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Ai Mark II Channel.

 Ai Mark II Channel.

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Progress on the Motion Work: A Step Closer to the Finished Engine

Hello again, fellow builders and enthusiasts!

The past few weeks have seen a continuation of work on the motion components of the 3" Burrell traction engine. After tackling the weigh-shaft bracket, it was time to move on to another vital part of the engine's motion work: the Die block and finally revisit crankshaft.

Crankshaft Fabrication and Challenges

The crankshaft is one of the most critical components of the engine, and creating it to the correct specifications has been both exciting and challenging. I started by sourcing a high-quality cast Iron casting that matched the original drawings. The initial task was to turn down the material to the desired diameter while maintaining tight tolerances. I made sure to take my time with this step, as it’s easy to go too fast and risk losing the precision needed for the subsequent steps.

Once the shaft was rough-turned, I moved on to the more detailed work: drilling for the flywheel and the bearing mounts. For these operations, I had to ensure everything was perfectly square and aligned, especially considering the forces that will be exerted on this component once the engine is operational. The key here was ensuring the centers were precisely aligned, which took several setups to verify.

The Milling Machine Setup: A Lesson in Patience

Much like the weigh-shaft bracket, I had to rig up a custom setup on the milling machine to drill the crankshaft accurately. This part of the project involved some trial and error, especially when I realized that even a slight misalignment could lead to significant issues down the line. However, with patience and a careful approach, I was able to drill and slot everything as required.

I cannot emphasize enough how much the setup process can make or break a project like this. Often, it’s the planning and the setup that separates a good result from a bad one. As you can see from the photos, using clamps, precision vices, and various measuring tools helped ensure that the shaft was securely held in place throughout the machining. It’s a lot of extra work, but it’s absolutely worth it to achieve the desired result.

A Nod to the Past

As I progress, I continue to refer to the fantastic resources shared by other builders of 3" Burrells. The wealth of information available in this hobby is a huge benefit, and I’m grateful to those who’ve documented their own builds. I’ve attached a photo of one of the earlier builds that I’ve been using for reference purposes (thank you to the original builder!). It’s an invaluable guide when I’m looking for confirmation that I’m on the right track.

Looking Ahead

With the crankshaft nearly complete, I’m now turning my attention to the next step: assembling the motion work to ensure everything fits together properly. This part of the build is all about the little details, making sure every component moves as it should and that there are no clearance issues. I’ll be documenting the process as I go, of course, so keep an eye out for the next update!

Until next time, stay safe in the workshop, make plenty of swarf, and keep building!

Stephen.

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