THE COMPLETED ENGINE, THE LONG HANDLE AT THE TOP MOVES THE REVERSING VALVE AND THROTTLE. A STEAM COCK UNDER THE VALVE IS USED TO DRAIN CONDENSATE FROM ENGINE AT START-UP, THE ENGINE SHOWN HERE MOUNTED ON A WOODEN BLOCK ( NOT INCLUDED IN THE KIT ) SO THAT THE FLY- WHEEL WILL CLEAR, THE EXHAUST PORT IS. JUST VISIBLE ON THE UNDERSIDE OF THE CYLINDER, The frame is made of five pieces of brass soldered together. The .37 x .50 section is made by soldering a .25 x .50 piece to the .125 frame part. The pieces can be clamped or screwed together while solder ing. Press fit the hub in place to hold it. Sweat all the joints at the same time with a torch. The solder must go comple tely through the joint at the heavy sec- tion so there are no leaks. Complete the machining, keeping the face with the ports square with the crankshaft hole. Use care when drilling the deep holes for the steam passages. First put in the .250 hole; and then drill the two deep holes. Finally drill the four port holes last. Turn the outside diameter of the piston to size chucking on the rod to hold concentri- city. The piston rod is held in the rod end with Loctite or a small pin. The pin and shaft are pressed or Loctited into the crank. The flywheel should be about the size on the drawing, but can be made in several ways. A good wheel can be made by turning the teeth off a stock gear of the right size or turned from solid. The Caldwell parts kit contains three parts (ring, hub, and plate) to be machined and soldered. ROUND ROBIN DESIGNED BY R. S. HEDIN ©1977, capweLt INDUSTRIES, LULING, TEXAS USA BILL OF MATERIALS Onc Piece of Brass in the following sizes: 020 x 19 x 2" -062x1x1" aoe ae edo +1875 x 2.5 x 2.5" Nag, xqs0 x15") 062 Diameter x 2" 25 Diameter x 1.5" +31 Diameter x 1" -43 Diameter x 1.5" 5 Diameter x .5" .87 Diameter x 3" 2.5" ID Tubing x .25 wall x .5" One Piece Steel Drill Rod: -1875 Diameter x 6" +250 Diameter x 3" +625 Diameter x 1" Steel Spring Wire: Fourteen #2-56 x 3/16" Machine Screws One #2-56 x 5/16" Machine Screw One #2-56 Hex Nut 020 Diameter x 1" The parts kit as supplied by Caldwell Industries contains materials sufficient to build the engine. From time to time metals shortages occur that force minor substitutions fron the bill of materials. In all cases sufficient metal pieces are ingluded so that the proper size piece can be made.& Screws for the prototype were made from 1/8" Rexagon stock, the only way to small scale hex-head 'bolts.' Regular machine screws can likewise be used. To get a smooth running and long lasting engine, put smooth finishes on the bearing surfaces and be careful to get the surfaces flat at the cylinder pivot. When sweat soldering put flux between the joints and heat until the solder flows through. A small fillet of solder should form at each joint. A good solder to use is a type sold for jewelry; it has a low melting point but greater strength than ordinary tin-lead solder, In the drawings where steel is specified, Caldwell supplies easy machining alloys unless drill rod is specified. Painting is best done by disassembling the engine, cleaning, masking and spray paint- ing. Auto engine paint in spray cans is good because it will stand the heat. Bake the parts in the kitchen oven at about 175° to get a hard finish. ROUND ROBIN THE CYLINDER IS MADE FROM SIX PIECES, THE CYLINDER ITSELF HAS RADIAL HOLES FOR THE UNIFLOW EXHAUST, A COLLECTOR BAND GOES AROUND THESE HOLES TO CATCH THE EXHAUST AND ROUTE IT TO THE PORT. THE TOP AND BOTTOM OF THE CYLINDER HAS BANDS TO PROVIDE FOR A WALL THICKNESS SUFFICIENT TO HOLD SCREWS. Before assembly, check all the parts for burrs and wash out the holes to remove any stray chips. First assemble the crank, pin and shaft. Screw the valve plate to the eccentric strap. Insatall this with the crankshaft in the frame with a .187 pin in the cylinder pivot hole. Check the travel and motion of the openings in the valve plate with respect to the 4 port holes. Openings in the valve plate should move around the port holes in a symmetrical mo- tion when the crank is turned. When the crank and eccentric are at the front and Tear positions, the corresponding ports should be opened or closed and the slots in the valve plate centered over the ports. If they do not line up, loosen the screws in the ecdentric strap ’and shirt the plate to correct the error. It may be necessary to enlarge the holes in the plate. When the valve plate is correct, assemble the rest of the engine. Use light oil on the bearing surfaces. Put a #10 flat washer between the spring and the frame at the cylinder pivot. Run the engine on air for a trial The ONE METHOD FOR MAKING THE SADDLE BLOCK FOR THE CYLINDER ASSEMBLY. A SCRAP METAL BLOCK IS TURNED TO THE CYLINDER DIAMETER AND A FLAT PORTION IS CUT THE APPROXIMATE WIDTH OF THE SADDLE BLOCK. THE FLAT STOCK FOR THE SADDLE CAN BE ATTACHED BY A SCREW AND SOLDER, AND THE CONCAVE SHAPE IS BORED OUT. THE OVERHANGING PORTION IS THEN SANED OFF, =a" CALDWELL INDUSTRIESThis is an advanced type of oscillating steam engine that has several unique features, The usual oscillator has early steam admission and late cutoff; in fact, the cutoff is close to dead center at the end of the stroke. ‘Therefore the engine wastes steam because no expansion is used. This engine has an inter- mediate slide plate between the ports to cut off the steam at about 70% of the stroke to use the expansion power of the steam. The slide plate is actuated by an eccentric on the crank. The engine is of the uniflow type that exhausts the expanded steam at the center of the cylinder through ports opened by the piston heat the end of the stroke. The engine is both double acting and reversible. A manual valve in the frame reverses the engine and acts as a throttle. The cock on the lower end of the steam valve stem drains condensate from the engine cylinder on start- ing. This is closed after the engine is hot. The photos and drawings show the details of the parts and how ake a 237 0-32 Tun they are assembled. The parts can be made in any sequence you “44(4) like. Although the drawings show the details of each piece, a few words about the fabrication of some will be helpful. @ Bexcer - Beass For the cylinder, make up the parts as shown on the drawing, Sacsexed 455/, leaving She tube. je, end rings, and saddle block a little long. Sweat these parts together with soft solder using a torch (al- cohol or propane). Layout the center on the face of the saddle block, then chuck the assembly in the lathe with the cylinder bore square with the lathe center. Face the saddle block and turn in the relief space. Drill and tap the #10-32 hole in the lathe so it is square with the face of the saddle block. Drill the .062 ports and file as shown. Make the drill rod stud; cut the threads with the lathe. Screw the stud into the cylinder assembly down to the bottom so it is jammed in. Leave the head holes to be spotted from the heads. @.Be Eve Beas -25 Ture 002 Den(4) —_ 062 Dens x 4-75 DR 2) 092 Pens @xLeame —BaRass 437 128,50 450: Socosees M35 | DRAWINGS NOT TO SCALE R AD R BIN DESIGNED BY | ou ° R. S. HEDIN @197 INDUSTRIES, LULING, TEXAS USA. chau Pas Dei Koo ‘7, CALDWELL