The next step was fabricating the crosshead. First, I marked out all the dimensions; then, I drilled the center before milling it out. Creating a perfectly parallel slot was not easy. The entire part required a combination of sawing, milling, and filing.
After grinding the curves on the belt sander and smoothing them with a file, the part went back onto the lathe for the ends to be machined. The bronze sliding block was fitted and test-mounted. To perform a final test, I had to manufacture and install the pump piston and pump body.
Many thanks, Sanjay and Chris.
Today, I started drilling a number of holes in the pump block. According to the plans, the pump doesn't use balls for the valves; I have to fabricate valves that need to be lapped in.
It was a very hot day today—41 degrees Celsius.
However, it was bearable in the workshop, and I was able to fit the pump block with a few flanges and covers. I am using O-rings instead of flat gaskets for the valve covers. The block isn't finished yet, though; the air tank and a pressure relief valve are still missing.
Looks great Michael. In the first photo in reply 17 where you put the yoke back in the lathe to do the ends, is it just held by pressure against the piece of brass hex or is there a screw in there?
The crosshead has M5 x 0.5 threads at both the top and the bottom.
The part is screwed onto the hex section.
I have a stock of brass parts with various internal and external threads; they always come in handy for jobs like this.