
is
22
of
Fig. 11.
Fi-r- 10.
Fijrs.
Fig.
13.
It
is
of
D-section,
and
of
the
same
23
Fig. 16.
Figs. 15
and
16.
Head Lugs.
3 or 4 degrees), it
is
24
Fig. 17.
Hear Part
Fig. 18.
of Seat Lug.
Seat Lug.
25
Fig. 19.
require a print of
i in. at each end.
this
main parts
26
sizes
27
Figs. 22
and
23.
28
is shown by Figs. 24
being side and bottom views. It is
made by turning the main part to the dimensions
given, allowing for machining. The central coreprint is ly^in., projecting f in. at each end. The
rear part for the f-in. bolt is cut out separately,
and
25, these
f-in.
on.
core-print.
Fig. 25.
Figs. 21
and
2o.
used, have only the large centre hole cored, leaving the ends solid to be drilled out in the casting.
Fig. 20.
Figs. 26 and 27.
Fig. 27.
Engine Plate.
30
with
fine
Painting
Core-prints,
etc.
All
core-prints
Cores.
31
CHAPTER
III.
33
3i
The treatment
tube lugs is the same as
but note should be taken of
35
36
sf
crown. In this case the bearings should be twopoint bearings, and not four-point, as shown with
the loose ball-races. These parts will not bo so
durable as well-hardened steel ball-races but if
balls not less than ^'V in., or T3(I in. for the top bearing and -^L in. for the bottom bearing, are used,
The malleable-iron
they will wear very well.
castings become very hard when they are brazed,
and thus stand a lot of wear. The loose steel
cone on the head will, of course, be well hardened,
and the radius of the bearing curves should not
be much greater than the radius of the ball used,
thus giving a good large bearing surface, instead
of the small bearing surface usual with V-groove
;
Fig. 28.
Figs. 28
and
Fig 29.
29.
BalJ-race.
discs.
One advantage of the absence of
loose ball-race bearings is that there are no separate parts to gst loose and cause play in the head
Bottom Bracket Axle. Fig. 30 gives the full
dimensions for the bottom bracket axle, which
should be made, preferably, from one of Leadbeater &; Scott's patent stampings. These have
bearing
exterior
3S
Fig. 30.
in Position.
shaped hexagon
may be
39
Fig-. 32.
Figs. 31
and
32.
Bracket Lock-nut,
40
angle.
41
Fig. 33.
42
drilled
of these
up and brazing. Other tubes requiring airholes for brazing will be the back stays, lower
horizontal tube, and front forks ; and the top tube
and bottom, front tube as well, unless the ends of
these are opened out into their lugs. When the
back forks, exactly equal in length, are finally
fitted to the crown, remove and load each tube
with brass and borax, knock the joints well home,
and peg securely. Fix a stay or strut between
the two fork ends, so that they will be held the
same distance apart as they will be when the
wheel is in position. In the absence of a suitable
stay, the hub spindle will do, the cones and nuts
being used to keep the fork ends the correct distance apart and the faces square with each other.
Shake the charge, placed inside the tubes, well
down towards the joints, and braze one at a time,
with the fork on its side.
Fitting Ball-head. Fit up the ball-head tube
to the top and bottom head lugs, the top tube
to the top head lug, and the bottom front tube to
the bottom head lug, and peg the joints. The ends
of the tubes should be hollowed out to fit up
against the head tube. Before brazing, see that
the three tubes are in one plane
to test this,
place a long straightedge across the ends of the
top and bottom tubes, and sight this with the ballhead tube. Also see that the ends of the tubes
are the proper distance apart to drop into place
with the seat lug and front engine lug on the drawWhile these joints are hot, scrape out the
ing.
ends of the ball-head lugs, where the ball races
fit ; this will save a lot of work after, if any brass
has stuck to these parts. Mark off, on the down
and bottom tubes, the position that the Ipwer
horizontal tube lugs will occupy, and clean the
tubes at these parts. Slip the two lugs on to the
down and bottom tubes before the seat lug or the
front engine lug is fitted to its tube.
filing
43
may now
be fitted
wheel
is
mud-guard
44
Next cut
of
joints.
The
now
45
brazed, thus ensuring them being the exact distance apart to drop afterwards into their places.
Before filing up the fork joints* try the front
wheel again, to see if any part has sprung or
given, and thus thrown the wheel out of centre.
It will, of course, be better to correct this now
than to wait until after the joints are filed up.
While the wheel is in the fork, both before and
after brazing, place the straightedge across the
front of the fork crown, and see that is is parallel
with the wheel spindle. Should the fork be on
the twist, this can be rectified by holding the
crown in the vice and inserting a bar between the
lower end of the fork blades.
and
is
marked
46
up
47
CHAPTER
MAKING
3i-H.P.
IV.
PETROL MOTOR.
THE motor
cylinder pattern
for
cylinder.
Boring Cylinder. The first and most important part to be taken in hand is the cylinder.
The boring and machining of this calls for the
greatest care and skill to obtain really good results.
The cylinder, etc., being all in one casting, increases the difficulty of accurate boring,
but makes a much more satisfactory job when
finished.
Before starting the boring operation,
the casting should be carefully examined for
Fig. 34.
MAKING A
3A-H.P.
PETROL MOTOR.
4<J
-IX
Fig. 86.
f
Figs. 35 and 36.
314 I-
"Vertical Section
Cylinder.
*
and Plan of Engine
50
good
MAKING A
PETROL MOTOR.
3i-H.P.
ol
Fig. 37.
bolted
straps,
one strap
coming across the thick part of the valve chamber and the other across the flange at the bottom.
Secured in this manner the casting is less liable
sprung out of shape. The cylinder walls
being only ^\ in. thick (finished), no allowance
can be made for any inaccuracy in setting. The
small lug on top of the cylinder will here be found
useful, as the back centre of the lathe can be
brought up close to the casting and used to test
the accuracy of this end the open end, of course,
can be more easily set by the cutter edges.
The cutter slot in the boring bar should be
within
in. of the end, to avoid any risk of the
end of the bar coming in contact with the cylinder
to be
-4
62
this would be
disastrous in the finishing cut or the one before
it.
It will be noticed that the last f in. of
tne cylinder is shown counter-bored. It will not
be necessary to bore this part if the casting is
accurately set, as the casting is cored out at this
1
part y ^ in. larger than the finished bore.
at Mouth of Cylinder.
setting, after the bore is finished, the
mouth
the cylinder should be
at
of
chamfer
the
This can be done with a separate
machined.
cutter, or a corner of the back portion of on-e used
for boring may be filed to the necessary shape.
This chamfer is necessary for the easy insertion
The
of the piston when the- rings are in position.
extreme end may also be trued up with the cutter
at this setting. This should be done to allow of
the under part of the flange being -^ in. from the
end and the cylinder 6| in. deep. To machine the
valve chamber, the casting should be firmly bolted
down to a perfectly true face plate, 2| in. out of
the centre, to get the opening true. As the surface in contact with the face- plate is so small, the
casting is liable to shift during machining unless
A sheet of brown
it is very firmly bolted down.
paper placed between the face plate and the mouth
of the casting will greatly assist in keeping it from
Machining Chamfer
At
this
shifting.
MAKING A
3A-II.P.
PETROL MOTOR.
53
54
in
MAKING A
3i-H.P.
PETROL MOTOR.
55
ing
I.
Fig. 38.
way
56
lightly
MAKING A
3|-H.P.
PETEOL MOTOR.
57
Fig. 39,
XX
(Fig. 38).
shown
58
greatly prefers, as, if well fitted, the joint is gastight even after the usual wear causes the ring to
part slightly at the joint; and if by accident all
three ring joints get in line when working, the
gas has not a free escape, as it would have with
rings having the plain diagonal slit. The style
shown in Fig. 41, however, is the one generally
adopted, and is merely a j-in. diagonal cut. To
make the joint shown in Fig. 40, i in. is cut
out each side for half the width of the ring, the
final fitting of the joint being done with a very
Fig. 40.
Fig. 41.
Fig. 42.
When
the joint
is
the piston groove
as tight as possible when pressed together to
allow the parts to spring away when released.
The rings, after the joints have been made, are
sprung together in a band clip and fastened to
the face plate or a special chuck made for the
purpose; the clip is then removed, and the rings
turned and smoothed to the finished size 82 mm.
They should just enter the cylinder freely, but
without any shake, with joints tight up. Reference to Fig. 42 will show that the inner part of the
fine
sharp-cornered file.
two parts should
finished,
fit
MAKING A
Hi-H.P.
PETROL MOTOR.
59
tric.
joint.
Fig. 43.
60
made from a
piece of mild steel or from a phosphor-bronze casting. The length over all is 2^ in. ;
diameter at shoulder, 1 in. ; thickness of shoulder,
T\ in. ; bore, y^ in. Above the shoulder it is
turned to f in. in diameter for a distance of f in.
up, and screwed |-in. whitworth thread. Below
the shoulder, for ^\ in. down, it is turned parallel
| in. in diameter, or to fit the inside of the exhaust valve spring. The guide requires very careful making.
The -f^-in. bore must be quite
straight, and the threaded part and the top of
the shoulder quite true with the bore, or the
exhaust valve will not shut true on its seating.
The TV* n hl e should be bored with a twist drill
or reamered out with a -f^-in. parallel rimer.
-
Fig. 44.
Fijrs.
44
and
Fig. 45.
45.
Exhaust Valve.
Three or four
that
45) should be
is,
the
MAKING A
34-H.P.
PETROL MOTOR.
61
Figs. 46
and
47.
62
,,
MAKING A
3i-H.P.
PETROL MOTOR.
63
The end of the stem is screwed twentyfour threads to the inch for f in. of its length.
It should be a very easy fit in the ^-in. hole of
the body, with just the least perceptible shake.
Grinding Valves. Both valves may now be
ground into their seatings with a little of the
the edge.
In grinding in the
finest flour emery and oil.
exhaust valve, the guide (Fig. 43) must be firmly
screwed up into its place in the cylinder. The
inlet valve must be ground into its
seating in the cylinder in the same way, to make
a gas-tight fit. Remove all trace of emery when
body of the
finished.
-^
------
in.
under by
in
j
and Lock-nut of
Exhaust Valve.
deep,
and
is
in.
tapped for J
in.,
to
the
inch,
suit
by twenty-four
half-way through.
If this nut is tightened up on to the lower washer,
with the spanner gripping the upper half above
the saw-cut, it will not get loose.
Two flats
should be filed on the shoulder of the screwed
washer to hold it whilst locking the nut.
Washer for Exhaust Valve Spring. A washer
should be prepared as in Fig. 51 for the exhaust
64
-|
MAKING A
Si-H.P.
PETROL MOTOR.
and
in.
in
inside diameter,
Fijr.
52.
the foundry or in transit. Chuck one of the castings by the central boss and turn the edge true,
and form half the joint, as shown in section at
Fig. 54.
The taper
of this joint is
exaggerated for
clearness
it
66
MAKING A
3i-H.P.
PETROL MOTOR
^\o'r^
68
3^
MAKING A
3i-H.P.
PETROL MOTOR.
69
is drilled
tne
70
MAKING A
3|-H.P.
PETROL MOTOR.
71
this
to
make
Fig. 55.
72
It will save
cut, until the outer skin is removed.
time in tool-grinding if the castings are rough-filed
all over, inside and outside, before starting to bore
or turn.
MAKING A
3|-H.P.
PETROL MOTOR.
73
cover
i in. in diameter.
be noticed that the shoulder of this bush is
let in flush with the cover (see Fig. 55, p. 71).
A small oil
It is secured with a small grub screw.
channel should be chipped or filed from the oil
fi-in.
It will
Fig:. 59.
Figs. 58
and
59.
Valve-lift
Lever.
Figs. 56 and 57.
Guide.
Tappet
74
cessed out to
and
re-
Exhaust-Valve
Lift.
The working
of this ex-
and smoothed
all
over.
g-
end
in.
f in.
MAKING A
3|-H.P.
PETKOL MOTOR.
outside diameter, by f
and
2g in. long
by
in.
in.
Figs. 60
and
61.
Connecting rod.
on the inside
filed
tribute the
oil.
Fig. 62.
Fig. 63.
Figs. 62
and
63.
Union Nut.
MAKING A
3|-H.P.
PETROL MOTOR.
77
Fig. 65.
Fig. 64.
Figs. 64
and
65.
Flywheel.
true
Face
up
off
73
Fig-. 06.
tool
Main
other flywheel
may now
The
manner.
The other side of the castings has now to be
turned, but this time the casting must be held
by the outside of the rim, as the recess on this
side, under the rim, is not deep enough for the
jaws to grip. Turn up the face of the rim to
make
off
for
the
MAKINTG A
3A-H.P.
PETROL MOTOR.
79
<>7
the
Main
namely,
in. ;
This will bring the large side
face off round this opening till it is i in. below
the surface of the rim face. The other side of
3 degrees.
bed against.
3 Me
Crank Pin.
Fig. 68.
is
80
fit
the
ii
from end
to end.
The short or
gear-side shaft (Fig. 67) is treated in the same
way, the plain end, to take the small gear wheel,
being f in. in diameter by f in. long. It is well
to leave the final size of this end until the gear
wheel is bored. The plain parallel part of this
shaft is l^f- in., the taper part A in., and the
screwed part -^ in. The crank pin (Fig. 68) is
turned from a piece of|J-in. or |-in. stuff; the
diameter is f in., to fit the large end of the con3
necting-rod bush, and it is 3 T ^in. long over all.
The two ends are f in. by
in., screwed twenty-
MAKING A
3-H.P.
PETROL MOTOR.
81
V*
Half-time Shaft.
Fig. 69.
turn
all
rest,
and
Fig. 70.
Tappet Rod.
g-
down
^
and
3^
Fig. 71.
Bod.
Fig. 72.
in.
in.
Gudgeon Pin.
is
diameter,
working back
This method of fixing the gudgeon pin, though
simple, has been found to be very effective; but
it is most important that it should be a good tight
fit in the piston, and fitted with a slight degree
of taper.
Set pins, however well fitted and secured by split pins, etc., are never reliable.
It will probably be found, upon trying the
gudgeon pin in the connecting-rod bush, that it
is too tight a fit.
If so, the bush should be
reamered out until the pin is a good fit without
MAKING A
3|-H.P.
PETROL MOTOR.
83
shake.
piece of brown paper on one side of
the reamer will cause it to cut a shade larger than
if used without.
The pin should be hardened,
and let down to brown in the centre and blue
In hardening, do not get the steel
at the ends.
so hot as to scale, or the fit will be upset, and dip
quite straight in the water end on. In fitting the
Fig. 73.
Figs. 73
and
74.
All that has to be made, for cutting keyways in an ordinary slide-rest lathe, is the tool
shown at Figs. 73 and 74. It is turned from a
piece of f-in. or -in. tool steel, the end being
given.
84
MAKING A
3-H.P.
PETROL MOTOR.
85
Fig. 75.
is
drilled,
86
Fig. 76.
Locking Plate.
in. is
MAKING A
3i-H.P.
PETROL MOTOR.
87
makes a reliable fixing, but the pulley is sometimes very difficult to remove if it gets jammed on
the thread.
Pinning Lock-nut to Shaft. The lock-nuts
which secure the two main shaft ends to the flywheel, and one end of the crank pin, may be
secured permanently by drilling a |-in. hole half in
the nut and half in the end of the shaft, and then
driving in a pin which is T^ in. shorter than the
hole is deep, and burring the edge of the hole over
the pin. The drilling must be done before the
shafts are hardened, the pinning being the last
operation of all when finally assembling.
Safety Lock for Crank Pin Lock-nut. The
lock-nut on the other end of the crank pin will re-
Fig. 77.
Figs. 77
and
78.
Fig. 78.
=Exhaust Cam.
78) is
tempered.
tight
bore, J
in.,
to
1^
fit
j
with a
in.
Fig. 79.
Figs. 79
and
80.
Fig. 80.
in
and
hole to
is
in.
fit
MAKING A
3J-H.P.
PETROL MOTOR.
^_-
igr.
Figs. 81
and
si.
82.
Fig. 82.
90
cycle ignition.
MAKING A
3.>H.P.
PETROL MOTOR.
91
Assembling the Engine. With all the component parts made and finished, the final assembling
of the engine may now be started. The two main
shafts should be fitted to their respective flywheels,
the nuts screwed right home, and secured with
small pegs in the nuts and shaft ends. One half
(the gear-side half for preference) of the crank
Fig. 83.
Inlet
92
surfaces.
go,
and
fit
76, p. 86).
side),
and
filled
with
lead.
To
prevent
any
of this
MAKING A
3^-H.P.
PETROL MOTOR.
93
screwed
ur>
and
Fig. 84.
Figs. 84
and
85.
Bottom Plate of
Jf'i<r.
85.
Silencer.
the Ignition. The timing of the igthe next operation. The ignition cam
must be fixed to the end of the half-time shaft
in such a position that the spark will pass when
the piston is at the top of its compression stroke,
with the contact-breaker case or rocker in its midway position. This will allow for retarding and
advancing the spark to the desired amount. It
must be noted that the actions of a wipe contact
and a make-and-break are different in this respect
that whereas with the wipe the spark will pass
at the plug points immediately the brass section
of the fibre cam touches the block on the spring
^wiper, with the make-and-break the spark does
Timing
nition
is
MAKING A
3|-H.P.
PETROL MOTOR.
95
Fig. 86.
Figs. 86
Fig. 87.
and
87.
Top Plate
of Silencer.
96
1^
Fig. 88.
Tube
for Silencer.
end.
I0 3/i
Exhaust Pipe.
to
connect
CHAPTER
V.
MOST readers
can
still
A carburettor
mouth
assist in
making
and
98
petrol
flywheel.
It is usual to provide a carburettor with what
is known as a float-feed, this being a simple device by means of which the ingress of the petrol
copper gauze.
-2Fig-. 90.
Sectional
View
3^-H.P.
MOTOR,
*t
of Carburettor.
100
convenient
body
piece.
fine
Or,
Fig. 91.
Fig. 92.
3|-H.P.
MOTOR.
101
end,
out Ij
in.
diameter by g
in.
Fig. 93.
102
90
and
in.
at the top.
Fig. 94.
true.
3|-H.P.
MOTOR.
103
After the valve piece H is screwed to the needlevalve piece and locked by a small lock nut (not
shown), it should be mounted between the lathe
centres and the brass piece H skimmed up true.
The point can be turned quite at the last, before
parting off the centre on which it was turned.
The brass piece H is fixed in such a position on
the needle valve that the point shuts dead on the
hole at the same time as the under edge of the
piece H just touches the flange of the body piece.
These two joints may finally be ground in with
just a touch of powdered pumice powder and
oil, or crocus powder.
A loose distance piece is slipped on the stem of
the needle valve just above the boss of H, to prevent the valve opening more than
in., and a
light helical spring is made to fit over the boss of
H and bear against the under side of the bridge
piece G. This spring must be light, and rather
weaker than the inlet-valve spring of the motor.
The throttle valve is a disc of brass about
No. 18 gauge riveted or screwed to the casting j,
which is Ts^ in. in diameter, with half filed away
where the disc fits. The operating level is one
with the piece to which the disc is fastened.
The petrol regulating tap to screw into the
bottom of E can be purchased for 9d. to Is., and
should be of about 2j mm. bore.
The outside of the body can be polished and
plated to give a good finish.
10*
CHAPTER
VI.
WHEN
petrol is vaporised, and its vapour combined with air, it forms an explosive mixture
which may be used as a propulsive force in driving a motor. It is thus utilised in specially constructed engines, resembling gas engines, the
construction of which has been fully described in
the previous chapters. The explosive mixture of
petrol vapour and air is admitted into the cylinder
of the motor, and exploded there by means of
electric sparks from an inductor coil specially
constructed for the purpose, and called an ignition coil. This is worked with electric current
obtained from a primary battery, or from a 4-volt
accumulator, the latter being preferred because
of its superior constancy to that of a primary
battery.
Ignition coils for petrol motors may be made in
one or two types (1) a plain primary coil with a
wipe arrangement to cause the spark, and (2) a
:
105
and makes
it
of wire
should
now be
paraffin
to cool.
glue.
106
ratus.
Wind on one layer evenly, then tie the
last turn down with soft cotton, and well baste
the turns of wire with melted paraffin. Proceed
107
ture
coil.
108
manner
Two
109
first
primary.
it
twisted together,
The quantity of wire required will be in proportion to the length of spark desired from the
coil.
Half-a-pound of No. 36 wire should yield a
a f-in. spark, and 1 Ib. a 1-in.
when wound over the primary previdescribed. The shorter spark will probably
spark, fib.
i-in.
spark in
ously
be
air,
sufficient
to
ignite
the
charge in a 3^-h.p.
petrol motor.
110
minal.
The whole should now be covered with paraffined paper, then with wide silk ribbon wound
on tightly, stitched down, and then the whole coil
soaked in melted paraffin until it ceases to give
out bubbles, when it may be taken out to drain
and
cool.
Ill
Fig. 95.
Diagram
of Condenser Layers.
112
in series with
of the primary
circuit.
Fig. 96.
appearance of trembling, hence the name of trembler being given to this part.
The electro-magnet,
armature, arid other parts, may be constructed
to form a separate instrument, and may be placed
in any part of the primary circuit.
But it is
usual for compactness to construct it on one
of
of
the
coil
the
core
the
coil
head
itself,
serving
as the electro-magnet, arrangements for this havbeen
made
when
the
core
and
bobbin
forming
ing
of the coil.
The armature of the trembler A (Figs. 96 to
99) is a piece of iron bar f in. in diameter and
This is attached to one end of a strip
5 in. thick.
in. thick,
of hard German silver f in. wide,
and 2 in. long, by two short brass screws or rivets.
113
Fig. 97.
D
Fig- 98.
114
Fig. 99.
Coil.
coils
are
all
fitted
115
with ebonite
Fig. 100.
Diagram of
Coil Connections.
116
117
"
Fig. 101.
ignition
said to be
Coils.
coil.
118
CHAPTER
VII.
THE
Fig. 102.
119
strength,
or
if
Fig. 103.
lathe
vertical engine.
The lug which fastens it to the
frame may be suitably fitted on the pattern for
those who prefer an inclined position for the
120
121
been machined.
Whichever way
it
is
done,
it
Fig. 105.
Figs. 104
must
and
105.
122
123
For injecting oil with an oil can a J-in. Whitworth thread, with a plain screwed plug, will
do; but for an oil pump worked from the saddle
a larger hole, to suit the particular connection
used, will be necessary. Another hole must be
drilled and tapped in the bottom of the case
Fig. 100.
Figs. 100
and
107.
Fig. 107.
and
this
may
be
with a |-in. screw plug but a small wastetap is handier and gives a better appearance.
fitted
oil
Cam Chamber.
now
124
and
the edge should be milled to facilitate holding whilst grinding-in and for removal. The
cover is secured to the case by four -in. screws,
as shown in Fig. 104. The cover must be chucked
again, back outwards, and the air-hole in the
centre formed. A flange should be left round
this, as shown in Fig. 105, so that the oil splashed
over the cover may run round the hole and down
again to the bottom of the case, instead of leakT
ing out on the outside. The hole may be T in.
or larger, and the head of the flange ^ in. in
diameter. A valve may be made of this if thought
desirable by fitting a yV^ n> cycle-ball, but it is
not necessary .unless automatic lubrication is
fitted.
-in.
Buahes.
3~ in.
screws
of
as
the
long by
1 in.
of phosphor-bronze is
in diameter, with a f-in. hole.
a mallet.
bush and
half in the case, f in. deep, to prevent any possiWhen the bush is
bility of the bush shifting.
fitted, knock it on the mandrel again, and face
off the ends flush.
Prepare the bushes for the
exhaust cam shaft in the same manner. The one
in the case is f in. long by -}i in. in diameter, with
a 4-in. hole. The cover bush is ^-f in. by
in.,
with a i-in. hole. Leave these holes a shade under
in
knock
the
screw
the
cover
in
bushes,
size,
place,
and pass a i-in. reamer through both whilst in
J-'.
125
Fig. 108.
all
part that
sides,
fits
and mark
126
piece of
hardwood across
the
mouth
of cylinder,
and
in.
apart.
ii. in.
127
Fig. 109.
iviotor
Cylinder Head.
128
Fig. 110.
cutters to
129
Whitworth thread,
under side for the
bed truly against. Next bore the
(Fig.
110),
-f-in.
valve guide to
opening and seating for the exhaust valve to the
sizes and angle shown in Fig. 108.
The sides of
the exhaust chamber should be cleared up with
the hook tool. The opening and seating for the
inlet valve may now be machined, and the top
130
full"
to
Fig 111.
.
in.
or
in Fig.
1-in.
tighter than with a tommy wrench. The pushrod guide can be made in a similar manner, two
flats being filed on the base by which to screw it
181
Fig. 112.
Fig. 113.
Figs. 112
made
and
118.
Exhaust Valve.
132
MOTOR BICYCLE
BUILDING:.
r
Fig. 114.
Inlec Valve.
type carburettor, then the inlet valve will be required of the size and form of Fig. 114. This
should be as light as possible consistent with the
work it has to do. The valve body (Figs. 115 and
116) is an iron casting, drilled -% in. and turned
to size. The valve must be ground to its seating
in the same way as the exhaust valve.
Inlet-Valve Spring. The spring for this valve
133
Figs. 115
and
116.
Body
of Inlet Valve.
cylinder flange. Place the cylinder on the crank case with the exhaust-valve guide
directly over the centre of the exhaust-cam chamber on the crank case. Mark off through the holes
in the cylinder flange with a scriber, remove the
cylinder, centre-dot the crank-chamber flangecarefully, drill
-Jg-
in. bare,
and tap
to suit pins
134
Whitworth threads, using paraffin to lubricate the taps. The holes must be tapped carefully, or the metal will tear and spoil the
thread. Remove the tap once or twice, and clear
ott the dust to avoid tearing.
Then replace the
cylinder, fasten it down with three screws, and
with a long drill made to fit the bore of the
exhaust-valve guide, drill the hole in the cam
chamber for the push-rod guide. This will ensure the push-rod being exactly in line with the
valve-stem. Tap it ^-in. Whitworth to suit the
.guide, and screw it in place and test for truth.
The push-rod will be a short length of steel turned
to fit the guide freely, one end, operated by thei-in.
Tj
smoothed
off
with a very
fine
smooth
file,
the
135
own
Fig. 118.
Fig. 117.
Figs. 117
and
118.
136
parted
otf
tool.
Smooth
off
Fig. 119.
Gudgeon Pin
for Piston.
the pin.
and tap
i-in.
137
let
down
to a
brown shade.
./
Fi-r. 120.
Piston Ring
Joint.
Better Form of
Piston Ring- Joint.
Fig. 121.
138
Fig. 122.
is
open.
With
perfectly,
139
apart.
mark
It
off
5f in. apart without marking off. The phosphorbronze bushes for the two ends may now be prepared. Chuck the large one, and bore and reamer
it out f in.
The small bush is finished -.?- in. in
diameter. Knock each bush on a true mandrel
of the proper size, and turn the large one f in.
full and the small one f in. full.
They should be
a very tight fit for their respective bores, as they
are to be shrunk in place. Heat the boss of the
'connecting-rod to about the heat of a hot soldering iron, and knock the bush in quickly with a
mallet, or press it in between the vice jaws, and
cool at once in cold water.
If this is properly
140
t'ig.
Fi<r. 123..
Figs. 123
and
124.
trate.
Setting
will
now
141
on which the bushes were turned should be inserted in the ends, and tested with the callipers
to see whether the bores are parallel. The rod
may be set cold if found out of truth. These
mandrels should be made rather long, say 6 in.
or 7 in., as, when used for setting, the extra
Fig. 125.
142
avoid
fracture,
to
end extending
the
mild
Cut
and
off
the
143
working of
Fig. 126.
Crank
Casting-.
144
threads,
left
method of holding
and
BICYCLE.
145
The groove
A, -^V in.
deep
catches
any oil which may leak
the
axle
out of
bearing,
by
and
in.
thus
wide,
prevents
it
The pulley
to the rider.
is 3j- in. in diameter, and
the belt groove is -^ in.
wide at the top by g in.
at the bottom, and the
flywheel rim will require
Fig. 127.
Section of Fly-
and connecting-rod.
Gear Wheels. The two gear wheels to work the
exhaust and ignition cams are phosphor-bronze
ton
HG
castings
having
respectively.
cam
may
and turned.
1:50
Fig.
Fig-. 128.
Exhaust^
Cam
Shaft.
Exlaust
12'J.
Cam.
Fig-. 130.
Ignition
Cam.
may
147
right
cam
is
brown
colour.
will
require
148
The Ignition.
latest
and earliest
ber mark the
positions,
as guides when fitting the level and rod to work
from the top tube of the bicycle. The advance
sparking apparatus best suited to this motor is
the small one of Bassee and Michel.
149
CHAPTER
VIII.
150
Fig. 132.
Figs. 131
and
132.
151
into
-jfV
drill.
drill will
152
Fig. 133.
153
throttling or shutting off the amount of gas admitted to the cylinder. Drill a fVin. hle through
the central collar E (Fig. 132), and turn up the
main
castings.
may
Fig. 134.
riveting.
when
shut, but
it
tively.
154
Fig.- 135.
very light spiral spring (not shown) will be required, fitted between the cross-bar of A and the
top of the valve plate c. This quickens the action,
should a
little
155
of the valve.
make
Fig. 136.
The
or nickel-plated, as desired.
may
fit
into the top of the carburettor, being
secured by tightening the pin of the split lug on
the carburettor ; to the other end is brazed a steel
washer, li in. in diameter, with |-in. bore and
156
Fig. 137.
(Fig. 137).
INDEX.
Advance
Apparatus,
Sparkin
'
to Case, 116
Coil, Fitting,
Insulation
122
Heads
Air-release Valve, 69
Axle, Bottom Bracket, 37
of,
109
108,
105
for.
Primary, 104-107
Secondary, 109
19,
20
Ball-head, Fitting, 42
Pattern, 27, 28
Ball-races, Fitting, 36, 37
Bearing Bushes, 71
Condenser
10
110
Round,
Crank Case
,
33
32
Axle, Fitting, 37, 38
32,
Tubes
Brazing
Dowelling Halves
Cylinder, 47-52
to
to,
to,
Bottom
98
3J-h.p.
IJ-h.p.
End
Fitting
of,
Cylinder
Machining, 65,
Oil Holes in, 69
Chamber Flange,
149-156"
of, 97,
for
for
123, 124
Cylinder
92, 93
ber, 97, 98
for IJ-h.p. Motor, Making,
Spray,
Cylinder
Motor,
Function
Motor,
IJ-h.p.
Cover
for
70
69,
,
Bracket, 40-42
Bushes, Engine, 71, 124
in Gear Cover, 73
for Half-time Shaft, 72
of Connecting-rod, 74-76
Main-shaft, 72
Tappet-rod, 73, 74
Carburettor Float-feed Cham
31
30, 31
Attaching
Tubes
of,
120
40-42
Brazing
Coil,
Core-prints, Painting, 30
Cores, Oval, 31
Tube Lugs,
Bottom Bracket,
Ignition
Core-boxes, 16
Engine, Fitting,
126
Boring Bar for Cylinder,
Cyl
,
for
110, 111
Crank
Motor,
Drilling,
143,
Pin,
Surface, 97
for, 87
Cranked Tubes, 10
Crown, Back Fork,
Frame from,
32-46
Fitting, 33
Pattern
for,
19,
,
i
i
'
Cylinder, Boring,
End
,
of
Crank Case,
Fitting Crank r aS 8
Flange, 128, 129
66
6R
93
to, 92,
158
Mouth,
56,
57
Machining Cham-
INDEX.
Main-shaft of Motor,
79,
80
159
160
Shaft, Half-time, 81
Main, 79, 80
,
(see
Main
HANDICRAFT
SJS-RJgS
(continued).
Electro- Plating.
Illustrations
&//*.
Photographic Chemistry.
Contents.
Introductory
Relation
its
Chemistry
to
Photography.
Some
With 180
Illus-
trations.
Dark-Rooms.
Dark-Room
Fittings.
Portable
With 137
Dark Tent.
Illustrations
Index.
and Diagrams.
weight Motor.
Index.
DAVID McKAY
This book
is
ni IE ~*
'
UL
:xt.
Hh,
from which
DEC 2
it
was borrowed.
Sh
2WEEKLOA
THE LIBRARY
UNIVERSITY OF CALIFORNIA
LOS ANGELES
TECHNICAL
000 882431
Practical Handrailini
ations.
Contents.
Principles of hi
Simple Handrails.
of Models
Obtain
Twi:
Construction and Use.
Orthogonal or Right-angle Sy:
Drawing,
The Uses
ithed Handrails.
for
ails.
,.
Practical BrtckWork.
With Numerous
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Painters' Tools
Objects, Principles and Processes of Painting.
Materials used by Painters.- Preparing Suifaces for PaintWoodwork, Painting Ironwork, Painting Stucco or Plaster:
and
House
Color
Combination.
Painting. Varnish
Whitewashing
Distempering
and Varnishing. Stains and Stafnirig. Estimating and Measuring Painters'
*^
Work. Index.
Contents.
and Appliances.
ing,
Painting
Illustrations.
Contents.
Cotton. Flax, Jute, and" China Grass. Wool. Silk. Cotton
Bleaching. Linen Bleaching. Mercerising. Wool Scouring and Bleaching,
Scouring and Bleaching Silk. Water. About Dyeing. Index.
Coloring
With Numerous
Illustrations.
Sanitary Construction
tion.
Typical Dwelling.
Index.
and Manufacture.
With
Illustrations.
etc.
Ores of Iron.
Other
DAVID McKAY,
(BOOKSELLERS)
New Volumes
in Preparation.
STA