Work on Samson continues each day, with tangible progress usually evident, and if not, a pile of swarf confirms things are progressing nicely!

Below: Tony cut out some discs for Dave, these being to the correct PCD (Pitch Circle Diameter – the circle at which the gear teeth engage, not the outer or inner radius of the teeth) for each gear as seen written onto each one.  This enabled final alignment and measuring for the position of the crankshaft pedestals.

Below: The crankshaft itself was a large lump of water-jet profiled steel, made in one piece.  Dave machined the square edges on the mill, to reduce the mass of the metal and remove waste material.  It was then set up on the pillar drill to enable the lathe centres to be drilled (after very careful marking out and much checking and re-checking!).  If these centres are out of position, the whole crankshaft would end up out of true and mis-aligned.

Below: The crankshaft is seen placed onto our TOS lathe (of Czech orgin) for machining to start.  Note the far section has flattended corners where these were milled off, whilst the near section shows these after machining to a circular profile.  There is still a very long way to go with this critical component.  The area on which the big-end will fit is clearly visible in the centre of the shaft.  The eccentrics (forward, backward and water pump) will be fitted after, likewise the sliding pinion for the final drive.  Also to be machined are the journals for the bearings, to there are a considerable number of factors to consider in this process.  The nearest end of the shaft is seen on the tailstock of the lathe, with a second hole evident – this is the centreline for the big end to enable the cranked throw to be machined in the round at a later stage.

Notice to all workshop volunteers: We are holding a series of workshop induction sessions, covering aspects of health & safety as well as other matters.  These are compulsory and we will try and contact everyone who works in the RHEC regarding these – but if you think we might have missed you, then please contact myself, Sarah Jarman or Ian Bean to book a place on the course.  After the 7th December anyone who has not attended will be unable to use the workshops until the next course in 2014.  Even occasional attendees should get in touch – it is very important that we ensure everyone working in the RHEC receives this induction, it being a part of a wider safety audit and upgrade of the systems we have in place in these area.  If anyone has any queries regarding this, then please get in touch with us as soon as possible.