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The following group of pics will complete the pattern for the mid case casting. The first pic is the crank side pattern turned over exposing the side with cheek patterns and the block side stack up laid in position for gluing to the block side board. Pic #6 is the block side board, which is removable to allow the release of the cheek sand parts, turned over, exposing the underside with the boards from pic #1 glued in position. The last 4 pics are the mold closed up and looking into the sides that produce the cheeks for the sides of the casting. The circle impressions and half circle mounds in the face and on parts of the patterns are alignment points for the sand parts to set in the correct position when assembled for the pour. The under side of the block side pattern has split circles because the separator board is missing when the sand is set. The moving of the side cheek sand together brings the half circles full for alignment. That separator board was the hard part to the development of this pattern. Each time I had to remind myself that the part of the pattern between the top and bottom was 3/4" to wide and the cross section of the part would be OK in critical areas when in the cast position.Attachment 50254Attachment 50255Attachment 50256Attachment 50257Attachment 50258Attachment 50259Attachment 50260Attachment 50261Attachment 50262Attachment 50263
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For those of you that do not visit the Quincy thread, here is a phone video clip form 9/7 when I ran my 60 inch Looper at Hillsdale Mi. Just think what a 100 inch will do on the 15' Jones cabover.
https://www.youtube.com/watch?v=NNPxRvdAusA
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Thanks again for traveling to Hillsdale and providing such a wonderful, nostalgic show. That shriek still sends chills up my spine.
Please keep posting images as your project progresses. Your 100 CID Beast will likely need a stiffer wheel.......
Tim
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That completes the major castings for the project. I had to make a lower starter bracket for the TIIX front cover also. Three other castings have been identified that will be required and those are for the coil holders on the heads, a new top main bearing cap and an adapter for the power head to tower housing. The Jones tower housing is so short that the unit is set bad to clear the water pump housing. This moves the lower carb back over the swivel pin and because Merc did not offset the reed assemblies upward the bottom carb will not clear. So the need for an adapter to raise the powerhead to clear. Those patterns have been completed. So another trip to the foundry is required. The following pics are of the castings from the patterns that have been viewed so far. Enough parts to do 2 engines with exception of the billet block. The next block will be cast. The drawings have been completed for the cylinder core box . I will work on the block patterns this Fall? Well maybe winter.
Attachment 50317Attachment 50318Attachment 50319Attachment 50320Attachment 50321Attachment 50322Attachment 50323Attachment 50324
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Over the last couple of weeks I have bee able to complete 2 heads. The end head, which serves as both top and bottom heads and the middle head. I made new cutter bits for my fly cutter to be able to cut 71/4" wide parts which will take care of all surfaces of the engine. This pair of heads are just test parts to again check all clearances and section thicknesses. The test heads were not heat treated and the finish reflects that. I have started cutting the mid case which is heat treated and what a difference in the cutting and finish. Having access to a laser is a great help. As you can see in the pic, I made a fixture for holding the heads for drilling and tapping the spark plug holes. It took less time to design, make laser cut files and weld together, than too readjust the mill head for the plug angle.Attachment 50409Attachment 50410Attachment 50411Attachment 50412Attachment 50413Attachment 50414Attachment 50415Attachment 50416Attachment 50417Attachment 50418
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The heads as finished met the goal of a 21CC combustion chamber. Three fixtures were required for the heads. One to locate the chambers for positioning the two 1/4" pilots holes for cutting chambers and drilling head bolts. One to turn the head in the lathe, centering on the pilot hole, to radius the edge of the combustion chamber and the one to cut the plug holes.Attachment 50420
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Perhaps you should give the foundry a plug. Those are some beautiful castings!
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Reason for 2 plugs per cylinder? Also what ignition system will drive that setup? Unless I am missing something here that's 12 spark plugs.
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Two plugs for redundancy. Less loss of power with a fouled plug than a dead cylinder. That is why piston aircraft engines have dual plugs. The Mercury ADI system will fire 2 plugs. Add an extra coil, wired in series with the standard coil. The primary circuit will charge both coils. That is all any dual output coil is, a single primary winding with two secondary windings. I have seen on the net "Hi Performance" outboards with dual plugs and the coils wired parallel. That will only fire one plug, the one with the least resistance to fire or the least resistance thru the primary winding. I spent a week in the early 80's at Merc outboard school, the system was new at the time. They had a test board set up, flywheel driven by electric motor, the first thing a friend of mine and I did was, at break when there was no one around, was to rewire and test the system with dual coils. Tested both wired in series and parallel. Only wired in series worked!
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Land and Sea dule plug heads from the 80's for the V6. Just used 2 set of 6 coils. Ign worked fine,the heads would crack!
Power gain? Never had the fire go out,so the Ign worked.