Webster Engine Works

4 Cycle GasEngine
Displacement: .75 ci
Bore: .875"
Stroke 1.25"
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
GENERAL ARRANGEMENT
J BW 1 OF 21
.9 : 1 7/ 27/ 2004
SIZE
N/ A N/ A
B
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All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
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1.688 3.625 1.125
4.938
2.688
.813
1.656
1.904
1.953
5.281
5.438
4.625
82 X .385(FS)
.196THRU
82 X .279(FS)
(4) HOLES
.144THRU
TAP #6-32(2) HOLES
.107THRU
ALL RADII
(OPTIONAL)
R.250TYP
.375
8.125
3.938
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
BASEPLATE
(1) REQD.
J BW 2 OF 21
1:1 7/ 27/ 2004
SIZE
ALUMINUM
ALLOY
ANODIZE,
DYEBLACK B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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.375
2.433
4.750
.290
2.000
1.090
2.500
.250
.750
1.250
.500
TAP #4-40
.089THRU
ALL RADII
(OPTIONAL)
R.250TYP
(REAM)
.500
.250(REAM)
82 X .279(2) HOLES
.144THRU
3.500
4.222
5.625
4.750
FORBEARING OIL CUP
OPTIONAL #6-32TAPPED HOLE
.313 1.125
TAP #6-32(2) HOLES
.107 .50
3.625
.156
SIDEFRAME
1.406
2.000
2.500
.719 1.063
1.250
TAP #10-32
.159THRU
TAP #8-32
.136THRU
ALL RADII
(OPTIONAL)
R.250TYP
(REAM)
.500
1.250
.722
.313
.500 1.125
TAP #6-32(2) HOLES
.107 .50
.156
CRANKSHAFTSUPPORT
2.125
1.250
FORBEARING OIL CUP
OPTIONAL #6-32TAPPED HOLE
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
SIDEFRAME& CRANKSHAFT
SUPPORT(1) EACHREQD.
J BW 3 OF 21
1:1 7/ 27/ 2004
SIZE
ALUMINUM
ALLOY
ANODIZE,
DYEBLUE B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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.313
1.500
82 X .225
(4) HOLES
.116THRU
.015
.625SPOT
.875
.875
TAP 10MM X1MM
FORNGK CM-6
SPARK PLUG - OR-
DRILL .213AND
TAP 1/4-32
.348THRU
FRONTVIEW
RIGHTVIEW
2.750
1.250
.250
.750
1.813
TO BORE
.188THRU
.500
.750
TAP #4-40(2) HOLES
.089 .313
TAP #6-32(2) HOLES
.107 .438
.375
HIDDEN LINESREMOVED
TO IMPROVECLARITY
.688
TAP #10-32
.159 .75
.375
BOTTOM VIEW
CYLINDERHEAD-FRAME
MATERIAL: ALUMINUM ALLOY
FINISH: ANODIZE, DYEBLUE
(1) REQD.
.500
BORE 1.000
2.000
.750
(2) RADII
(OPTIONAL)
R.250TYP
REAR VIEW
.094TYP (5) GROOVES
.094TYP (5) FINS
SEENOTESFORDETAILS
.188PORTHOLE
SMALL 45 CHAMFER
TO EASERING COMPRESSION
AND PISTON INSERTION
CYLINDER(1) REQD.
MATERIAL: 12L14 STEEL ORCASTIRON
FINISH: HI-TEMP BLACK PAINTON
VISIBLEEXTERIOR- TBD @ASSY.
RIGHTVIEW
1.500
1.125
TAP #10-32
SEENOTES
.159
2.000
.250
.500
*SNUG SLIDING FIT
IN CYL. HEAD-FRAME
1.000*
.015
.250SPOT
TOP VIEW
(4) HOLES
SPOTTED FROM
CLY. HEAD-FRAME
#4-40TAPPED HOLE
LAPPED BORE
SEENOTES
.875
FRONTVIEW
NOTES:
1. MAKECYL. HEAD-FRAMEFIRST- DRILLING, TAPPING,
AND COUNTERSINKING ALL HOLES.
2. MAKECYLINDER- STOP BORING AT .873 TO ALLOW
FORFINISH LAPPING.
3. USING CYL. FRAME-HEAD HOLES ASA GUIDE,
SPOT, DRILL, AND TAP CYLINDERMOUNTING HOLES
4. SCREWCYLINDERTO CYL. HEAD-FRAMEWITH(4)
#4-40 FHSCREWSAND DRILL PORTHOLEIN CYL.
BY SPOTTING THROUGHCYL. HEAD-FRAME
5. SPOT, DRILL, AND TAP #10-32 OILERHOLEON TOP
OF CYL.
6. REMOVECYLINDER, OPEN PORTHOLETO SLOTSHAPE
ASINDICATED, THEN LAP BORETO FINISHED SIZE.
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
CYL. HEAD-FRAME& CYLINDER
(1) EACHREQD.
J BW 4 OF 21
1:1 7/ 27/ 2004
SIZE
SEEABOVE SEEABOVE
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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.047
.031
3.250
.219
.314
.156
POLISH SHAFTIF USING
BRONZE MAIN BEARINGS
TAP #8-32FORCRANKPIN
GREASECUP
.136 .438
R.875(OPTIONAL)
POLISHJ OURNAL
.281
.625
.313
.500
.500
1.250
.375
CRANKSHAFT
MATERIAL: CRS
FINISH: ASNOTED
(1) REQD.
3.750
(REAM)
.313
.625
(OPTIONAL)
(3) EQ. SP. HOLES
.750ON 1.625P.C.
(2) PLCS
2.750
A
A
FLYWHEEL (1) REQD.
MATERIAL: CASTIRON ORCRS
FINISH: PAINTBLACK
TO RECEIVE
CAM DRIVE
GEARSPIGOT
BORE.500 .188
.750
(2) PLCS
.188
(REF)
1.125
(2) PLCS
.250
SECTION A-A
.313
.500
(REAM)
.313
.500
.563
TBD @ASSY.
.218(APPORX.)
CRANKSHAFTSPACER
MATERIAL: CRS
FINISH: N/A
(1) REQD.
MAIN BEARING (OPTIONAL)
MATERIAL: BEARING BRONZE
FINISH: POLISHBORE
(2) REQD.
.375
.031
ASSEMBLY TO
FRAME
.063UPON
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
CRANKSHAFT, FLYWHEEL, CRANK
SPACER AND MAIN BEARING
J BW 5 OF 21
1:1 7/ 27/ 2004
SIZE
SEENOTES SEENOTES
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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.873
.750
.688
R.188
.625
(2) HOLES
.089TAP #4-40
B
B
1.000
.250
.750
.688
SECTION B-B
.563
.094TYP
.094TYP
.051
.771(REF)
(REAM)
.188
.500
PRESSIN PISTON OIL TUBE
UNTIL J USTBELOWPISTON
SURFACE
.094
PISTON
SCALE: 2:1
MATERIAL: 6061-T6 ALUMINUM
FINISH: FINE TURNED FINISH, DO NOTPOLISH,
MICRO-GROOVESHELP TO HOLD OIL
(1) REQD.
OIL TUBE
SCALE: 4:1
MATERIAL: BRASS
FINISH: N/A
(1) REQD.
.063
PRESSFIT
IN PISTON
.094 .188
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
PISTON AND PISTON OIL TUBE
J BW 6 OF 21
ASNOTED 7/ 27/ 2004
SIZE
SEENOTES SEENOTES
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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3.063
.250
.375
.563
.375
(4) PLCS
R.125TYP
.356
1.50°
.313
.031
.250
CONNECTING ROD
MATERIAL: 6061-T6 ALUMINUM
FINISH: POLISH
(1) REQD.
.250
(REAM)
.188
WRISTPIN BUSHING
MATERIAL: BEARING BRONZE
FINISH: POLISHBOREAFTER INSTALLATION
(1) REQD.
.313
.375
(REAM)
.281
CON ROD BUSHING
MATERIAL: BEARING BRONZE
FINISH: POLISHBOREAFTER INSTALLATION
(1) REQD.
WRISTPIN
SCALE: 2:1
MATERIAL: DRILL ROD
FINISH: HARDENED, TEMPERED & POLISHED
(1) REQD.
.313
.850
(2) PLCS
.219
CHAMFER
.015 X45
(2) PLCS
.188
.094
(2) PLCS
.010
.156
DRILL AFTERPRESSING
WRISTPIN BUSHING INTO
ROD
.063
CONNECTING ROD ASSY.
LIGHTPRESS& LOCTITE
BEARINGSINTO ROD
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
CON ROD, BUSHINGS, WRIST
PIN, AND CON ROD ASSY.
J BW 7 OF 21
1:1 7/ 27/ 2004
SIZE
SEENOTES SEENOTES
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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.125
.250
.250
.125
.063
2.172
OIL HOLE
.047
TAP #4-40
.089THRU
2.047
2.157
(REAM)
.125
.219
.750
ROCKERARM
MATERIAL: CRS
FINISH: CASEHARDEN (OPTIONAL)
(1) REQD.
ROCKERARM SPACER
SCALE: 2:1
MATERIAL: CRS
FINISH: N/A
(1) REQD.
ROCKERARM SPRING
MATERIAL: SPRING STEEL
FINISH: N/A
(1) REQD.
ROCKERARM WASHER
SCALE: 2:1
MATERIAL: BRASS
FINISH: N/A
(1) REQD.
TAPPET
SCALE: 2:1
MATERIAL: 3/8"X #4-40 S.S. SCREW
FINISH: THIN HEAD TO DIM. SHOWN
(1) REQD.
CAM SHAFT
MATERIAL: DRILL ROD
FINISH: HARDEN, TEMPER, POLISH
(1) REQD.
EXHAUSTCAM
MATERIAL: CRS
FINISH: CASEHARDEN, POLISH
(1) REQD.
.125
.250
TBD @ASSY.
.105(APPROX.)
.010
R.13
(APPROX)

1.35
.144
.156
.281 1.750
.125
.250
.015
.050
.938
.844
.063
.250
.562
R.356
.254
(REAM)
.375
.185
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
ROCKERARM, SPRING, WASHER,
SPACER, TAPPET, CAM SHAFT, & CAM
J BW 8 OF 21
1:1 7/ 27/ 2004
SIZE
SEENOTES SEENOTES
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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MACHINEFORLIGHTPRESS
FITWITHCAM.
.375
CAM GEARMODIFICATION (BRASS)
STOCK DRIVEPRODUCTS: A 1B2-N32048
W.M. BERG: P32S-28-48
(1) REQD.
CAM GEARWASHER
MATERIAL: CRS
FINISH: N/A
(2) REQD.
IGNITION CAM
MATERIAL: CRS
FINISH: BREAK SHARP EDGES
(1) REQD. .500
.250
MACHINEFORLIGHTPRESS
FITINTO FLYWHEEL.
.500
DRIVEGEAR MODIFICATION (STEEL)
STOCK DRIVEPRODUCTS: A 1C 2-N32024
W.M. BERG: P32S28-24
(1) REQD.
.688 (REAM)
.313
.375
.187
.188
.063
CAM GEARASSEMBLY -
LOCTITE AND PRESSCAM TO
CAM GEAR, ARBITRARY POSITION.
FLYWHEEL ASSEMBLY -
LOCTITE AND PRESSCAM DRIVEGEAR
TO FLYWHEEL, ARBITRARY POSITION.
.375
TAPPED HOLE
FORSETSCREW
#6-32
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
GEARMODS, C.G. WASHER, IGNITION
CAM, C.G. & FLYWHEEL ASSY.
J BW 9 OF 21
1:1 7/ 27/ 2004
SIZE
SEENOTES SEENOTES
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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.625
.094 .813
.500
.313
.094
.438
.281THRU
(4) HOLES
.089THRU
.250
1.000
.125
.500
.188
VALVEBLOCK
(1) REQD.
INTAKEVALVEBLOCK
(1) REQD.
.500
82 X .225
(2) HOLES
.116THRU
.125
.625
1.000
82 X .172
(4) HOLES- SPOTTED
FROM VALVEBLOCK *
.089THRU
COUNTERBORE
.375 .031
.313THRU
.500
.313
C C
.031 .375
SECTION C-C
* EXHAUSTVALVEBLOCK ISIDENTICAL,
EXCEPTTHEFOURHOLESARETAPPED
#2-56 THRU
(1) REQD.
.125
.313
.188
.219
D
D
SECTION D-D
DRILL .188 .500
THROUGH PORT, INTO
GUIDE AFTER LOCTITING
AND PRESSING GUIDESINTO
PLACE.
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
VALVE BLOCK, INTAKEVALVE BLOCK,
& EXHAUSTVALVE BLOCK
J BW 10 OF 21
2:1 7/ 27/ 2004
SIZE
ALUMINUM
ALLOY
NATURAL
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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1.000
.109
.040THRU
.020
45.00°
VALVE
MATERIAL: STEEL / STAINLESSSTEEL
FINISH: POLISHSTEM
(2) REQD.
(MAY BE2 PC. / FABRICATED FROM DRILL ROD)
VALVERETAINER
MATERIAL: STEEL
FINISH: BLUED
(2) REQD.
VALVEGUIDE
MATERIAL: BRONZE/ BRASS
FINISH: N/A
(2) REQD.)
.250
.093
.250
.187
.094
.625
.250
.031
E
E
.375 .094(REAM)
.313
SOME HIDDEN LINESREMOVED TO IMPROVE CLARITY
MACHINE45 X.015 VALVE SEAT-
LAP VALVE TO VALVE GUIDEUSING
FINEVALVE GRINDING COMPUND
UPON FINAL ASSY.
.188
.188
.219
2.50°
SECTION E-E
.094
.031
.625
.188I.D.
INTAKEVALVESPRING
SEVEN TURNS .013 MUSIC WIRE
(1) REQD.
.625
.188I.D.
EXHAUSTVALVESPRING
NINETURNS .022 MUSIC WIRE
(1) REQD.
VALVE BLOCK ASSY. -
1. INTAKEVALVESPRING ON TOP WITHINTAKE
PORTPOINTING TOWARDSTHEFRONTOF THEENGINE.
2. VALVE BLOCK SANDWICHED BETWEEN INT. & EXH.
VALVE BLOCKS- NO GASKETORSEALERREQD. W/ CAREFUL
MACHINING.
3. RETAINERPINSARE.25 LONG SECTIONSOF DRILL ROD,
MUSIC WIRE, ETC...
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
VALVE GUIDE, VALVE,
VALVE RETAINER, VALVE SPRING
J BW 11 OF 21
2:1 7/ 27/ 2004
SIZE
SEENOTES SEENOTES
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
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.125
.188
.094
.281
DRILL .070
TAP #2-56
N.V. BLOCK
MATERIAL: BRASS
(1) REQD.
.094
.125
.188
.156
.219
.438
.094
DRILL .031 THRU
THEN .063 438
N.V. SEAT
MATERIAL: BRASS
(1) REQD.
N.V. SPRING
(1) REQD.
SOFTSOLDERIN N.V. BLOCK &
N.V. SEAT, POLISHASSY.
.750 .188
.250
15° (APPROX)
#2-56 SCREW
KNURLED
BRASSKNOB
NEEDLEVAVLEASSY.
(1) REQD
.375
.093I.D.
(8) TURNS .013
MUSIC WIRE
.125
.250
.250
.250
20° (APPROX)
.063
.354
.031
VENTURI
MATERIAL: BRASS
(1) REQD.
.375
.140
.219
.250
.313A.F.
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
VENTURI & NEEDLEVALVE
ASSEMBLY
J BW
2:1 7/ 27/ 2004
SIZE
SEENOTES SEENOTES
B
This drawing may be freely used or modified for any non-profit purpose.
All accuracy and safety issuses are the users responsibility. The originator
and the provider are not responsible or liable for any lossesor damages
incurred fromthe creation or use of the productscontained in this
drawing.
12 OF 21
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1.500
1.000
.875
.875
(4) HOLES
.129
HEAD GASKET
MATERIAL: .015 COPPER, TEFLON,
ORSTD. AUTO GASKETSTOCK.
(1) REQD.
EXHAUSTPIPE
MATERIAL: ALUMINUM, BRASS, ORSTEEL
FINISH: POLISH
(1) REQD.
CON ROD KEEPER
MATERIAL: .015 THK. BRASSORSTEEL
(1) REQD.
CRANK OILIERCUP
MATERIAL: BRASS
FINISH: POLISH
(2) REQD.
SCALE: 2:1
CRANK PIN GREASECUP BODY
MATERIAL: 5/16"HEX BRASS
FINISH: POLISH
(1) REQD.
SCALE: 2:1
CRANK PIN GREASECUP CAP
MATERIAL: BRASS
FINISH: POLISH
(1) REQD.
SCALE: 2:1
.500
.170
.219
.188
.250
.344I.D.
.375O.D.
30.00°
.625
2.250
1.313
.188
.031
.313
.031 DRILL .030 THRU,
THEN .302 .300
.344
.375
.250
THRD. #6-32
.131
.188
.094
.313
THRD. 5/16X40TPI
.313
THRD. #8-32
.165
DRILL .063 THRU
THEN .250 .250
.325
.063
.360
.375
BORE .272 .313
THRD. 5/ 16 X40TPI
STRAIGHTKNURL FINE
A
B B
2 1
2 1
A
DATE
DETAILER
125
SURFACES
MATERIAL FINISH
SCALE
SHEETNO.
+/ - 30' +/ - .005 +/ - .015
ANGLES 3PLC DEC 2PLC DEC
TOLERANCEUNLESSOTHERWISENOTED (C) J oe Webster 2004
HEAD GASKET, EXH. PIPE, CRK. KEEPER,
CRK. OILER& GREASECUP ASSY.
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.188
.188
.750
.313A.F.
F
F
THRD. #10-32
CYL. OILIERBODY
MATERIAL: BRASSORALUMINUM
FINISH: POLISH
(1) REQD.
RC CARB. ADAPTER
MATERIAL: BRASSORALUMINUM
FINISH: POLISH
(1) REQD.
SCALE: 2:1
.375
SECTION F-F
1. DRILL .063 THRU
2. DRILL .089 .875
3. BORE .625 .563
4. TAP #4-40
1.125
FLAT
FILE
.010
.500
CYL. OILIERVALVE
MATERIAL: #4-40 SHCS
FINISH: ASSHOWN
(1) REQD.
GRIND TO POINT
CYL. OILIERSPRING
(1) REQD.
.75(APPROX)
.125I.D.
(10) TURNS.020 MUSIC WIRE
.188
.196
.750
.375
.219
45.00°
.188THRU
.394*
.500
.250
* SIZED TO FITCHOICEOF CARBURETOR. THROUGH
EXPERIMENTATION ITWASFOUND THATTHEENGINE
RUNSBESTWITHRATHERA SMALL BORECARB. I USED
A CARBFROM AN O.S. MAX .12 CZRADIO CONTROL
CARENGINETHATHASA BOREOF .166"AND ITGIVES
AN RPM RANGEOF ABOUT1000 - 5000 RPM.
ITISRECOMMENDED THATA SIMILARCARB BEUSED OR
FABRICATED BECAUSETHENEEDLEVALVEAND VENTURI
GIVESONLY MARGINAL PERFORMANCE- ALTHOUGHIT
ISAN EASY/CHEAP ALTERNATIVE.
(I SIMPLY USED HI-TEMP LOCTITETO AFFIX THECARBINTO
THEADAPTER.)
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The following notesaren't meant to be comprehensive, step-by-step
building instructions, just a few noteson how and why I did things.
SHEET1. J ust a few viewsto show the general arrangement of parts.
SHEET2. BASE- Thisisthe engine baseplate. Since all engine partsmount and
align off of this, it issuggested that the holesbe layed out and located
somewhat accurately. Notice that the countersunk holesare on the bottom
of the plate. The external dimensionscan be altered to suit aslong asthe hole
spacingsfor the engine frame remainsthe same.
SHEET3. SIDE FRAME& CRANKSHAFTSUPPORT- Again, try to stick to the dimensions
given, asthese parts, along with the BASEmake up the backbone of the engine.
Alignment of the remaining engine partsrely on good workmanship here. Also, the
bearing and cam shaft holesneed to be sized for light pressfitsof their respective
partsand accurately placed for proper gear spacing.
SHEET4. CYLINDERHEAD-FRAME& CYLINDER- Nothing especially difficult here,
but two thingsare worth noting. There are two optionsgiven for a spark plug - use
whatever you are comfortable with. I started with the tiny 1/ 4"-32tpi sparkplug
because it isalso the same size of a model airplane engine glow plug which I could
use to start the engine on glow fuel (without having to rig oiling and an ignition
system). I then switched to spark with gas and oil mix, and quickly fouled thistiny
spark plug. So I redrilled and retapped for a 10mm x1mm NGK CM-6 spark plug that
I could get from my local motorcycle dealer for a lot cheaper.
The cylinder bore isthe other item that needsparticular attention - make sure to
bore it straight and without any taper. Finish within .002"of size, drill port and oiler
holes(using cyl. head-frame asa guide), then lap to a finished size of .875". Simple
lapscan be fabricated or purchased, and detailson how to use them can be
found on the Internet, in the model engine newsgroups/ web sites.
SHEET5. CRANKSHAFT, FLYWHEEL, SPACER, and BEARING - I made my crankshaft
from a 5"section of 1/ 2"X1 1/ 4"Cold Rolled Steel, both shaft and crankpin were
turned between centers, but it could be fabricated and silver solder together
from three piecesif you wanted to go that route. Also, notice that it'snot
counter-balanced for ease of construction - a lot smoother engine would result
if you took the time to redesign the crank and add the appropriate wieghts.
The end of the crankpin isdrilled and tapped to receive the grease cup - don't
forget the tiny crossdrilled hole, and to polish the journal.
The flywheel can be made from cast iron, CRS, bronze, etc... - any heavy metal
should work fine. I chose cast iron, in the form of a dumbbell that I purchased from
Wal-mart. Be careful if you take thisapproach asthere can be small voids/ casting
flawswhere it matters- I waslucky and none presented any problems. Be certain
when boring the .500"counter bore that it'sconcentric with the crankshaft bore,
and that the modified CAM DRIVE GEARis a snug fit - it will need to be pressed and
Loctited in place. See sheet #9 for details.
SHEET5. cont. - The three .750"holesare for appearance only, asa matter of fact, I skipped them
altogether on the prototype engine. A nice cosmetic touch would have been a spoked flywheel,
but since it would require a rotary table for the mill, I didn't bother. Again, feel free to experiment.
If you choose not to use ball bearingsto support the crankshaft, then you will have to make the two
bronze MAIN BEARINGSasshown. Aim for a light pressfit into the SIDEFRAMEand CRANKSHAFTSUPPORT.
Using Loctite asgood measure, pressthem in with the flangestoward the inside of the engine, making
sure to align the oil holeswith the #6-32 tapped oil cup holes. (Alternatively, wait until bearingsare in
place before dilling the .063"oil holes.)
Also on thissheet isthe CRANKSHAFTSPACER- adjust thicknesson final assembly for .001"to .003"of
crankshaft endplay.
SHEET6. PISTON & OIL TUBE- The ring groovesin the PISTON were sized for the ringsmentioned
elsewhere in these plans. 1/ 16"wide ringswould offer lessfriction and probably seal just aswell -
simply adjust the ring groovesto accomodate. Use a 3/ 8"endmill to machine the con rod slot, being
careful not to go beyond the .688"dimension because you may cut into the lower ring groove. Be
sure to drill the wrist pin perpendicular and on the exact centerline of the piston - thisisnot the time
to rush things. (Make sure the con rod slot isgoing in the right direction.) Small #4 set-screwsare used
to retain the wristpin in it'sbore. The OIL TUBEis simply a short section of brasstubing, Loctited into
the piston asindicated.
SHEET7. Nothing too remarkable here. J ust be sure to drill both CON ROD holesat the same
setting and size the BUSHINGSfor a light pressfit into the rod ends- use Loctite for added security.
Drill the .063"hole in the wrist pin end after the bushing isinstalled. Be sure thishole ispointed up
(towardsthe OIL TUBE, and ultimately towardsthe CYLINDEROILER) upon final assy.
SHEET8. The EXHAUSTCAM started out asa .185"thk. disk of steel .712"in diameter with a reamed
.375"hole though it. It wasoffset turned on the lathe asdescribed by Hamilton Upshur in Volume 79
of Strictly I.C. magazine. There are many other methods- use whatever you are comfortable with.
The planscall for hardenening of many parts, i.e. CAMSHAFT, CAM, ROCKER ARM, etc... Thisnot
necessary, but doing so should result in a longer wearing engine.
When making the CAM SHAFT, shoot for a pressfit into the engine frame and a free rotating fit with the
CAM GEAR. Alternatively, you could use a set screw though the bottom of the SIDEFRAMEto retain
the CAM SHAFTin it'sbore.
SHEET9. Modify CAM GEARand CAM DRIVEGEARasshown. Use Loctite and pressthem to their
respective parts. The position of the gear teeth are not important at thisstage - the engine will be
timed on final assembly. When making the IGNITION CAM, round off the sharp edgescreated when
milling the flat spot - it isthisflat that operatesthe ignition points. Use a short #6 set-screw to hold this
CAM to the crankshaft - see assembly notes for locating details.
SHEET10. The INTAKE& EXHAUSTVALVEBLOCKSare nearly identical with one exception - the four holesfor
the #2 screws. I used studs screwed into the EXH. VALVE BLOCK so my INT. VALVEBLOCK had only though
holes- no coutersinks. Doesn't really matter what you choose, just make sure all mating surfacesare flat
and smooth so you won't need gaskets or messy sealers. The 3/ 16"port holesaren't drilled until the VALVE
GUIDES(shown on sheet 11) are pressed in.
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SHEET11. Onto the VALVEGUIDES- make sure your 3/ 32"reamed holesare concentric with the
valve seats. To cut the valve seats, I simply used a 90 chamfering bit in the lathe's
tailstock and lightly touched it to the rotating valve guide, creating a narrow valve seat which
waslater lapped to the valve. I used brassfor the guideson the prototype engine, but I think
bronze or cast iron would be a better choice.
The VALVESwere made one piece out of whatever steel I had laying around. Stainlesssteel
would be a great choice, or two piece vavlescan be fabricated and silver soldered together.
SHEET12. Do yourself a favor and skip building thisVENTURI and NEEDLEVALVEASSY. While OK
for initial starting and breaking in - much better resultscan be had from conventional throttling
carburetors- either onesfrom radio control glow engines, or onesfabricated to work like one.
Shoot for a small bore carb, something from a .10 - .15 ci 2-stroke glow engine or one with a
bore of .156"- .188", you won't need anything larger than this.
SHEET13, 14. Nothing special here, just the remaining componentsthat will need to be
fabricated. If you're careful about machining the cylinder spigot and it'sfit into the head,
you may not need a head gasket - I used one for good measure. The design of the exhaust
pipe ismostly cosmetic - I like balogna cut pipes, but do whatever you wish here. (Originally
I had second thoughtsabout pointing the exhaust back, but it wasactually found to have
a benefit - the unburned oil in the exhaust helpsto keep the gearsand cam lubricated.)
The CRANK OILERCUP and the CRANK PIN GREASECUP were purchased from a vendor at
Cabin Fever - unfourtunately I don't remember who it was. Approximate dimensionsare
given should you wish to fabricate your own.
The CYLINDER OILERisan optional item if you mixoil in your fuel. Again, there are other,
more attractive designsout there, but thiswasa quick and dirty way to do it.
Also shown isthe optional RC CARBADAPTER... highly recommended.
ASSEMBLY - Assembly should pose no particular problems, however it issuggested that the
partsbe made in the order that they are presented on the plan sheets. Although I've tried
to be thorough with the noteson the plansthemselves, a few pointsare worth mentioning.
Pressthe bearing(s) and CAM SHAFTinto the SIDE FRAME, slide on one CAM GEARWASHER,
the CAM GEARASSY (with the CAM pointing towardsthe frame) followed by another
washer, and secure with a cotter pin. Be sure that the gear spinsfreely on the shaft - adjust
asnecessary.
Attach the ROCKER ARM (with TAPPETin place) to the SIDEFRAMEusing the shoulder screw,
washer, and spacer. Fasten on the CYL. HEAD-FRAMEand secure thisassembly to the BASE
PLATE. Attach the CRANKSHAFTSUPPORT(with bearing(s) in place) to the BASEPLATE.
Assemble the CRANKSHAFT, CRANK SPACER, and FLYWHEEL ASSY. - at thispoint the crank should
spin freely, independently of the flywheel - we will adjust timing and secure thislater.
The CYLINDER, it'sgasket, and the piston/ rod assy. must be installed asone group. Slide the
piston/ rod assy. into the cylinder, and with the crank at BDC, slide the big end of the rod onto
the crank pin. Rotate the crank while moving the assy. forward, into the head'sbore (don't
forget to align the ports). Secure the cylinder to the head, then attach the GREASECUP using
the CON ROD KEEPER like a washer. You did remember to make sure the oil holesin the rod
and piston were pointing up, didn't you?
The assembled valve block can now be attatched to the head - no sealer isrequired
if both surfacesare flat and smooth. Exhaust valve timing isset by rotating the crankshaft
counter-clockwise (asviewed from the cam side) until it isabout 15 - 30 before
it'soutward most stroke. It is then held in place while the flywheel isrotated C.C. until
the cam just starts to lift the exhaust valve off of it's seat. Clamp, lock, & secure everything
in place and drill the two roll pin holesasshown on the next sheet. If set properly, the
exhaust valve will close a few degreesbefore TDC.
Timing the IGNITION CAM ismuch simpler. With the pointsand ignition cam installed,
set the pointsgap to about .020". Rotate the flywheel until the piston isabout 15
before TDC. Loosen the set screw on the ignition cam and rotate it clockwise until the
pointsclose and just start to open, lock the ignition cam in place.
The INTAKEand EXHAUSTpiecesare simply pressed and Loctited in place for sake of simplicity
and I haven't had a problem with them so far.
Finish assembly with the oilers, spark plug, igntion condenser, etc... Check that all moving
partsare free, and that you have compression / no leaks. Rotating the flywheel
counter-clockwise (viewed from the flywheel side) should produce a "snorting"sound
through the carburetor asthe intake valve lifts. Asyou passTDC on the compression stroke
the engine should feel "bouncy"or "snappy", indicating good compression and that your
engine isready to run. Some folkslike to break-in their engine by driving them with an
electric motor, or even connected to the lathe spindle. If yoursisfree enough, it shouldn't
be necessary to do this.
STARTING and RUNNING - I use a 12 volt car coil and 12 volt battery for my ignition system
because I don't want any doubtswhether it'sfiring or not. I have a 1 oz. fuel tank set so that
the fuel level when full isabout 1/ 4"lower than the needle valve. My engine runsgood
on straight Ozark Trailscamping lantern fuel with 5w-30 motor oil in the cylinder oiler.
(Some folksrun straight methanol, some run gasoline and oil mix- do whatever worksfor
you. ) If you use the oiler, set it so that it dripsoil about once every 6-10 seconds-
experimentation may be in order to find the right setting to limit smoke, fouled plugs, oily
mess, etc... When using an RC carb set at about 1/ 8 throttle, my engine startson the first
flip and will rev like crazy when prompted. Keep in mind, thisisnot a high speed engine,
there'sno balancing and inadequate cooling, so keep the speedslow.
SUMMARY - Thisengine wasdesigned to be easy & quick to build, so there are no fancy
radiuses, complicated governors, forced cooling, exotic materials, etc... It'sa bare-bones
internal combustion engine in the rawest form. Asa matter of fact, mine isn't even
painted. Sure, I specify to anodize this, polish that, etc... it'snot necessary for operation,
but it would be a nice touch don't ya think? If someone took their time and incorporated
a few cosmetic details, it would be a pretty decent looking engine (I should know, I did
just that in CAD).
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15°
EXHAUSTVALVETIMING ISSETBY ROTATING
CRANKSHAFTCOUNTERCLOCKWISETO ABOUT15
BEFOREBOTTOM DEAD CENTER. ROTATEFLYWHEEL (AND
CAM GEAR) UNTIL THEEXHAUSTVALVEJ USTSTARTS
TO LIFT, ASSHOWN. CLAMP / LOCK IN PLACE,
THEN DRILL FOR, AND INSTALL ROLL PINS.
UPON FINAL ASSY. & AFTER SETTING EXHAUST
VALVE TIMING, DRILL (2) .093 HOLES
THROUGH FLYWHEEL AND CRANKSHAFTAND
INSERTROLL PINS
CRANKSHAFTSPACER
SIZED FOR.OO2" CRANK
END PLAY
BRONZE MAIN BEARINGS
SHOWN. INSTALL W/ FLANGE
TOWARDSTHEINSIDEOF THE
FRAME. ALIGN OIL HOLES
WITHOIL HOLESIN FRAME
(2) PLCS
THEFOLLOWING ADDITIONAL (NON-DETAILED) ITEMSARE NEEDED FORASSEMBLY:
IGNITION POINTS:
(1) REQ.
SOURCE: PEP BOYS, AUTOZONE, NAPA, ETC...
(1969 DODGECHARGER, 383, 4BL, W/ SINGLEPOINTDIST.)
IGNITION CONDENSER:
(1) REQ.
SOURCE: SOURCE: PEP BOYS, AUTOZONE, NAPA, ETC...
(1969 DODGECHARGER, 383, 4BL, W/ SINGLEPOINTDIST.)
SPARK PLUG: NGK CM-6
SOURCE: MOTORCYCLESHOP, ONLINE, ETC...
CRANKSHAFTBALL BEARINGS: 5/ 16"I.D. X1/ 2" O.D X 5/ 32"THK., FLANGED
SOURCE: W.M. BERG: P/ N B2-21 -OR- STOCK DRIVEPRODUCTS: P/ N A 7Y55-FS5031
(4) REQD.
PISTON RINGS- 3/ 32"X.875"
(2) REQD.
SOURCE: OTTO GASENGINEWORKS
(410)-398-7340
2167 Blue Ball Rd
Elkton MD 21921-3330
http:/ / www.dol.net/ ~dave.reed/ otto.html
SHOULDERSCREW: 1/ 8"X3/ 8"
(1) REQD.
SOURCE: WM. BERG: P/ N PL-5 -OR- STOCK DRIVEPRODUCTSP/ N A 9X15-0412
ROLL PIN: .093"X5/ 8"
(2) REQD.
SOURCE: HWSTORE, STOCK DRIVEPRODUCTS, W.M. BERG, ETC...
COTTERPIN: 1/ 16" X1/ 2"
SOURCE: HWSTORE, STOCK DRIVEPRODUCTS, W.M. BERG, ETC...
(1) REQD.
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NOTESPG. 3
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