Duclos Gearless Ep. 6

In today’s episode, I’ll start with discussing the surface treatment of some of the finished steel parts. I decided to go with a black oxide finish, which I had professionally done by a local heat treatment company. Beside the aesthetics, I’m hoping to gain some corrosion resistance. Corrosion is a big concern for me, as even a small amount of corrosion will take away from the finished engine. I try very hard to use corrosion resistant materials where possible, but sometimes that’s just not economic. That’s the first time I’m using black oxide, and we’ll have to see how it’s going to hold up.

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I continue with some of what I refer to as the fiddly bits. They are small, intricate, and time consuming.

The indexer, which makes the gearless part of the engine possible, is next. The indexer is going to be part of the push rod, and will index a quarter turn every revolution of the crankshaft. I’m going to leave it at this very brief explanation, as I’ll come back to it very soon, when assembly of the engine begins.

First, I turned the material to the outside diameter in the lathe. Then, it is chucked up in a collet block, and machined on four sides on he mill. Material is 303 stainless.

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Back to the lathe, for paring off.

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…and the finished part.

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The Toggle Bracket is the pivot for the latch of the governor, and also the part that holds the push rod in place. I’m holding off with the other parts for the governor until after a successful test run.

First, I machined the contour on the mill. Unfortunately, I didn’t have a better fitting piece of brass stock, so I had to machine off a lot of material.

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Next, parting off on the lathe.

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Then, I chucked the part on the boss using a collet to clean up the second side.

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Finished Toggle Bracket.

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To conclude this episode, I have a few more pictures of finished parts:

The valve body covers. Made out of 6061 Aluminum.

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The tapered bushings, to mount the flywheels.

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The cam. Since the cam gets mounted directly onto the crankshaft, it needs twice the duration then a “regular” four stroke cam.

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Thank you for visiting my Workshop.

If you have any questions, please feel free to leave a comment and I’ll get back to you.



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