Building the Prototype AMD Series Engines

26 May 2013

This month saw the start of the build for the prototypes of my engines.  I started by ordering a large pack of metal bar stock from Noggin End Metals, which arrived in very short order.

I am building five prototype engines as follows, to test the design in its basic configurations:

• Engine 1.  AMD5S,  air cooled SOHC, glow ignition, lubricated by oil mixed with fuel
• Engine 2.  AMD5S, water cooled, DOHC, spark ignition, oil pump
• Engine 3.  AMD10S,  air cooled SOHC, glow ignition, lubricated by oil mixed with fuel
• Engine 4.  AMD10S, water cooled, DOHC, spark ignition, oil pump
• Engine 5.  AMD20IL4, water cooled, DOHC, ignition method TBD.

Work started with cutting off blanks for the cylinder heads, cylinders and crankcase parts from a large bar of 2×2 aluminium alloy.  I used the bandsaw for this.  The next job was machining a datum face and edges onto these blanks using a fly cutter in the milling machine.  It is vital to do this as accurately as possible as these will be used as references for all further machining operations.

A large, exciting and expensive pack of metal has arrived from Noggin End Metals.

Set up for machining the end of the crankcase of the multi-cylinder square to the long face.

Machining the first datum face on one of the blanks for the multi-cylinder engine.

The set up for machining the datum edge square to the datum face on one of the engine blanks. The parallels are just to set the height at this stage.