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Author Topic: Wilesco D3 modification build thread (near finished with video's)  (Read 3779 times)

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Hi folks
I haven't done a build thread in quite awhile & thought I would document this little Wilesco D3 & many of the modifications I intend to do to it. Every now & then I like to take one of the simplest & least expensive steam engine plants & pack it with as many modifications as I reasonably can.
this is what I started with, a used but very good condition D3 that had very low usage...as I imagine is common with these engines because of the very low usable boiler capacity & all the work associated with an Esbit fired steam engine for a 7-8 minute run.
The Donor...
 

It has earned a bad reputation because out of the box its a poor runner with a near non existent boiler capacity, many components are mis-aligned straight from the factory. I have 12 things written down on my to-do list, we'll see where we end up (hopefully not in the trash)

taken down to key components.



the boiler really doesn't have much capacity



The Center flue is now removed & the boiler bottom removed as well



Boiler bottom end cap now repositioned at the bottom of the boiler.



A bottom boiler plug was turned out of Brass on the lathe with an 8mm x 30mm sleeve for a 250W heater (I know its way to much, but it was best suited size wise for this application) a small brass lug with a #2 screw installed to keep the immersion rod from slipping out of the vertical application.



Now to work on the top of the boiler, a 6mm x .075 bushing was made (for a pressure gauge) , I was planning on installing a whistle on the rear but scrapped that plan.



Made a brass plug for the center top hole of the boiler with dedicated pin holes to receive the cap




Pressure gauge & stand support fabricated



Coming soon , the electronics installed in the base & ball bearings in the axle...
Bruce, St. Paul Indiana, USA
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  Nikola Tesla

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Re: Wilesco D3 modification build thread
« Reply #1 on: December 28, 2020, 08:33:11 am »
Can you provide the specs for the heater? I don't know much about them.
Bob

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Re: Wilesco D3 modification build thread
« Reply #2 on: December 28, 2020, 09:52:20 am »
Can you provide the specs for the heater? I don't know much about them.
8mm od x 30mm long 200-300W. can be seen  on Amazon.
Bruce, St. Paul Indiana, USA
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  Nikola Tesla

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Re: Wilesco D3 modification build thread
« Reply #3 on: December 29, 2020, 07:08:49 pm »
Bearings installed in the firebox



axle was very true




brass inserts made for the bearings




2k watt voltage reducer installed in base





base tidied up



a Wilesco valve (from a converted whistle) installed in the steam line & a pivot pin (functioning) oiler installed in the steam chest




A brass end cap fabricated with set screw to ensure straight running of the axle/flywheel (to keep them distanced properly)There is a lot of lateral movement (slop) built into this inexpensive plant which allows the axle to wonder ,its important for the axle to be stable in its location to keep the piston connecting rod centered as much as possible for smooth operation.




running it in now...went from 6psi stall to 2.5 psi stall speed , probably as good as I'm going to get for a single oscillator. I'm waiting on one more item to come through the mail (might be awhile) the way USPS is functioning these days.
Bruce, St. Paul Indiana, USA
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Re: Wilesco D3 modification build thread
« Reply #4 on: December 29, 2020, 09:35:45 pm »
Awesome build!
My Workshop Blog:  http://doug.sdf.org/

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Re: Wilesco D3 modification build thread
« Reply #5 on: December 29, 2020, 10:04:32 pm »
Bruce, St. Paul Indiana, USA
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Re: Wilesco D3 modification build thread
« Reply #6 on: January 01, 2021, 12:31:46 am »
Finally had a chance to read through this, What an Improvement!!  :o
Nick

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Re: Wilesco D3 modification build thread
« Reply #7 on: January 01, 2021, 06:20:39 am »
Some very nice improvements, you´ve made on that D3 there.

Great job Bruce !!!
Cheers
Jan
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Re: Wilesco D3 modification build thread
« Reply #8 on: January 01, 2021, 08:06:16 am »
Now that is a serious and nicely done set of upgrades!

Gil

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Re: Wilesco D3 modification build thread
« Reply #9 on: January 01, 2021, 08:41:59 am »

Finishing up with the D3 & decided it needed an outboard drive pully , so fab'ed one up real quick. I have one more thing I want to do with it...but I'm waiting for that part to come in the mail.



The "near" finished Wilesco D3



Wilesco D3 doing a fair amount of work (for it's size)



Bruce, St. Paul Indiana, USA
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Hi Bruce a superb upgrade to that little Wilesco unit.
I was looking at the multi step pulleys you are driving with the engine. I think you say they are Jensen transmission units. They look brand new, maybe they are new old stock. Are they available to buy anywhere at present?
Regards Brian

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Hi Bruce a superb upgrade to that little Wilesco unit.
I was looking at the multi step pulleys you are driving with the engine. I think you say they are Jensen transmission units. They look brand new, maybe they are new old stock. Are they available to buy anywhere at present?
Regards Brian
Hi Brian , thanks for your interest, re:the Jensen transmission , I made those out of the Aluminum base Jensen #15 generator's, when I was there I was able to secure a handful of just the bases & decided to make a set of transmissions out of them , I have the double & Charlie M. has the single, they are custom made & not available anywhere.



Bruce, St. Paul Indiana, USA
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Bruce, St. Paul Indiana, USA
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Re: Wilesco D3 modification build thread
« Reply #13 on: January 01, 2021, 10:07:55 am »
Some very nice improvements, you´ve made on that D3 there.

Great job Bruce !!!
Thanks Jan  :)
Bruce, St. Paul Indiana, USA
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Re: Wilesco D3 modification build thread
« Reply #14 on: January 01, 2021, 10:08:21 am »
Now that is a serious and nicely done set of upgrades!

Gil
Thanks Gil  :)
Bruce, St. Paul Indiana, USA
"Originality thrives in seclusion free of outside influences beating upon us to cripple the creative mind."
  Nikola Tesla