Jasonb

if you turn some 1/16" spigots on the end of the bar for the bosses and put 1/16" holes in the flat stock that will locate them while soldering. I'd leave the bosses a bit long at this stage particularly the short ones. For the weighshaft have a long spigot to locate a "washer" on the other side of the flat bar.

hold by the boss in the lathe chuck and put the hole through which will remove the spigots.

Then clamp down to the mill table to bring the bosses to length.

Finally filing buttons or rotary table to round off the ends of the flat bar.

To me the clamps were not ideal

The rear one has the stud at the packer end of the clamp not near enough to the work so most of the force is going into the packer.

The left one is making contact with it's side not the end so will easily twist.

Right not too bad but can't really se it fully.

You need a traveling tool kit and a small restoration project to pass away those lonely evenings in the hotel.

It was Ricky who was saying between rod and crosshead.

As I said in that post your packer to extend the guides would have the least effect on other parts.

Same here. Packing between piston rod and cross head will not alter how far the cross head comes out, it will only move the piston up in the cylinder.

Options are, the last would not affect the current movement range of the piston and be the only item that has no knock on affect that would need other parts altering too.

- Shorten columns
- Raise Bearing pedestals
- Extend guides

Sit down with a bit of paper and lay out the heights from bed to crankshaft and then to underside cylinder. Then use two coloured pens to add drawing dims and those measured off your finished parts and compare where the two place the guide. I's say it is somewhere in the two height options for base types.

Adding up some lengths, I think you should be seeing 0.109" or 7/64 of crosshead below the trunk guide for the longer 5/8" stroke version.

Check that you have not used steel base dimensions for oen part and cast base for another as that would account for 1/8" of extra stick out.

Does the engine turn over at the moment? If so what are the clearances like for the piston at each end of travel as dropping the trunk guides down could see the piston hit the top cylinder covers