db5 engine - choppers paradise!

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db5 engine - choppers paradise!

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db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:18 am

following here I should post an excerpt on the db5 engine - no need to read through all the fun on the original thread -
just hard facts and how-to's for all going the masochist way in turning the ge-fab engine into a scale reproduction of the real aston engine.

note parts of this can also be used for separate engine part mods -
always see if the desired mod will fit onto the stock parts as one mod is sometimes requiring another on other parts -

as we should keep this section largely clean, please pm me on any personal questions or post on my original thread if you so desire
;)
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:19 am

as promised, a slow start has been made on the engine head -
when finished I should be able to fix the exhaust and carbs just like they're fixed on the original engine,
also the lines will be closer to the original as the supplied parts were when new...

still a bit of a job though...
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first step: mask the head for silicone casting.. second step: silicone rubber mixed and cast...

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third step: take off masking tape - result OK…
this is how it looks like once the silicone is separated from the head -
this should serve as a casting mould for the separate rubber plug pegs AND I can cast the missing 14th head retainer seat

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fourth step: casting the resine parts - childrens plasticine used to make a rough seam...
I'm happy with this - what I have now: I have closed the wrong distributor opening and also even more important,
I have restored the missing 14th head bolt mount...

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the red shaded part should be removed (tomorrow) to get the rear part of the head right...
resine cast (still needs some treatment) proper carburator mounting surface...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:20 am

here's todays efforts (so far - maybe I'll manage to do a bit more later...),
I'll also cut off the alternator, can't leave that the way it is now, especially if I carry on with all the mods I plan to do...

the engine head has been heavily reworked further to the previous efforts, around 1 and 1/2 hours more work:

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a bit of milling on the nuts as well as removing the cast spark plug sleeves...
this is the exhaust side, now closed with resine just like the carb side has been yesterday...

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as can be seen, the rudimentary blobs at the front have been removed - should be replaced by proper breather pipes later on...
...and what has been done to the front top section, now I like it much more!

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as you can see, I've also removed the cast part at the rear of the chain drive housing - should be replaced by a nice new piece..
...and finally, this is how the rear section of the cylinder head looks like - a bit more like the original...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:21 am

boring, boring, took me almost 3 hours to do what you'll see below,
still not ready (or at least not as far as I intended), but a bit of progress and -
STILL a lot of time before the other parts are in hand...

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ok, so this is right after the alternator has been cut off, set aside for further work... cut off the inside tag on the fan mount backside...

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one last look at the original front view... a few moments later with water pump housing removed...

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sanded everything flat, new nut placement to follow... lower casing rectified...

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...a lot of mess during cutting and sanding... partly finished now - new large water pump housing with hose adapters installed - fan mount glued back, new nut seats created... more to follow...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:22 am

I've modded my mod of the timing case, now I'd consider it about 80% ready - done also some nice altering of the thermostat housing...

as it needs a few more hose etc connections I've started to add the missing pieces,
gee, had a very thorough reading of the DB5 parts/repair manual and seen what can be added to the hose/wire/tube section...

also, a pretty small mod (and a large cut on my thumb...) has been accomplished on the oil filler,
now I'll be able to fill the engine, who exactly made the oil?? see pictures

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timing case after another burst of ideas, still not finished... thermostat housing half-way around - tube connecting parts added, more to come...

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the oil filler, I particularly like this piece!!!!! watch for action below :-)

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open... -> closed (still needs to get re-chromed...)

a few more steps done so far,
milled the oil filler cap and the oil filler opening,
also milled the holes for the breather tubes,
as I was milling, done also some small improvements to the cylinder head,
a small step on the thermostat housing as well...

nothing really earth shattering but as I have plenty of time I'm playing with what I have...
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a bit more on the thermostat, this small item will be connected to 6 tubes/wires... -> small improvements to the head surface...

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first test with milled opening, should be completed once the head is painted... -> ...and open, note also the milled breather tube bases...

it's not a really big job, took me an hour or so -
most of the time slow work as you have only one try (if you don't have access to spare issues like me ) -
file down the handles, drill (by hand, NO machine with this small hole as it would melt the plastic), mill out the original mount tag -
oh yes, hinge made from spare etched 0,1 mm alpaca, should do a pic to show how it looks like, when finished insert wire...

now I'll use some chrome foil to make the lid nice again and fill the red script anew...
so anyone could do it, no dremel or super glue involved
Last edited by baby_astons on Tue Oct 25, 2011 9:04 am, edited 1 time in total.
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:23 am

a few steps further on, here's what happened:

bare metal foil cut to (oversize) format,
placed over the oil filler,
laid out over the whole part - note there are some places where the foil will have some creases,
best results to smooth creases out achieved using your fingernail,
use light pressure as foil would tear or come off it's adhesive backing,
use toothpick to work on small details,
new hinge fabricated (old one got lost - of course after new has been finished I found the old one ,
0,6 mm plastic rod inserted into hinge opening and (hand) drilled 0,32 mm hole,
silver wire 0,3 mm used to connect hinge and oil filler cap...

happy modding...

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bare metal foil -> foil cut to shape and partly peeled off

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first contact to filler shape -> edges still not smooth

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now almost smooth... -> picking :-) out details...

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size compared to ruler - note script on filler... -> 0,32 hole drilled in plastic rod insert

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0,3 wire inserted -> completed hinge/filler cap assembly, more work required to fix to filler opening...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:24 am

now after a whole lot of useless tries, here's a bit of stuff that I managed to do on the weekend -
much less than hoped but still a bit to toy around:

made the spark plugs of two alloy pieces, first the threaded part that goes into the cylinder head,
I needed to make a 1.7 mm thread as this would be the 1:8 equivalent of the M14 spark plug thread -

second part was an alloy piece, milled to a hex nut with an inner thread of 1.7 mm to go together with the previous part -
if I don't screw it up both should be screwed together to form the bottom part of the plug.

now on to the plastic isolator bit (ok I couldn't do in ceramic for all wise guys ),
this is 1.5 mm and got a 0.8 mm hole in it for the center piece that will join the bottom and the isolator part -
the isolator goes onto the first two, inside went the last part - a 0.7 mm metal core that will be glued in and keep the plug together -

I plan to make the thread seats into the head to have the spark plugs removable...

oh, almost forgot, sourced a fine NGK spark plug script and printed as a decal piece -
should look pretty nice once the spark plug cap went over all the work

now onto the next 5 plugs...

btw. the last picture is the start of another nice mod: the alternator and the new etched vent part -
but that's another story

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working on the threaded lower part... -> you can (hopefully) see the threaded pieces...

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...a part of the involved instruments... -> ..isn't this lovely?? the isolator bit should get 3 grooves to look just like the original...
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old alternator sanded and prepared to receive some nice mods...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:25 am

done a bit more until my 1,0 shank drill broke (titanium heavy duty but brittle like hell and expensive alike...) -
off to buy a new one tomorrow...

now I've inserted an alloy piece to back the cylinder head for milling the spark plug shafts,
next step was to cast resine into the whole lot from inside to secure the alloy piece,
off I went to the workshop for some heavy milling,
milled the holes with the 6 mm shank drill,
inserted the 1 mm and broke it while trying to locate the third hole for the spark plug -
it's so immensely brittle - a small dislocation of the shank head simply snapped it off...

out of frustration got to make the head breather pipes from 2,5 mm brass rod -
sorry paul, no hollow tube as I wanted to avoid closing the top - next time...

btw I'm now at 52 parts doing the head and timing case, pretty sharp as the original parts count would have been 3...

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...the alloy rod milled and prepared to insert... -> inserted and fixed with two dots of glue...

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resine cast 10 seconds ago... -> 5 seconds on...

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10 seconds more... -> 15 minutes on, already sanded.

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spark plug seats milled, center thread drilling still ahead... -> breather tubes (almost) ready...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:25 am

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copper prepped for cutting... -> this should be cut and fixed to the front...

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now you see me... -> now you don't...

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nice fit... -> polyester car filler in place, already dried and ready for sanding...

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happy with the overall shape now... -> drilling holes prepared for front nuts...

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again a bit different - timing case evolution...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:49 am

here's what I have done to the valve covers -
which btw in their original form missed the point for me (as did many other parts - would you have guessed by now??...)

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so far standard procedure for (almost) everyone here: removing the original nuts... -> next step shaving off the (disturbingly rough) paint coat,
applying styrene strip pieces around the parts - should help having a wider body and more rounded look...

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the covers should be more rounded and smooth edged, with only a small edge on the bottom line... -> of course the front part wasn't right for me either...

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sanding in process, note acorn holes have been made, also partly recessed to form an even surface on the rounded valve cover...
as I don't know yet how I want to do the finish, first step is to give it a shot of primer to see any surface imperfections...

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primer finished Mk1 -> primer finished Mk2 - now over to thinking what to do (paint or - maybe - have it plated...)
Last edited by baby_astons on Tue Oct 25, 2011 10:45 am, edited 1 time in total.
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:50 am

here's the next part of the engine saga:
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the red markings will have to go... -> ...and gone...

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this side will need "mild adjustments" as well... -> ...and done...
now I'll go for screwing the engine parts together, masking off and filling with resine,
this way all apertures (gaps by ge fabbri, holes by yours truly) will be gone, more when resine cured...

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don't think the gear box will survive my saw
outlined what I'm going to do to the front side, as of course the shape of the 'box front is wrong

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one step further and the oval is much better now... -> holes where the bolts will fit - eventually

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off the sump... -> the hole's getting bigger...

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the lower part's getting a new shape... -> ...and the hole's even bigger now...

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now some will ask where will this end... -> ...closing up a few holes...

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not yet finished, but soon there'll be more... -> a bit of strip styrene gone into the build...
Last edited by baby_astons on Tue Oct 25, 2011 9:07 am, edited 1 time in total.
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:52 am

a few bitsies more started on the engine -
Image
first, started with restoring (I call it so rather than mod ) the exhaust manifold,
should fill all the empty spaces as I want to display the engine and one would see all the missing parts -
re what should have been made better...

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same problem, other side of the engine:
cut apart the carbs, made new flanges and started repairing the mistakes,
still a long way to go...

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this is how the carbs will attach once the cylinder head and the carbs are finished...

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filling the belly part of the carbs, green pots are to be shortened and glued to the underside of the domes, exhaust starting to show right shape…
note the green pots are from a ball point pen and will be painted – no special mystery about the colour...

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already cut up and preparing for final sanding and drilling the nut holes...

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still a bit to go but nearing...

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the back side of the exhaust manifolds, holes and grooves for mounting prepared...

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the engine side, now finished - well almost, the triangled part will have to wait 'till tomorrow - the engine side of the carburettor manifolds, almost ready...

following piccies of the finished manifolds - no welding visible, so nothing done in 8th scale as well

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as compared to the original (albeit rusted...)
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Last edited by baby_astons on Tue Oct 25, 2011 9:09 am, edited 2 times in total.
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Re: db5 engine - choppers paradise!

Postby baby_astons » Tue Oct 25, 2011 8:54 am

back to serious stuff - as promised, with a new chop job on the engine;

I've left the engine alone for a while on my working table, just looking at it and pictures to determine what was wrong,
now I've made a decision what to do to it -
in spite of having done several changes I wasn't too happy about the proportions of the timing part of the head,
as well as the fact that the spark plugs were in the wrong place compared to the block:

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I decided that a part of the rear of the block had to go to fix that section

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and this is how it looks now: the lower part will receive the clutch housing front part while the upper part is now OK to receive the (revised) head...

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first the markings have been set what had to go - as you see, cutting was pretty successful ->

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fixed the head parts to each other and filled with resin, now it's one part again, and the right size ->

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... unfortunately I sanded a bit too much on the left cam cover :oops: , so there;s been a gap, now filled with a piece of styrene...

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... now the cylinders and spark plugs align much better and the form of the cam cover front looks also more like the original ->

so the dr is now much more happy with the engine, even if it's not ready yet
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Re: db5 engine - choppers paradise!

Postby baby_astons » Fri Oct 28, 2011 6:07 pm

a lot of thought went into this as I wasn't happy about the height ratio between the lower block casing and the cylinder part -
a final decision was made and I made a silicone rubber "stamp" of the block side, relocated the silicone and cast the remaining gap with resin...
I simply didn't feel confident to fill the necessary height with polyester and sand it to a perfectly smooth transition between the cylinders :?

well, at least that was the bold plan :mrgreen:
the silicone needed to be cut back where the oil filter and the block mount were located or else the casting wouldn't have been level,
all remaining holes were filled with children plasticine to avoid the resin from escaping...

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left before casting attempt -------------------------------------------------> right thereafter :mrgreen:

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original (or at least what remained from the original after my last mod) ----------------------> new rear

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as you might see from here, I also got rid of the (wrong shape) nut seats -
AND the engine mount is now recessed just like the real one and not standing proud off the cylinder part...

now over to the port side...
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Re: db5 engine - choppers paradise!

Postby baby_astons » Sat Oct 29, 2011 12:20 am

which looks like this now after the same treatment like the starboard:

Image Image
port side --------------------------------------------------------------------------> and the rear

now onto the polyester + sanding to get it smooth + add some missing details...........
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Re: db5 engine - choppers paradise!

Postby John b » Fri Nov 25, 2011 10:40 am

Where's the rest of this master class?
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Re: db5 engine - choppers paradise!

Postby Paul » Fri Nov 25, 2011 10:04 pm

John b wrote:Where's the rest of this master class?

Hi John,

Astons is putting the posts up as he is working on it.....

You must also please take in to account that Astons is also doing all this so that extra ones can be made ! :)
Just :) to Cause a Landslide - Some :superlglue: will be included .....

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Re: db5 engine - choppers paradise!

Postby baby_astons » Sat Nov 26, 2011 9:28 pm

as requested, here is the next part of the saga -
just to give it a detail again, please note that I'm moving this engine diary from my own DB5 build to here -
but only when a few installments are finished as it's a silly job and I want to have it cleaned and in one sweep...

the block theme has been pushed further by filling the front lower part -
I suppose they omitted that part as the front axle must be a pretty beefy part and interfering with the engine -
so as I have now altered the engine, the suspension will be another interesting mod then... :?

also, the port side of the block has been brought to better shape,
finally, almost finished with the oil pan...

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the recessed part was too short ---------------------------------> rectified...

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lower front portion of the block filled with resin...

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this is how the oil pan has evolved since I got my hands on it last time :mrgreen:
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Re: db5 engine - choppers paradise!

Postby baby_astons » Sat Nov 26, 2011 9:37 pm

as you will note I've reworked the oil pan very nicely just to discover that it was the wrong shape, so needed to play around again;
made also the preps for the oil line coming from the oil cooler as well as the oil drain plug, also the holes for the 10 front bolts holding the pan.
the whole front part had to go and was also replaced by an accurately shaped flat piece...

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this is how it looked last time ------------------------------------------> and now after I discovered the mistake and changed things...

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more of the same part, note the lug parts,
small center hole prepared for easy drilling once the part will be replicated in resin...

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upper and lower view, tomorrow I'll prime the whole part to see if there's anything that needs to be repaired -
if not, first part completed... :mrgreen:
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Re: db5 engine - choppers paradise!

Postby baby_astons » Sat Nov 26, 2011 9:42 pm

relocated the oil filter housing as it was too low on the block,
fabricated a few bits for the oil pump housing (which was completely missing of course),
reshaped the rear of the block to have a sloping join line to the lower block,
made a new rear oil pan surround with holes for the nuts/bolts,
made new lug seats, the right number, nuts should be separate parts from brass...

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before details have been added (old oil filter seat gone) -----> after details placed

(most) of the work on the block is finished now -
there are two pretty small touch-up jobs that need to be done as well as drilling the cylinders and milling a bit off the side,
never mind this is how it looks like now:

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LHD side with rib added --------------------------------------------------> RHD side with more of the ribs + the finished oil filter housing + stud for water drain...

now onto the clutch housing and the gear box...

btw found out that the main problem with the size difference to the 1:8 e-type engine is that the aston engine is also too wide -
but that's one thing that I won't be altering, even if I know now... :mrgreen:
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