eagle_con_rod

THE CONNECTING ROD

Rather straight forward machining, here are the steps I used. Probably a better way, but once again it worked for me.. The Buehler is certainly not a common tool for the HSM, but I use it often for precision sawing, just "cause I have it".

The first step was drilling holes for the bolts to connect the two pieces on the end of Con Rod that hold the split bearing. I drilled the holes sized for tapping 4/40. After cutoff, the top half would be re-drilled to 4-40 pilot size. This assures that the holes will line up later. The bottom will be tapped 4-40.

Cutting off the top end of the piece. The Buehler saw makes this a simple step, and highly accurate.

The end of the Connecting Rod has been re-joined by the 4-40 screws that will be used. The hole was aligned with the center and directly over the slit. It is being reamed to 0.437 for the split bearing.

Next I marked out a taper, super glued the piece to a sacrificial Aluminum base, and milled it to shape in a milling vise. The ends will be cleaned up later.

A groove was milled down the center, on both sides, using a ball end mill, PRIOR to finishing the ends. This allowed the piece to be lined up to the X axis, and guarantee that the groove would be straignt down the center of the taper.

Now it is time to form radius on the end of the rod that goes inside the piston. I made a fixture (used the same piece of Aluminum that was used to hold the head for slotting) The two 4-40 bolts serve as stops to prevent going around too far on the cut. The rod pivots around the brass stud.

This is the fixture used to form the radius on the end.

PAGE LINKS FOR CONSTRUCTING THE EAGLE.