The Excelsior Project, 11: Engine Parts

Perforated steel has filled in the shape of the combustion chamber, and the valve guides are fixed in place. Note that bondo has been used as the glue (3 places) to fasten the guides. TIG-tacking always pulls a little as it cools, but bondo will setup fast and NOT pull; leaving the guides exactly where they should be. The hole in the middle of the aluminum plate is the position of the camshaft. What's missing now are the camshaft supports, cylinder head mounts, rocker studs, and (of course...) the intake and exhaust ports.

The exhaust ports are held in place. Everything about this engine is big, compared with others of this era. The stubby exhaust pipes will be 1.75" in diameter, and the bronze exhaust nuts shown below are almost 2.5" OD >

Here the intake port is mostly finished. Port size is 1.375" which matches the carb, a Schebler deluxe. This carb is not entirely correct, as it came out in about 1924, but will do for the mockup. The Schebler Model H is what I've been looking for, but they seem to be a little hard to locate. Something like hen's teeth...

All ports are now located, and the bevel drive, cams and roller rockers need to be finalized. Yes, you read correctly, "roller rockers". The 1916 Cyclone engine (from which this was modeled...) had 3/4" bearings in the rockers> I have a set of the patent drawings. I think it's pretty cool... roller rockers in 1919.

On the left is the fifth and final mold for the seat. It's used to make the seat pan, shown on the right. The mounting bolts have been Tig-welded onto 18-gauge sheet metal, bonded to the base with epoxy, and fiber-glassed. I'm glad my part of the seats is over. Now it's up to Walter to work his magic with the leather...


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