Connecting Rod! Big Steam Engine Build, Part 5

This episode on Blondihacks, I’m making a steam engine connecting rod for my big engine Exclusive videos, drawings, models & plans available on Patreon!
/ quinndunki
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[@Blondihacks]

Hey everyone! Since a lot of folks are asking… 1) Yes you can buy replacement castings as needed for these kits. The little errors I made don’t warrant making the part again 2) Yes, various heroics to move the bore are possible, but unnecessary. The error is easily corrected upstream in the mechanism. This is common in model engineering.

[@reddnmilla]

I just appreciate what can be learned and the fact that your aren't afraid to post mistakes.

[@themoppie1000]

We all you know you've improved it, it's now de-stroked for an extra 50rpm on the top end.

[@yowie0889]

@@themoppie1000 Must be for a 1/4 mile drag application

[@greeceuranusputin]

@@themoppie1000"We all you know you've improved it, it's now de-stroked for an extra 50rpm on the top end." Stroke not changed, that's baked into the crankshaft.

[@AaronAlso]

Having worked in several plants that manufacture engine rods I can tell you that they typically have locating features cast into them called "knorfs or gnorfs" - I can't remember. These are used by the first few operations to get a center bore perpendicular to a milled surface which all other operations use for reference.

[@Dales_Workshop]

Count me as another voice in appreciation of your acknowledgement and dissection of your mistakes. I learned a lot.

[@eberseth]

I like the post mortem. Done in engineering projects all of the time. It's all coming together.

[@bkoholliston]

Dorthy Parker quote in the opening! Yay! Nice save on that part.

[@johnmcclain3887]

So often little errors creep in on ordinary jobs, and you can't just go get another part, and do it again. I started in machining because I couldn't afford to buy new things, always getting old, used things, often broken, and fixing up. I've been a mechanic most of my life, and machining was just the way around problems. The fixturing you're doing is only slightly less complicated than what often has to be worked around on "real world demands" You did a nice job getting around the slip-ups. Nicely done!

[@TheObersalzburg]

I believe that in real life, a slightly rounded slot, as you cut, rather than the specified square-bottomed slot in the con rod reduces the possibility of stress cracks. 👍

[@tjh44961]

Agree. Every English steam engine kit I have had or seen, Stuart, Reeves and others, specified round-bottomed slots i the top end of a rod. A square bottom slot is a stress riser.

[@RonCovell]

Quinn - thanks for another great video. I can only imagine your disappointment that there were a few missteps, but I'm glad you soldiered on in spite of them, and we can all learn from from these lessons. Remember, short-stroke engines run faster, anyway (smile).

[@vmitchinson]

@@dodgydruid 🙂

[@neorecormon1769]

i can imagine what your comment means to a youtuber, it must be the same feeling what you get when you get a promotion at work or catch a nice fish!

[@onnokonemann9326]

Though this mistake did not change the stroke just the compression 😉

[@RonCovell]

@@onnokonemann9326 Thank you for your correction - I got confused for a minute.

[@ericdaniels5358]

The algorithm is wild. Ron Covell I found your channel about a week ago and I was watching Jay Lenos Garage on the Doble E and the recommended section led me to this channel, and to top it all off you two watch each other! Life is wonderful and surprising.

[@GilgaFrank]

Sometimes it's far more educational to watch a video about how to recover from mistakes rather than one where someone just turns out a perfect part so kudos for being honest about the mistakes on a fairly tricky job. Other machinists might have scrapped the part and ordered a replacement.

[@ZeedijkMike]

Mistakes can be made, and fixed. I just remind myself of the Hubble Space Telescope. Might have been an expensive repair, but the result was breathtaking. Keep up the amazing work you do.

[@oleukeman]

I appreciate the analysis of your error and proposed correction to your methodology. That’s how we learn when doing something we’ve never done before and we get the benefit from your slip up. Keeping it real! 👍

[@gcl2783]

Excellent narration of initial execution and retrospective.

[@billoxley5315]

No one ever learned anything by being perfect, welome to the genius club!

[@bartylobethal8089]

I applaud your use of calipers for marking.

[@jaswmclark]

"Wisdome comes from experience, Experience comes from making mistakes." I have been described as very experienced.

[@mkegadgets4380]

A good machinist does not make mistakes. A real good machinist can fix any mistakes a good machinist makes. Great video thanks for sharing.

[@mathewmolk2089]

Say what? Even Joe Pi and Heir Gotswiter make mistakes. 75 years old here and have been full time in manufacturing and machine design/build sine 1980. Next machinist I find that does not make mistakes will be the first one that ever worked for me that didn't make mistakes,,,,,and that includes the tool makers.

[@mkegadgets4380]

A smart machinist learns from their mistakes. A real smart machinist, learn some other peoples mistakes.

[@uspockdad6429]

I don’t have a lathe, a mill, or any metal working equipment at all. Also have never done any metal working. But I never miss a video from BlondieHacks. So detailed, sprinklings of humor, and great info all around. I also love she is not afraid of showing her mistakes. My favorite ‘maker’ channel on KZbin!

[@fullmetalpenguin]

Gotta say, Quinn, your set-ups are the primary reason I decided to become a Patreon patron. As a fan of creative problem-solving, they are well worth the very modest admission price.

[@ErikBongers]

What I love about this channel is that I can learn so much from your mistakes before I go and make the same mistakes.

[@SethKotta]

Thank you for sharing with us your catastrophes.

[@trevorjones2473]

This ladys humility astonishes me, well done Quinn, we say anyone who never made a mistake never did anything, love you're vids, thank you.

[@0623kaboom]

myself I watch for the mistakes ... learn more that way ... not only WHY it is but perhaps a few ways to overcome it as well ... and even deal with it ... more information better understanding better knowledge ...

[@paulmyoldfella8034]

blondish thanks love videos great to see old school turned to new thanks love this

[@AlRoderick]

I like that you posterized the post mortem.

[@firebird8600]

Yay it's Blondihacks time!!

[@LaddGardner4]

It'd be a bore (chortle) if errors were never made because we'd never learn how to recover from them gracefully. Simply ordering new parts isn't an option for most of us, but following your resourceful and patient workaround approach is approachable, with the right attitude. It's what I love about you, Quinn: Teaching good practices, but also the best mindset for aspiring machinists. So proud of this channel.

[@brandonlewis2599]

Thanks for showing your honest mistakes. We all learn from them!

[@mrfarmall-vk4gw]

I stuggle with my machine operations, i get it all figured out in my head and then after i do it i realize how that was not the way it should have been done! Nice video 👍

[@brucewilliams6292]

I really appreciate your doing the postmortem on the layout. May of us just don't get enough time machining complicated layouts to understand best practices and your experiences shared really help! Thank you every so much.

[@bernieshort6311]

Hi Quinn, nice video and remember this, it’s not a cockup up if you are able to save it, it is only when you run out of ideas of how to rectify your mistake that it becomes so. I went to many a senior engineer in my early days at sea and honestly told them I had made a mistake, the only question they ever asked me was, “what are you going to do about it.” So long as I had a way out, everything was good in the world of marine engineering. It is one of the reasons I like your video’s and became a patron, when you get into trouble, you always find a way out and explain where you went wrong, and what you should have done to not make the mistake in the first place. It is really a very valuable channel for anyone who is setting up a machine shop and starting out in model making. Kudos to you for all your efforts and your honesty.

[@notabagel]

thanks for leaving in your errors. it's clichéd at this point but it's so interesting to see how you make and recover from mistakes. it also makes me feel like I could eventually get as good at machining as you.

[@capitaleyes4942]

Agreed. I've learned so much making my own mistakes but it's nice to learn from others' mishaps for a change. I've probably learned more valuable lessons from Quinn's hobby-sized shop than I have from a more polished Abom and his larger scale operation. Both make great videos but most of what Adam works with is out of reach for a hobby machinist like myself.

[@pyromedichd1]

The only people who don't make mistakes are the people who don't do anything. If you had to make 10 of the same part no doubt the last made would be the best and most efficiently made because you would have learned from your mistakes and gained speed as each subsequent part was made. IMHO, the sign of a real expert is not that a one off part is made perfectly the first time, its that the expert can think through errors and find ways to correct as the project progresses. This is true for metalworking, woodworking or most any other skill set.

[@rexmyers991]

Another excellent video. Thank you for sharing your thought process step by step. I am learning a lot.

[@mdhebert]

I think videos that recover from problems are the most helpful ones I watch on KZbin. You're sharing and honesty are appreciated. Thanks.

[@Bluswede]

I'll add my voice to the chorus of, "Thanks for not covering up the mistakes.". It shows a good character, AND, helps us slobs out here keep from making those same errors. Good on Ya'!!

[@raymitchell9736]

At the beginning of the video you asked "What Fresh Hell is this?" and often I ask myself the same question... and then I'm reminded to be thankful that it is a "fresh" Hell and not the same old stuffy Hell that I have gotten accustomed to... Great recovery on the missteps and I'm sure it will turn out fine. Now if only my freshness would turn out as fortuitous.

[@luckyirvin]

sweet fine channel, makin good ones every time

[@kurre_kallkvist]

I ended up on this channel looking for tips on how to grind cutting tools for my lathe. That was a week and about 20h of steam engine making, fly cutting and computer building ago! I love this channel; when I was chamfering the ends of some short axles I turned today, I kept telling my self it separates me from the monkeys! 🐵

[@soundmaster1966]

Quinn, you really did great in solving this issue. And explaining your suggestions for how to avoid this the next time. Others may just have said: „I make a new one.“ 😉👍

[@ChrisHiblerPinball]

I'm glad you mentioned "gun metal". I messaged Keith Appleton to understand what he was saying. Sure as heck...he was saying gun metal. It just sounds like goon-metal when he says it. 🙂

[@trainman419]

If you _really_ want a second try, PM research will happily sell you another casting. Just email them and they'll be happy to send you an invoice for another. Ask me how I know...

[@tnilmerl]

Wahoooo! It’s Saturday and there a new video from my fav channel…..

[@moltenaluminium]

For milling the square bottom, Use your lathe again with the cutter in the chuck.

[@danarbuckle6640]

Thanks for including mistakes in your videos. Mistakes are inevitable, especially when you are new to machining as I am and it is good to see how you proceed after one.

[@bhoiiii]

Putting a casting in a tool holder. That is the Inception of machining. Would never have thought of that. Thanks and cheers.

[@tosselton291]

Yes Hind Sight is a wonderful thing!

[@leighmackay7486]

Quinn, your dauntless character is exposed when you’re problem solving. Thanks for another great video. Time attached to your leather apron strings is time well spent.

[@markfletcher6511]

First of all, I want to thank you for listing the tools you use and showing the places where improvements could have been made in the setups. I have been a patron for a few years, and that is because I learn something in just about every video that you post. More than that, I find your videos to a wonderful source of encouragement to fledgling machinists. I, of course, fall into that category. For that, I am grateful.

[@RobertLiesenfeld]

I cannot sufficiently articulate how much I appreciate you showing your mistakes, where things started to go wrong, and what you should have done - this is the essence of learning. If you’re not making any mistakes at all, you’re probably not challenging yourself enough. Besides, I strongly suspect you think the part looks vastly worse than it actually does - it’s not perfect but a slightly flawed part that works is better than one of pristine appearance that does not. Loving this engine build series. The scale of this one is always startling when you bring the pieces together for test fits!

[@paulmorrey733]

Thanks Quinn

[@trailrider0194]

I think you showing your mistakes and explaining how it should have been done makes your videos much more helpful to others. We all make mistakes it’s always less painful to learn from the mistakes of others.

[@bloognoo]

I love that 'Fettling' is a transatlantic term.

[@jmiddlefinger]

I know this is an old video, but I wanted to just quickly tell you that I really appreciate your videos. I’ve had a really difficult day today, and I kind of binged your videos. I love the content, but a lot of it is that I enjoy listening to your voice and find it sort of calming. I appreciate you and look forward to seeing what you accomplish in your new shop!

[@davidapp3730]

The way we would accurately lay out a hole was to scribe the center of the hole then scribe a square around the center lines about 0.030" away from the center. That way you can spot the center mark with a center drill with a pilot diameter smaller than the square. The square lines indicate to you if you are off the center. All that had to be done with a height gauge to be accurate. You can get close to within a couple of thou doing that. Use a magnifying glass as you drill.

[@bobjohnson8970]

"A full thousandth of a furlong." My day is made!

[@lisag2771]

Thanks for another great video.

[@greglaroche1753]

Good outcome on a difficult job.

[@DawidKellerman]

If only Quinn had a furnace! ... Thank you for sharing I learned something!

[@julianp.1713]

Use a holder that has the V notch for holding a boring bar.

[@j.behrens7332]

Yeah! New Video. And it's still warm.

[@SgtCude59]

Great save , great video

[@martyboi83]

Cant wait for the DRO install , I have a warco wm250v equivalent lathe and have still not got round to fitting my DRO kit that I have had for about 5 years 😂

[@steveallen8987]

Hi there, I particularly like your post machining analysis. I think the idea of machining a mounting fixture for complex parts is often overlooked. I often have to make multiple identical parts, so building a fixing block is often my first course of action. If you don’t like the part there is nothing to stop you machining a replacement from stock. The you could have a bit of fun by fish bellying it. ( the shaft it taper turned down to both ends from the middle, so larger diameter in middle and smaller diameter at each end) looks very good and realistic to full size practice. Steve

[@OldSneelock]

Yo;u have learned a valuable lesson for the next one.

[@codprawn]

For accurate centre punching I use a dart first - it is sharp and pointy. You can buy a set of darts very cheaply. Make good scribers as well. Then I follow up with a proper centre punch. Much easier to catch the line just right.

[@simonbirt6121]

Ive been making engines, steam and internal combustion for a long time, yet I still put holes in the wrong place and cut things too short. I have a scrap bin to remind me that I am at times an incompetent. Very impressed with your progress in learning your craft.

[@a.c.m.4548]

I'm a woodworker and occasional welder (when my tools break) and your machining videos are infinitely interesting and informative for me.

[@headspace3477]

I do a lot of demilled gun parts kits builds. Most of the factory parts are hardened, at least on the surface. Sparks are the norm. Horay for carbide.

[@headspace3477]

I would appreciate a video on hard milling. I do it but I really don't know the correct way. I usually just use a already chipped and worn carbide mill.

[@allenhunt3070]

Well, milling rough castings in a kit presents a lot of challenges. Glad to see that you spent the time to present the mistakes and how you could have avoided them. Thanks!

[@umahunter]

Don't worry that part will be moving anyway 😂😂😂 everybody has those days where you learn the hard way it sucks but learned what you did wrong and how to fix it so now you know for the future keep moving forward👍👍👍

[@rickyretic]

I think I might have over bored the off-center hole in the correct position and sweated in a piece of bar stock. That would allow me to relocate the hole to the correct dimension. Just a thought, I have been there myself, usually I allow myself a 5 minute pity party and get on with the correction. In the end I am always pleased that I just bit the bullet and made the correction. Always enjoy your videos Quinn so please keep them coming.

[@mattbarker3613]

Another great video 👍

[@Happy_2_Wheels]

Please never stop making videos, I got to your channel by chance some time ago, and now I learn so many things thanks to you, also I absolutely love the incredible attention to detail you have on everything you do!

[@george8873]

Really like how you show your processes of doing things, explain your thought process, and then include your solutions to any problems you may have come across. Especially how you do it in a light-hearted manner. Really makes great videos that are enjoyable to watch, even for those like me that really has no intention of ever using mills, lathes and all the other tools you use.

[@billofalltrades2633]

Great video, very informative!

[@MatthewPettengell]

Well played on the conversions, furlongs and perfectly rounded 1" to 25.4mm XD shame there isn't more decimals places there

[@pesterenan]

For the amount of setup steps that you need to do between every operation, I was surprised at how little went wrong! This looks so difficult to me! Nice one Quinn, I guess in the end everything will go right!

[@nothing2loud]

Great work. I broke one of the ears off the cross head side when I machined my engine.

[@mrvector257]

You mentioned you have a DRO for the lathe, but haven't installed it yet. Are you planning on doing a video of the install? I think that'd be a great video.

[@mathewmolk2089]

Just do it, Quinn. I am so spoiled I have a 14K hard time doing anything without a DRO on ANY machine and I have been at it longer then you 'been alive. . Our big lathe does;t have a DRO and I absolutely DREAD doing anything on it, which makes me twice as likely to scrap a part just form the fear factor,,, WTF, Over, I'm even going to put one on the surface grinder!!! One scrapped part can pay for the Chi-Com DRO. (I hate buying any commie anything but the DROs work just fine and you can buy 3 for the price of 1 Accurite. ) You can keep one for a spare and have 2 on machines. When you are making quick one=off parts for something like a part for an emergency machine repair I would say he DRO let's you concentrate on the part, and not the dials and cuts the time by a good 75%. Way less screwing up too when you are in a hurry, especially on lengths when setting the cutoff tool, Touch off the end, Enter the thickness of the tool, move the cartage to the negative of your dimension and lock the cartage. Part to length within a couple thousandths in 5 seconds (Plus tool change and cutting time) It's almost impossible to screw up too. ,,,,, Just there would be a lot less to watch in the Videos, though. Almost CNC like once you get you get use to it......Then it makes you think you can't live without it.

[@robbytheremin2443]

I believe rounded corners in the slot are better. Reduced stress risers.

[@jtyhrg]

Well, just, thank you !!

[@alanharney5278]

Two rules for any shop 1. Mistakes make us better 2. You can ensure a high quality result if you bleed on the work. I got number 2 down. Still working on number 1.

[@ChristopherTate]

Obviously the way to get the square-bottomed slot is to chuck an end mill in the lathe and feed the shaft in with the carriage. Worked for the rest of this dang build, so why not? :)

[@ron827]

That tool holder material was harder than "Chinese Algebra"'! Machinists don't make mistakes, they make engineering changes.

[@jamessimmons1888]

Good video Quinn, You always have to learn from mistakes, just a part of life, not the end of it, life goes on.

[@chrisjacks2599]

machining castings is the ultimate process puzzle.

[@BEZmer2001]

This is awesome!!!

[@andrewmullen4003]

Thanks for your integrity and honesty, and well recovered, glad you can still use the offending rod.

[@andrewference1479]

Props for showing your mistakes Quinn. I'd have binned the part and ordered a replacement casting :p

[@notquitecopacetic]

What fresh hell indeed. I got my laugh, but immediately started feeling empathy driven guilt :) You are a stronger person than I. I would have ordered a new part and pulled out the Time Travel Cam (trademark transferred to you in perpetuity). Well done!

[@dangerrangerlstc]

She may just have to borrow TOT's time travel lathe and put all the material back.

[@allenglishknives6823]

Great video, thanks 👍🏻 I’ve had a couple of days like that working on my motorcycle 🙄 make a mistake and it quietly sits there waiting to jump out way down the line 😂😱

[@evanbarnes9984]

I knew this would be the video today! I was rewatching the big steam engine playlist last night and noticed a 5th unavailable video in the playlist. So stoked!

[@classicbandgeek]

You had the opportunity to make a flawless, seamless video of making a part (or replacement part) where each operation went smoothly - and I'm glad that you didn't. Machining can be both challenging and rewarding, but it is always humbling. Thanks for showing how things can take a wrong turn in spite of what one's thought processes seem sound, and then using those same smarts to make corrections and salvage the part.

[@lesstoneuk]

You could machine out the centre of the rod and remake to correct dimensions or add the error to the crosshead so one compensates for the other. Drastic solution is to forge the error out but that'll be difficult because it's a casting and final machined.

[@andrewjames7616]

Thankyou 👍

[@clifffiftytwo]

Thank you so much for sharing. I went on to watch several other videos for the various approaches and fixtures and tricks, understanding the limitations of available machines affect everything. In summary, were you to do this again, I take it the first step would be attaching the part to some kind of semi-permanent fixture rather than laying out the holes? Castings are such fun -

[@rickpalechuk4411]

There are some good lessons learned in this installment, very informative, thanks for sharing Quinn. Cheers

[@QlueDuPlessis]

Aaargh My OCD would flip out!

[@keithgutshall9559]

Don't worry about the length of the rod , you can get it on the adjustments on the piston rod.

[@johnapel2856]

Yet another step closer to a running engine! Pffftttt, mistakes... I thought I made a mistake once, but I were rong. 😁 Thanks, and Meow to Sprocket.

[@paulthomas3782]

Well done Quinn, Nice recovery the Con rod looks awesome.

[@markwatters6875]

Thanks mate 👍🇦🇺

[@zirconia21]

Unexpected Shim- UNREGISTERED