HERE THE CYLINDER LINER IS DONE, PRESSED INTO THE CYLINDER, AND THEN SOME STEPS TAKEN TO ASSURE ALIGNMENT LATER.
I had turned the liner OD using a live center on the right end (before boring) The center was removed, and the center drilled spot was used to start the first drill for the bore.
When drilling and boring the ID, I used a steady rest. (probably not needed, but it didn't hurt) The steady was placed so that if any distortion resulted, it would not matter because it would be in the area of the water jacket.
Completed cylinder liner. It will be lapped later
Here is the cylinder, with liner press fitted in. Each end was faced off, to the finished length. I used an expandible arbor in the liner, (which was not lapped yet) to hold it in the chuck..
Prior to inserting the liner into the cylinder, I tested the amount of expansion of the cylinder by heating it to 500 degrees, then quickly measuring the bore. I measured at least .003 expansion, which told me that the liner should easily slip in. Just to be sure, I put the liner in the refigerator while the cylinder was heating up the second time.
I bored the cylinder liner to .8755, for a reason. I had a piece of .875 drill rod, that I polished slightly, for a slip fit into the liner. Here I am using an indicator to align the cylinder bore exactly parallel with the mill table X axis. and parallel to the table top. The Cylinder base was then just skimmed to guarantee it parallel with the bore.
OK, now that the cylinder and liner are done, how in the heck am I going to make sure that the bore will be aligned at exactly 90 degrees with the crank shaft when fasened to the base?
The late, great, Phil Duclos to the rescue! I was going to make his Odds"n"Ends engine next, and have the plans. The technique he uses for alignment is simple, and accurate. A 1/4 inch groove was milled across the bottom of the base, .075 deep, at right angles to the bore. A corresponding lip will be milled on the base. That will be shown later.
PAGE LINKS FOR CONSTRUCTING THE EAGLE
