For the camshaft, I’m staying with the spirit of this engine, as it will be built up of multiple pieces.
I started with the cam blanks, turned and parted off. They are made from 1144 Stressproof Steel.
The second side of the cam blanks are finishe turned:
Drilled and tapped for a set screw:
The two cam blanks, ready for the cam profile:
To set up for the milling of the cam profile, I chucked up a piece of shaft in the collet block, and milled a flat for the set screw.
The collet block is set up vertical in the CNC mill and the cam blank secured.
The profile is milled using a t-slot cutter, to be able to cut both cams in the same program.
The process was then repeated for the second cam. The only difference, it is a mirrored version of the first one.
The two cams finished:
The shaft has two flats milled, which need to be indexed 180 degrees. The collet block makes quick works of the indexing.
With the shaft still in the collet block, I engraved a line on the end of the shaft. This will help to time the camshaft.
The assembled camshaft:
To finish up the gear train for the camshaft, I needed the idler gear. When I designed the engine, I utilized stock gears from SDP/SI. SDP has CAD files for all their gears for download on their site, which is a tremendous help in the design process.
For the idler gear, none of the stock gears would fit my application. My solution was to use a stock gear and modify it to my need.
To illustrate the design of the idler, and to adjust the backlash in the gears, I attached a CAD rendering below. The hole in the crankcase cover is drilled oversize, allowing some adjustment.
The stock gear, as received from SDP:
In the lathe, the gear was then bored out to the correct diameter for the miniature ball bearing.
A bushing is turned, to hold the bearings, and to mounted it to the crankcase cover.
The gear, bearing, and bushing assembled:
The idler installed on the engine:
The finished gear train, with the camshaft installed.
To note is the line engraved on the end of the camshaft as mentioned in an earlier, for timing of the camshaft.
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If you have any questions about the engine or any of the other projects, please leave a comment below, or email at yogisworkshop(at)yahoo.com
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