The Boll Aero 18

As a practice before making the 4 cylinder, 4 stroke engine for the mini caterham, I have decided to make some simpler engines.

The first engine I have chosen to make the Boll Aero 18. It’s a 1.8cc diesel engine with a 1/2 bore and 0.550″ stroke. I intend to make this as a practice for making cylinder liners, pistons and shafts and achieving the correct fits / tolerance.

If you would also like to make this engine the drawings are available here: http://modelenginenews.org/plans/BollAero18.pdf

Improvements to the Manual Shaper

So yesterday I did a little more work to the manual shaper to reduce some of the play in the cross slide.

I removed the guide spacers and measured them against the cross slide rail. The rail measure 10.9mm while the guide spacers measured 11.9mm. So my movement was coming from the 1mm of clearance between the two parts.

I decided to machine 0.75mm off the guide spacers to create a 0.25mm clearance between the cross slide rail and the saddle / guides.

This made a massive improvement without completely locking up the saddle. Let me know what clearance you would have made?

Drawings for the ‘Make Your Own Shaper’…… Shaper.

I have now completed the ‘Make Your Own Shaper’ YouTube video series! Go check it out if you haven’t see it already! https://youtu.be/oxzIVbL2ONw

In the first video of the series I said I would be making the drawings for the shaper available to purchase here on my website.

Now I’m not very good at putting a value on my work, so what I’ve decided is that if you would like the drawings, so that you can ‘Make Your Own Shaper’, simply make a monetary contribution to https://www.paypal.me/mrmechanical of whatever value you think is fair. Use the word ‘Shaper’ as a reference and include your email address, and once your payment is received I will email you the drawings.

All money received will support my YouTube channel and allow me to continue to make video’s like the ‘Make Your Own Shaper’ series.

With the purchase of the set of 26 drawings you will also get email support from myself should you need assistance.

Thank You!

Make your own Shaper!

My most recent YouTube series see’s me making a manual Shaper. I have always looked at shapes and wished I had the space for one (they are a large machine). They are however very useful for cutting internal key ways.

This Shaper however is very compact and will prove to be useful when I need to cut internal key ways and splines for the various gears and hubs on the mini Caterham project.

I now have two videos already uploaded on YouTube showing the making of the shaper body, ram and lever.

Once the build is complete and the design is debugged I will be making the drawings available to download on this website for a small fee. Keep checking back here for or on my YouTube channel for updates!

Assembled body and machined ram / lever parts for the shaper project!
Latest video on the shaper project.

First Cut using the DIY Power Feed & Making a 2 Piece Vice

Two piece vice – parts faced of using the power feeder to achieve the finish shown.

Following the making and fitting of my DIY Power feed to my milling machine, yesterday I recorded a new video showing how well the power feed works. It was one thing to move the empty table using the power feed but this didn’t demonstrate how the motor would perform under the cutting loads and resistance of material when milling.

In the video, to demonstrate the performance of the power feeder, I faced off a piece of S275 25mm square bar. I am pleased to say that the power feeder worked very well and showed no sign of a struggle at all. The finish achieved using the power feed was also a great improvement on that I have achieved by manual operation.

Once I was happy with performance of the power feed I set it to work on it first project. Making a 2 piece vice. I have a project coming up (next video) where I will be making a small manual shaper. Some of the parts needed to make this shaper are 8″ x 8″ plate and these will not fit in my machine vice. Also, I need to face these parts off so they cannot be clamped down to the table. Hence, I made a 2 piece vice. The Video is online now, check it out!

Power Feed Bracket Plans – Free Download

As featured in one of my recent youtube videos – ‘DIY Power Feed For Milling Machine’, here you can download a free copy of the drawings I used for the bracket.

I made this power feed for a Warco GH Major milling machine but it may also fit other milling machines.

Parts Used:

100 x 50 alloy box section:

M8 Cap Head Screws