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Builds, Repairs, Show Your Machines! => Technical Tips, Builds, and Help => Topic started by: creepy on May 29, 2019, 03:49:58 am

Title: "Stuart Beam Engine" full build
Post by: creepy on May 29, 2019, 03:49:58 am
Hi Folks
This is a full build thread for the "Stuart Beam Engine", part one consists of an overview of the build, with hopefully an update (video) once a week.
This is a casting kit which I believe has been around for many years.
I have included a link to my YouTube site where the videos will be posted.
Please comment and feel free to offer any advice as I hope we all learn something together.
Please be patient of my video skills as I'm no expert.
Regards.
Gary

https://www.youtube.com/watch?v=AK0C40r1pTc&t=28s
Title: Re: "Stuart Beam Engine" full build
Post by: Scorpion2nz on May 29, 2019, 05:27:28 am
Are you going to build as per plans or do as I did
I do not like the outboard pedestal bearing idea.
I put the bearing where the “Stuart” name was and fabricated a crankshaft .

[attachimg=2]
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on May 29, 2019, 07:22:47 am
Hi
Yes I was going to follow the plans but will take on board your concerns and solution, I was aware of the outboard support issues especially around stability and alignment.
My initial idea was to place both the main body and support on a heavy metal common base attached to a wooden base, eg steel or brass plate, but I will certainly look at all options.
Thank you for your feed back.
Regards
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Scorpion2nz on May 29, 2019, 01:22:23 pm
I went with my design as it gives me a smaller footprint and by avoiding a heavy extra base plate keeps it a bit lighter .

Here it is with a 105 mm diameter boiler .

Title: Re: "Stuart Beam Engine" full build
Post by: creepy on May 29, 2019, 06:29:09 pm
Very nice setup, love the boiler.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on May 29, 2019, 07:35:44 pm
Hi Gary,

Very much enjoyed your first video, very instructive and very informative. Cannot wait to follow you along with the build of your Stuart Beam from the castings out of the box to a running model engine......just brilliant!

Thanks also for the tour of your lathe and mill and your workshop, that was a treat.

So glad you've joined the forum.
Title: Re: "Stuart Beam Engine" full build
Post by: Nick on May 29, 2019, 08:05:33 pm
Very nice introduction video Gary, can't wait to follow the build  ;D
Title: Re: "Stuart Beam Engine" full build
Post by: classixs on May 30, 2019, 04:32:15 am
Very interesting, will be looking forward to follow your updates.
Title: Re: "Stuart Beam Engine" full build
Post by: Hero on May 30, 2019, 07:47:01 am
Great project. I'll follow it with interest.
Title: Re: "Stuart Beam Engine" full build
Post by: Steamandoil (Tim) on May 30, 2019, 09:17:22 pm
I am along for the build too. Welcome to the forum.
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on May 31, 2019, 07:51:31 am
Hi Folks
Here is the First video of Part 2, (Had to break up video as it was getting to large) Section 2 to follow soon.
When I was editing the video I noticed the sound was poor (background noise) so I'm going to strive to improve both the Audio and Video
I'm still learning how to do these live recordings.
I hope you find the content interesting, please comment.
Gary

https://www.youtube.com/watch?v=J3TVjdKO-Mw
Title: Re: "Stuart Beam Engine" full build
Post by: Swift Fox on May 31, 2019, 01:37:20 pm
Looking forward to seeing this evolve, thanks for the videos so far!
Title: Re: "Stuart Beam Engine" full build
Post by: Scorpion2nz on May 31, 2019, 01:53:24 pm
Good start but i was a Little worried with your surface plate  work .
I use a full sheet of wet/dry and go in a variety of directions as traveling  back and forth can lead to a slightly bowed surface . As for boreing the bore i thought the chest surface was done first and then the bore as it was easier to get both in the same parallel.

Cheers
Dennis
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on May 31, 2019, 03:27:57 pm
Brilliant Gary, you have me hook like and sinker.

What a great resource this thread is going to be. Thanks for the effort of documenting this build of your Stuart Beam.
Title: Re: "Stuart Beam Engine" full build
Post by: Nick on June 01, 2019, 01:37:28 am
Thank you for the large amount of footage already Gary! A lot of work just to build the engine, and then to take the extra time documenting  :)
Title: Re: "Stuart Beam Engine" full build
Post by: IndianaRog on June 01, 2019, 07:06:35 am
Gary, I neither have the equipment or skill to do what you are doing, but I love watching a skilled craftsman turn a bunch of rough castings into the finished product.  Thank you for taking the time to document it all.

Roger
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 06, 2019, 06:47:05 am
Hi Folks
Here is part two of the Stuart cylinder build, I have decided to break this portion of the build into smaller videos to keep them as short as possible and I can post them up at a smaller time frame (at least one per week).
Hope you enjoy.
Gary.
https://www.youtube.com/watch?v=aeihrn6_fTI
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on June 06, 2019, 06:55:25 pm
Enjoyed every minute of the Gary, please keep videoing the build process.

Thoroughly enjoyable viewing and good camera skills.
Title: Re: "Stuart Beam Engine" full build
Post by: Nick on June 06, 2019, 10:51:33 pm
Yes Gary, as Jim said, please keep on with the videos  :)  much better than watching the TV  ;)
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 07, 2019, 01:42:25 am
Thanks Guys
I'm really surprised how well Supa Glue holds parts for machining, I wish I knew about it years ago.
The build is proceeding slowly but I,m getting there.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Belugawhaleman on June 11, 2019, 12:08:32 pm
Great work Gary so far on the engine and the videos. Thanks for sharing.
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on June 17, 2019, 09:54:11 pm
How's the build coming along Gary?
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 17, 2019, 11:13:00 pm
Hi Jim
I'm still working on the build, it's moving on slowly, video will be a bit late as I have been unwell and it's freezing at the moment in the workshop/garage, (Highland weather)  I'm also waiting for Stuart to send me cast piston rings as I do not like the "O" ring supplied in the kit.
Hopefully I will post a video at the end of this week.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on June 17, 2019, 11:44:58 pm
Sorry to hear that you haven't been the best Gary.

Yes, we've had some cold days here on the coast as well. I was in Goulburn up your way a little while ago and it was brass monkey weather the elevation you are makes it a lot colder!
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 20, 2019, 04:11:35 am
Hi Folks
In this video I machine the flywheel.
*Please Note* some sections of the video are sped up 5 times (drilling etc)
The cylinder is still not complete as I'm waiting for parts (cast piston rings) from the UK, when they arrive I will video the completion of the cylinder assembly.
Please comment.
Thank you
Gary

https://www.youtube.com/watch?v=m4tAwuDGizY
Title: Re: "Stuart Beam Engine" full build
Post by: Stoker on June 20, 2019, 11:07:51 am
Thank you Gary, for providing such thorough documentation of your build.

That flywheel turned up real nice, and I'm sure you'll get well balanced performance out of it!
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 20, 2019, 06:03:05 pm
Thank you for your kind comment
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on June 20, 2019, 06:27:12 pm
Well Gary that was 15 minutes of thorough enjoyment, much better than TV!

Thanks for taking the time to explain each operation so clearly.
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on June 20, 2019, 07:05:14 pm
Gary, what is the indexible cutter you are using?

Also with your HSS lathe bits, are they chinese HSS or name brand HSS?
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on June 20, 2019, 07:07:33 pm
Whoops one more :)

Would something like JB weld which is steel/cast iron coloured camouflage the sand blow holes in the flywheel?

 
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 20, 2019, 08:39:03 pm
Gary, what is the indexible cutter you are using?

Also with your HSS lathe bits, are they chinese HSS or name brand HSS?
Whoops one more :)

Would something like JB weld which is steel/cast iron coloured camouflage the sand blow holes in the flywheel?

 
Well Gary that was 15 minutes of thorough enjoyment, much better than TV!

Thanks for taking the time to explain each operation so clearly.

Thanks very much Jim for the kind comments.
Answer to question one, not sure the cutter came with the lathe when I bought it. (with lots of tips)
The HSS cutters I bought online from (ozmestore1) I suspect they are chinese but very good quality and his service is very good. (Australian seller)
And yes I too thought about JB weld, might give it a go.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Stoker on June 21, 2019, 12:05:35 pm
The problem with using JB Weld to fill those casting voids is that it won't polish up like the rest of the flywheel. If you are going to paint those surfaces, then it will work fine, but if leaving them in the bright, then not so well. Perhaps a bit of silver solder (the soft kind), would work a bit better, or perhaps actually peen a small bit of actual silver, or coin silver, into the void. Real silver or the solder will darken over time, but so will the exposed iron, and all of it will brighten right back up with a quick pass of crocus cloth or other fine abrasive.

Just thinking out loud here.
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 21, 2019, 06:33:49 pm
The problem with using JB Weld to fill those casting voids is that it won't polish up like the rest of the flywheel. If you are going to paint those surfaces, then it will work fine, but if leaving them in the bright, then not so well. Perhaps a bit of silver solder (the soft kind), would work a bit better, or perhaps actually peen a small bit of actual silver, or coin silver, into the void. Real silver or the solder will darken over time, but so will the exposed iron, and all of it will brighten right back up with a quick pass of crocus cloth or other fine abrasive.

Just thinking out loud here.

Yes you are right, JB Weld would be a different shade, (color) I didn't think of that, I will give some thought to your other suggestions, thank you for your reply, much appreciated.
I will look on YouTube for any suggestions.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 21, 2019, 11:26:51 pm
Hi Folks
A few photos of the painted flywheel.

[attachimg=2]
[attachimg=3]
[attachimg=7]


Spoiler allert
Jim asked if I was going to add a governor, this is one I purchased from Jin, I will try and adapt it to the Stuart.
[attachimg=4]

[attachimg=5]
[attachimg=6]

Any questions please ask.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 27, 2019, 06:57:16 am
Hi Folks
Here is part 4 of the build.
Hope you enjoy
Gary
https://www.youtube.com/watch?v=bipSiSFtgmw
Title: Re: "Stuart Beam Engine" full build
Post by: Stoker on June 27, 2019, 09:30:38 am
Another great episode!

As long as the end of the shaft doesn't interfere in any way with the rod, I see no reason to cut it back.

Just a question .... why did you do the taper reaming by hand instead of using power at low RPMs? Perhaps just so you didn't have to bother with the critical alignment of setting it up, which can often take much longer than the actual work itself, especially when it is a quick and easy job like this one?
Title: Re: "Stuart Beam Engine" full build
Post by: classixs on June 27, 2019, 12:36:51 pm
Been somewhat absent in this thread, so had to view a couple of movies to catch up...

You´re doing a great job there Gary !

Thank you so much for taking the time to share, i really enjoy watching the progress on this beaut.
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 27, 2019, 06:47:45 pm
Another great episode!

As long as the end of the shaft doesn't interfere in any way with the rod, I see no reason to cut it back.

Just a question .... why did you do the taper reaming by hand instead of using power at low RPMs? Perhaps just so you didn't have to bother with the critical alignment of setting it up, which can often take much longer than the actual work itself, especially when it is a quick and easy job like this one?

Thank you for the comment
This was a hand reamer and a very small one, I always hand ream as I can feel the way the reamer is cutting, (traditional method) I guess you could machine ream very slowly, but personally I wouldn't, (I'm not that brave)
There are of course machine reamers which are specifically designed to ream under power and with the wide spread use of CNC machines they are becoming more of the norm.
This is the only taper reamer I have of this size so discretion is used when I use it.
Thank You
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 27, 2019, 06:54:41 pm
Been somewhat absent in this thread, so had to view a couple of movies to catch up...

You´re doing a great job there Gary !

Thank you so much for taking the time to share, i really enjoy watching the progress on this beaut.

Thank you for your kind comment.
I didn't realize how hard it is to machine with a camera tripod sitting right on your hip. (it's like having a 4 year old tormenting you)
But thank you, I hopefully will improve my videoing.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on June 27, 2019, 06:55:25 pm
I've read a lot of positive comments about Jin's governor's Gary.

Another thoroughly enjoyable video installment of the Stuart build, it really great following this through .
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on June 28, 2019, 01:17:46 am
I've read a lot of positive comments about Jin's governor's Gary.

Another thoroughly enjoyable video installment of the Stuart build, it really great following this through .

Thanks for the kind comment Jim.
I'm hoping the governor won't be to much hassle to adapt to the Stuart, I to have heard a lot of positive comments about the governor and Jins service is excellent. ( even Keith Appleton likes them, and that's saying something  ::))
thanks for watching.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jon Cameron on June 29, 2019, 11:53:07 pm
Hello Gary,

Just seen this thread, (gotta love a good build thread). I agree with the earlier comments on machining the cylinder, as it's easier to align and gain measurements for everything using the machined flat valve face on a surface plate, to get the correct distance for the bore, and also makes aligning the bore and cylinder end parralel, by using the machined face against one of the jaws. You seem to have done a good job on the cylinder dispute it's poor quality of cast. Maybe you had done this during cleanup, but just run a small needle file down the steam passages as they may also be quite poorly cast so won't allow passage of steam through.

With regards to filming with a camera tripod under you, perhaps maybe a camera mount that attaches to the rear of the cross slide either via a magnetic base or to the tee slots in the cross slide. Either way I wouldn't worry about your filming as it's showing all the details needed. (Also American pie in the background was actually quite pleasant to hear).

Keep up the good work and I look forward to seeing more progress on the build. 😊
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 04, 2019, 05:00:48 am
Hi folks
Part 5, machining the column.
Hope you enjoy
Please comment
Gary
https://www.youtube.com/watch?v=g9iXoCaO7rU
Title: Re: "Stuart Beam Engine" full build
Post by: Jon Cameron on July 04, 2019, 06:34:40 am
Enjoyed watching the instalment of the build, and it's coming along nicely. I've been looking at the model engineer beam engine, but I fear that it's too big for my lathe, so may have to look at a smaller beam engine design.
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 06, 2019, 04:34:27 am
Enjoyed watching the instalment of the build, and it's coming along nicely. I've been looking at the model engineer beam engine, but I fear that it's too big for my lathe, so may have to look at a smaller beam engine design.
Jon, Thank you for your comment.
I have a Bengs beam engine that I'm going to build in the future and they are a lot smaller, the big difference between Bengs and Stuart is that Stuart has a lot more castings and Bengs are constructed more from bar stock and pre-milled prats (you don't need a large lathe or mill)
I haven't built a Bengs yet but there is a lot of samples on YouTube.
I put a link in the post.
All the best.
Gary
https://www.bengs-modellbau.de/en/
Title: Re: "Stuart Beam Engine" full build
Post by: Stoker on July 06, 2019, 02:43:01 pm
This thread continues to inform and inspire .... thanks for that !
Title: Re: "Stuart Beam Engine" full build
Post by: Nick on July 06, 2019, 03:00:14 pm
Beautiful finish on that column!  8)
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on July 06, 2019, 06:47:59 pm
Another very enjoyable installment Gary, really enjoying these and such a pleasure to watch you work and explain the various steps.

Are/were you a professional machinist by trade?
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 06, 2019, 07:01:49 pm
Thanks gentlemen for your kind comments and yes Jim I was a machinist (just retired) by trade, I did my apprenticeship at AIS (Port Kembla Steelworks)
and then worked in Nowra machining gearboxes for a farm machinery manufacture, (long gone) I then joined the Air Force and became a Aircraft Engine technician.
All the best
Gary.
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on July 06, 2019, 07:27:13 pm
Gary your expertise shines through in your videos.
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 10, 2019, 10:39:39 pm
Hi Folks
Here is Part 6, hope you enjoy.
Gary
https://www.youtube.com/watch?v=CRkAFz57PMQ&t=16s
Title: Re: "Stuart Beam Engine" full build
Post by: Nick on July 10, 2019, 11:35:59 pm
I love these videos Gary and hope to someday have half your skills! Sure wish you would have machined my Stuart beam  ;)
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 11, 2019, 12:21:24 am
I love these videos Gary and hope to someday have half your skills! Sure wish you would have machined my Stuart beam  ;)
Thanks Nick for your kind words, skills are always gained by practice and mistakes and I'v made lots of the latter.
Regards
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on July 11, 2019, 06:39:54 pm
Just got to watch this now Gary, what a brilliant series this is.

Such a pleasure to watch a skilled machinist at work and terrific to follow from the beginning to where you're at now.
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 20, 2019, 05:52:39 am
Hi folks
Part 7 of the build, machining the bearing blocks.
Sorry some of the sound was messed up.
Hope you find it useful.
Gary
https://www.youtube.com/watch?v=gtUPzU9ZdkA
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on July 20, 2019, 06:43:29 pm
Another enjoyable update Gary, clever use of superglue.
Title: Re: "Stuart Beam Engine" full build
Post by: Nick on July 20, 2019, 11:09:35 pm
Thanks Again Gary  ;D
Title: Re: "Stuart Beam Engine" full build
Post by: Stoker on July 21, 2019, 10:44:10 am
Gary, I'm a couple of videos behind just now ... blame Apollo 11, but I promise to get caught back up with your excellent efforts soon!
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 22, 2019, 02:06:32 am
Thanks Again Gary  ;D
Gary, I'm a couple of videos behind just now ... blame Apollo 11, but I promise to get caught back up with your excellent efforts soon!
Another enjoyable update Gary, clever use of superglue.
Thanks folks,
I'm slowly getting there.
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on July 22, 2019, 02:39:35 am
Its a pleasure to view and a BIG thank you for going to the trouble of documenting it Gary.
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 25, 2019, 06:08:06 am
Hi Folks
This is part 8, machining the valve eccentric, hope you find it interesting.
Regards
Gary
https://www.youtube.com/watch?v=puInl2IgFzY
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on July 25, 2019, 06:38:33 pm
Another enjoyable update to your Stuart beam engine build Gary.

Where did you source the little brass/glass drip oiler?
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on July 25, 2019, 07:08:22 pm
Another enjoyable update to your Stuart beam engine build Gary.

Where did you source the little brass/glass drip oiler?
Thanks Jim
The oilers are from a Ebay shop (RDGTools) based in the UK, his omline Ebay name is (rdg355) not cheap but very good quality.
Cheers
Gary
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on July 25, 2019, 07:12:26 pm
Cheers Gary

I've been buying the small ones from 21st Century Steam Co in the UK

https://www.21stcsc.co.uk/oilers
Title: Re: "Stuart Beam Engine" full build
Post by: creepy on September 10, 2019, 01:19:35 am
Hi Folks
"It's Alive"
Test run on air to carry out adjustments, I will connect to steam soon, then post up a longer video.
It it is still very tight, especially the piston rings.
Gary
https://www.youtube.com/watch?v=kEkMeyOeAug
Title: Re: "Stuart Beam Engine" full build
Post by: Scorpion2nz on September 10, 2019, 05:30:39 am
Well done
Always a relief when they start to live and breathe .

Cheers
Dennis
Title: Re: "Stuart Beam Engine" full build
Post by: Nick on September 10, 2019, 08:53:18 pm
It lives! And sure is looking good  8) 8)
Title: Re: "Stuart Beam Engine" full build
Post by: Swift Fox on September 11, 2019, 04:11:15 am
Nice to see it finished and running!
Title: Re: "Stuart Beam Engine" full build
Post by: Jim on September 11, 2019, 09:12:10 pm
Running well Gary!!!
Title: Re: "Stuart Beam Engine" full build
Post by: Stoker on September 12, 2019, 11:24:09 am
This has been a wonderful and informative build thread, and now brought to a fine and successful conclusion. Looking forward to the steam tests, but I have no concerns at all, as it has obviously been well built!