Scale engine project

They are PLA plastic models, true to scale with full details, that I 3D print. A running engine made from metal castings is a huge undertaking that can take years. Begins with a successful 1/4 scale block casting. Working on it, but need help.

Flat32:cool:
 
Nice work, maybe someday someone will be able to 3D print a full size metal block, then we won't have to worry about finding crack free old blocks.
 

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Never had one of those, but assume it is pretty much a generic overhead valve engine. Mine will be an accurate representation of a Ford 59A engine. Haven't modelled the carb, fuel pump and crab distributor yet. Long way to go.

Starting out I was intending to do only a bare block.

Flat32:cool:
 
Large brown one is a 1/4 scale raw casting version representing the block with no machining. Large gray one with heads is 1/4 scale but fully machined representation missing only threads in the bolt and stud holes. Can't print them.

Three remaining gray ones are 1/6, 1/8 and 1/12. I can print them in any scale within the printer's limits, but smaller the printing layers become more evident and holes start getting lost smaller than 1/12. Keep in mind all of these have all the water jackets and true to scale wall thicknesses.

Click on the thumbnail picture and I think it will take you to my Photobucket where you can see more by clicking around.

Flat32:cool:
 
RalphM said:
Wow! That's pretty neat, how do you get the water jackets and internal details to print?
Click to expand...

You would be surprised what 3d printing can do. I actually met flat32 awhile ago over the discussion of being able to print the block. That was the first hurdle, next is the casting....Not an easy task! It takes a special type of devotion to pull off what he is doing with this project.
 
None of us realize nor appreciate what is required be done BEFORE any 3D printing can begin. The Printer has to be instructed on what to do and how to do it. In the example of these blocks the Ford drawings have to be put into a format transferable to the Printer. Believe me, it can take hours and hours to "back" your way into the dimensions or interpret the Ford drawings. Then you must be capable of "drawing" those dimensional characteristics on your computer screen. This doesn't even consider educating yourself on what or which printing compound materials will give reasonable results.

Overall just an astounding bunch of frustrating work most people are not(including me) equipped to do.
 
My grandson is now working for a company that is making some of the 3D printers that work other materials, and printing a flathead block is not that far in the future. I hope I live long enough to get one. But as he says, "Programing is a *****". Also some of the stuff is behind closed doors.
 
I know all about the casting/ machining part. My Dad is a pattern maker, he has done countless models, core boxes, match plates, etc through out his life. I grew up around all of it, although I could never do it myself, I know the process. Of course all of this was BC (before computers) and he figured all of it out in his head and on paper.

And before CNC machining.
 
My first manifold was made before I had any CNC machine and all of the patterns and core boxes were made in my kitchen from hydrocal plaster over a 4 month period while my wife was back in Taiwan.

Models to make the core boxes were made from various materials including plastic flex hose, clay, carved styrofoam, wax, and some cut pieces from a stock aluminum manifold. Made two castings poured by a foundry that told me the mold would fail. He charged me $1200 for the two trial pours that turned out good. One of them I gave to JWL as a raw casting that he finished up and dyno tested. It's in his book. The experience dealing with the foundry lead me to learning the entire mold making process, building a foundry furnace and subsequently making my own castings. Then got a CNC machine and learned how to use it. Make patterns now with CNC and machine all of my castings with it. My beloved Tormach PCNC 1100.

I'm currently hung up on making the core boxes for the 1/4 scale block water jackets. The water jacket cores in full size are easier to do than small scale ones because of how fragile the small ones are. While making the core boxes using RTV silicone is logical the damned stuff shrinks in varying ways.

Henry's core boxes were cast iron and I'm trying to duplicate their design, but can only guess how they were constructed. Need help on this one.

Flat32:confused:
 
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