The work continues on the intake valve. With the valve stem finished I need to make the
flat part of the valve. In this photo here I have chucked up a piece if 1/2" X 4" X 4"
steel and had drilled a hole in the center for the valve stem to go into...
In these (2) photos the valve stem and the steel plate are mig weled together...
The valve is now chucked into the lathe and the flat steel plate turned round so it looks
like a valve. You can see this in the first photo. In the second photo, all the rough turning
is done and the valve is now round. Notice the use of the live center to help support the
With the roughing all done I now transfer the intake valve to another lathe for the finishing
work and the grinding. In photo #1 I have the valve all turned to the finish dimensions. In
photo #2 you can see I have undercut the back surface of the valve face. The 1/2" wide face
around the edge of the valve is where the gas will be sealed off...
In these next (2) photos you can see the valve grinding taking place. Photo #1 shows the
Dumore Toolpost Grinder all set up for grinding the back face of the valve. Photo #2 shows
the 1/2" wide strip (the valve surface) all ground. The valve is ready for action now. It
will need to be lapped in when the intake valve housing is completed...
Here in these (2) photos you can see the completed intake valve in the intake valve housing
and main housing assembly...
Photo #1 shows a couple of 3/4-10 nuts that I narrowed down in the lathe. These will be for
setting the spring tension. Also for the spring I needed to make a keeper. Photo #2 shows the
spring keeper being roughed out and a hole drilled for the valve stem. The next (2) photos
show the keeper bushing being cut off in the lathe...
In the first (2) photos you can see the facing off and chamfering of the keeper bushing
taking place and in the third photo you can see everything all assembled...
Now to make a guide for the gas valve. Photo #1 shows a piece of round stock cut to length
and positioned on the main housing assembly. Photo #2 shows the round stock all welded to
the main housing assembly. I welded this part on now because if I had put it on earlier the
main housing assembly would have been hard to machine in the lathe with the piece of round
stock sticking out...
I found an old valve that was real close to the size I needed for the gas valve. Photo #1
shows turning the O.D. down and recutting the angle from 30 deg. to 45 deg. Photo #2 shows
the valve in the valve grinding machine with the surface all ground smooth and true...
In photos #1 & #2 I am drilling and reaming the guide for the gas valve. In photo #3
I have flipped the main housing assembly over and am opening up the hole that will become
the gas valve seat...
Photo #1 shows the gas valve in the main housing assembly before the seat was cut. Photo #2
shows cutting the seat by hand. The seat cutter picks up on the guide for location. Photo #3
shows the seat all cut, and the gas vavle...
Before I could finish machining the gas valve seat I needed to make a thin bushing. The largest
guide I had for the seat finishing tool was .375 diameter. What I did was make a brass bushing
.437 diameter with an I.D. of .375 to slip over the tool guide. In photo #1 you can see the
bushing being reamed. Photo #2 shows the bushing and tool guide inserted into the valve stem
guide. Photo #3 shows the finishing tool and the seat all finished except for lapping the
valve and the seat...
This first photo shows the parts I made up for supplying the gas to the gas valve. I used
just common pipe fittings with some minor rework for these parts. The next (2) photos show
these parts welded onto the main housing assembly. A pipe plug in the end will allow access
to the gas valve and the valve seat...
Photo #1 shows the main housing assembly in the drill press with the (4) mounting holes
being put in. Photo #2 is a view from the mounting side of the main housing assembly showing
the (4) mounting holes completed...
The valve chest is getting closer to completion. Here in these (2) photos you can see the
main housing assembly and valve assembly all mounted to the valve chest (no gasket). What a
lot of work to get this far. The valve chest does need to be cleaned up and the exhaust valve
and seat reconditioned...
In photo #1 I have rotated the valve chest and you can see the intake valve. Notice the flange
O.D. of the main housing assembly. I need to scribe a line on
the mounting surface and mill the flange flat in this area. Photo #2 shows the main housing
assembly mounted in the shaper with the flat being cut...