Big end bearings

The big end bearing surfaces were tinned with white metal using a soldering iron.The caps were installed on the rods with 1mm. aluminium shims. Both sides of the big ends were then filed flat. Two thick aluminium washers were made to contain the white metal.The white metal ingot was melted and poured slowly into a bucket of water to form granules. These granules were packed into the big end  space between the aluminium washers clamped very tight with a 5mm. bolt This must be a water tight seal to retain the molten bearing metal. The rods were spun in the lathe on the fixture previously shown.Melting of the metal was acheived using a Mapp gas torch while the rod was spun at about 1000 rpm.
Potentionally this is a dangerous operation.
The result was excellent as the metal is solid and all impurities finish up on the inside.Using the same fixture the big ends where bored to fit the crank journals
The block on the caps used in the manufacture were drilled and reduced to make oil scoops for  oiling.

Connecting rods

 Profiling the rods with the blank screwed on a  scrap piece of steel.

The  profiled rods caps and mountiing block

 The caps super glued to the rods to enable the rods to be drilled and tapped 3mm.

Tapping the rods

The rods bolted together to enable the big ends to be pocketed. Note the jig used to hold the rods.The small end has been reamed  6mm to fit on a 6mm dowell, the big end cap is held in a small Starrett vice which is screwed in a slot in the plate to enable the rods to be accurately aligned.

This rod has been bored.

 Using the same jig the rods have been tapered and fluted

The same jig mounted on the face plate will be used to centrifically cast the white metal for the big end bearing. The final boring of the bearing will be turned on this jig.