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Not so much time for boat now but something have to do all the time.
I start doing some interior modifications and updates. https://cimg9.ibsrv.net/gimg/www.off...486c9467e7.jpg Toilet is made so stupid that I can't understand. Fountain may have used smaller models wc module in 47', there is 20cm room above toilet roof. I take roof of to get enough room for comfort toilet use. Later I will explode whole interior but now practicality takes precedence over appearance. https://cimg0.ibsrv.net/gimg/www.off...e418ec5d5f.jpg https://cimg1.ibsrv.net/gimg/www.off...1cb0355be6.jpg Every old hose and wc sanitary part are out, I hate old boat smell when sanitary gas come through hoses and plastic parts. New ones will be Vetus stuff. https://cimg3.ibsrv.net/gimg/www.off...6a63c45188.jpg Old holding tank is just 35 liter, electric wc use much more water than manual one so you can't do many days trips. I will put manual pump wc and I made card board holding tank model, 68 liter tank can be fitted in same space. I think to made it from 1.5mm thick 316 stainless steel. https://cimg4.ibsrv.net/gimg/www.off...0ae596e124.jpg https://cimg5.ibsrv.net/gimg/www.off...3c096858cc.jpgAnother stupid thing is ice box. Compressor refigerator is 100 times better, I bought 65 liter model and it fit barely in place of ice box. Kitchen will be updated later too. https://cimg6.ibsrv.net/gimg/www.off...6e21ef9214.jpg Engine get some setback, world does not exist same size seat inserts than Transmash, bigger ones and smaller can be find but no this size, with right height. But no problem, I machine them from aluminium bronze billet. Then I have perfect size. https://cimg9.ibsrv.net/gimg/www.off...20d885ba43.jpg Cylinder blocks get more even cooling flow, every liner have now own cooling exit channel. Coolant go first to exhaust manifolds, then heads from 5 points between exhaust ports, then cylinder blocks and finaly to these coolant manifolds. https://cimg1.ibsrv.net/gimg/www.off...d98b811da4.jpg Engine machine shop did good job for cylinder liners, they hone them straight and nice surface. I asked them to do first hone very rough to carry oil in hone grooves, hone pattern are smaller pitch than normal 45 degree, its 30 degree so piston won't "pump" as much oil up. Final hone is very smooth to get good wear resistance. Time show am I right way or not. https://cimg7.ibsrv.net/gimg/www.off...2da8e8e49b.jpg Drives get steering and mock up tie bar. Geometry is good and drives turn now 21 degree from center, 42 degree total, shold be good maneuverability. https://cimg0.ibsrv.net/gimg/www.off...538259e501.jpg A lot of washers and bushings had to turn from 304 stainless for steering rod ends. https://cimg8.ibsrv.net/gimg/www.off...2d13512175.jpg Steering arms are welded to trim cylinders, this time I dared to weld myself, hope they stay one piece... little by little all go forward, electric job had gone forward too, maybe 70% connected now. Next thing is build owen, I bought engine internal coatings and plan is coat everything I can. |
Amazing!
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Might be the coolest sounding 47 to pull up to a doc when complete. Subscribed to this awesome build
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Long time, no post. Project is going on, still waiting engine parts, I try do all other things forward now.
https://cimg7.ibsrv.net/gimg/www.off...bbadb7fcd0.jpg https://cimg9.ibsrv.net/gimg/www.off...460044ebbe.jpg Trailer poorly suited to the boat, it was straight bottom boat trailer. Support beams was one piece and not for step bottom, I cut them pieces and try fit to bottom so load is evenly distributed. Sharp eyes see ship engine exhaust valves boat stands:D https://cimg0.ibsrv.net/gimg/www.off...4c641c5a91.jpg https://cimg2.ibsrv.net/gimg/www.off...4ba3def1cd.jpg https://cimg3.ibsrv.net/gimg/www.off...9bde653d81.jpg https://cimg5.ibsrv.net/gimg/www.off...6d53ccca6a.jpg Finnish company Sorvaamo Karpiola made awesom job! From my epoxy spline mold to real driveline parts, my friend turn blank pieces in big lathe and Karpiola brothers do splines. Parts fit perfectly to Transmash crank spline. There is no weak links between engine and propellers, 2MW power should be no problem. https://cimg6.ibsrv.net/gimg/www.off...9aefba339b.jpg https://cimg7.ibsrv.net/gimg/www.off...24a4f1dd13.jpg I will coat many engine parts with Techline coatings but it's so expensive do in some company so I build own owen. Heating element and fan from my father-in-law workplace old stock, some surplus of the sauna building urethane insulating foam, relay, thermostat and owen is ready. Parts have to bake at 150C temp. Pistons get crown ceramic and skirt lubricating coat, combustion chambers ceramic coat, valve stems-, cam followers- and splitbox gears lubrication coatings. I hope I get some friction off from everywhere. It will help a lot because cooling system had to work less hard and parts not wear so quick. Does anyone here use Techline coatings? Its American company and it have nice resale in Finland. Any experiences? https://cimg8.ibsrv.net/gimg/www.off...c41132a74b.jpg ALuminium parts go to soda blast, next week show results. Soon have all parts to assembly transmission/splitbox package. https://cimg9.ibsrv.net/gimg/www.off...7c2a16d86c.jpg Valve seat material came and it's now in CNC shop, I have to draw CAD drawing to get right seat inserts. Material is alumium bronze, its good seat material, next to beryllium copper in my mind. These blanks are cast 35km from me, in Finland Pirkanmaa you can get and do anything you want from submarine to space shuttle if you are clever enough. We have so much top level companies in small circle that anything can be done. Stay tuned, project goes on thing by thing. |
I started test assembly the transmission. Input shaft and coupler sleeve is in just right dimensions! Big relief because they cost so much to made, expensive trash can parts. Now driveline won't break between engine and transmission. Flywheel mounting to coupler have to be done but otherwise transmission and splitbox can be assembled.
https://cimg0.ibsrv.net/gimg/www.off...3c18619766.jpg Coupler fit nice in smaller ZF 5hp500 front plate that fit in this 5hp600 transmission, it have smaller turbine and smaller shaft seal, it's still 5mm too big for coupler but I find 120-150-12 shaft seal that goes right in place with no modifications. https://cimg9.ibsrv.net/gimg/www.off...c90b504be9.jpg Input shaft lenght is right, it fit nice to lock groove that keep sleeve not to go back and front. https://cimg4.ibsrv.net/gimg/www.off...d865152545.jpg Small design errors show up, Turbine bearing holder doesn't fit to new input shaft gentle radius, but it was easy job to turn more space there. https://cimg3.ibsrv.net/gimg/www.off...09b895129d.jpg https://cimg1.ibsrv.net/gimg/www.off...af23aadda7.jpg Needle bearing race is pressed in coupler that keeps coupler in line to transmission centerline. Extra shaft seal inside gearbox is needed too to prevent lubrication oil pressure to leak before in enter transmission via hollow input shaft. https://cimg2.ibsrv.net/gimg/www.off...8648674460.jpg Another end of input shaft have lock ring to keep axial play in check. now assembly is possible because there is enough room for input shaft to go backwards so lock ring can be assembled. https://cimg6.ibsrv.net/gimg/www.off...d69ac5f77e.jpg Hydraulic retarder is removed, boat doesn't need brakes... Next thing is measure new clutch pack clearances and fit as many plates I can. 3000hp transmission have to be quite sturdy. https://cimg3.ibsrv.net/gimg/www.off...6ba76faca8.jpg 1000nits outdoor IP65 monitor came from China. It looks good quality and picture is good, I test it. It's easy to use, no coding, all works and go on when power is on! Good. Monitor is little bigger than they told so it won't fit to mock up dashboard, but it doesn't matter, I have to cut new anyway. This screen show all engine gauges, it works on HDMI cable so signal is easy to save in memory stick or harddrive. That way I get unlimited channel datalogger cheap. Real dashboard will be in engineroom, mounted top of transmission. I will use as many mechanical gauges I can, short pipes and wires, no disassembly when remove engine from boat. https://cimg5.ibsrv.net/gimg/www.off...cef1cf9e62.jpg Screen have ambient light sensor so it should can adjust brightness always. https://cimg7.ibsrv.net/gimg/www.off...3c1315c242.jpg Camera is 4K industrial model. It have lockable lense adjustments, mechanical of course! I'm automation engineer and hate all electric stuff. I learn in school that if you can do something without electronics, do it mechanical so it will work forever. Camera stand have to be very solid so picture won't shake in rough conditions. I think to make adjustable background lightning so its easiest way to adjust screen brightness because it buttons go hide under the dash. https://cimg3.ibsrv.net/gimg/www.off...dafb5a8c90.jpg Seat insert CAD files are ready, my friend can start turn them with CNC lathe. Intake seat have 4 angle valve job and exhaust traditional 3 angle. https://cimg4.ibsrv.net/gimg/www.off...02972c5265.jpg I made test pieces from aluminium to see real valve heights, angled dimensions make so easily error, just like this case, valves should got too deep if I have had skip this test and do real ones straight. CNC lathe make inserts close so head machine company doesn't have to mill so much material of by seat machine, there is about 0.5mm work reserve. Hope you like long post, all in all, things go forward and I hope next summer Fountain is floating! In early june my city arrange watercourse event (I don't know real english words) and I like to get Fountain in party, it will make just right headaches for communists. |
Always a great read, thank you
Hard for this guy to understand how single diesel and all the running gear weights less then 2 BB In any case still love following |
It will weight about same twin 1350's. They are 730kg/piece with M8, 1460kg both.
Transmash will be lighter than three supercharged bbc in sure. V12 weight 800kg without accessory, maybe 1000kg ready, transmission is 200kg, splitbox 80kg, extension boxes 40kg/pcs (they are heavy, steel construction), drives 40kg/pcs and carbon driveshafts 10kg/piece. It makes 1460kg:cool-smiley-011: |
It's time for most complicated part of this build, transmission and splitbox combination.
I have take 100 pics from assembly and modification, but I will show now some of them so you don't be bored to death. https://cimg3.ibsrv.net/gimg/www.off...1321556fe0.jpg https://cimg5.ibsrv.net/gimg/www.off...63282c11fa.jpg First modification to rotating clutches was remove the retarder parts, maybe 8kg weight saving. Shorter bolts needed and I change them to 12.9 grade because they will hold all engine power. https://cimg7.ibsrv.net/gimg/www.off...839214cf4b.jpg Rotating clutches are way bigger than borg warner 72 transmission clutches. I put as many extra friction plates as I can. Forward drive clutch A have now 8 plates, B 5 plates, reverse 4 plates. I 4th gear (highest I will use) A and B clutches are both engaged so they need to be tough. https://cimg5.ibsrv.net/gimg/www.off...a9fa984f3b.jpg Homemade assembly tool is needed to assembly clutch C drum, piston return springs have to compressed before snap ring can be installed https://cimg6.ibsrv.net/gimg/www.off...91992e9cb6.jpg https://cimg3.ibsrv.net/gimg/www.off...45701b6cfc.jpg https://cimg9.ibsrv.net/gimg/www.off...bc73069c1a.jpg I have made pressure testing device to find out any hydraulic leaks on rotating assembly clutches, if they hold compressed air, they will hold hydraulic pressure. https://cimg3.ibsrv.net/gimg/www.off...a49598901a.jpg Rotating oil feed to clutches have taken other transmission model that have higher pressure, its made from steel so piston rings won't eat themselves to grooves. ZF ecomat transmission have basicly three different models, less torque capasity model have low pressure, small parts. Intermediate model have high pressure, small parts and toughest model have low pressure and best parts. My transmission have now 50% higher pressure than high pressure model, best parts and more plates than ZF any model had. https://cimg9.ibsrv.net/gimg/www.off...b365c53d0d.jpg I have solve hydraulic puzzle otherwice exept lubrication pressure. Now transmission have no converter and converter oil pressure have used somehow to keep lubrication pressure in check. These valves have something to do for it but I'm not sure, one is mean pressure valve and that is simple to modificate but others are little difficult to understand. I have to pressurize transmission with external electric pump to test that all pressures are ok. https://cimg2.ibsrv.net/gimg/www.off...d59eacad1d.jpg Yellow line is lubrication pressure, valves 5, 15 and 16 do something to it but I can't see whole picture how it works. I will make part 2 update soon. Transmission is already assembled and clearanced but it's too long post for one part, stay tuned. I think there are not so many bus transmission to 3000hp 4 speed splitbox offshoreboat transmission conversation made ever in this world... |
Originally Posted by ksalmine
(Post 4918921)
I think there are not so many bus transmission to 3000hp 4 speed splitbox offshoreboat transmission conversation made ever in this world...
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Transmission part 2. This is long story and lot of pics but I want show this to you.
https://cimg8.ibsrv.net/gimg/www.off...2b2de215bf.jpg Front part and rotating clutches ready to drop in. Old stock input shaft is just lifting device. https://cimg7.ibsrv.net/gimg/www.off...4a94dbd3b9.jpg Brake D piston and seals. https://cimg6.ibsrv.net/gimg/www.off...a1005ad086.jpg Brake D friction plates and end plate, friction disks are two faced so there will be steel disks between friction ones. Newer Ecolife transmissions have one sided friction plates, other side is steel. I don't know why ZF change it. https://cimg5.ibsrv.net/gimg/www.off...11a8a0aa33.jpg Piston return springs have to compress so BIG snap ring can be assembled. https://cimg4.ibsrv.net/gimg/www.off...0e905439e8.jpg Front end have light press fit so preheat is needed to 80C. https://cimg3.ibsrv.net/gimg/www.off...347c95d86d.jpg https://cimg2.ibsrv.net/gimg/www.off...247a11c474.jpg Front end can just drop in when housing is hot. https://cimg1.ibsrv.net/gimg/www.off...f85b3ed02e.jpg Input shaft have to push through coupling sleeve. This picture show how shaft is in place, but you can see bearing race behind spline, sleeve must assembly first with bearing and shaft seal to keep lubrication pressure in coupling. https://cimg0.ibsrv.net/gimg/www.off...ade420c111.jpg Coupling sleeve endplay is shimmed both side of shaft spline, inner ring leans to needle bearing outer race. https://cimg8.ibsrv.net/gimg/www.off...f2adcd0efa.jpg Sleeve in place, I turn 110x2mm thread on its end and small cone half way so flywheel can be fit over the sleeve. Engine doesn't have flywheel at all an I want smoother idle. No power go through flywheel, it is just flywheel. https://cimg7.ibsrv.net/gimg/www.off...15d6362672.jpg I solve sleeve endplay adjustmet making split ring, it can be assembled to 11mm wide groove between engine crankshaft and transmission input shaft. I put 77mm snap ring inside split ring to keep it in place (not shown in picture), split ring have inside groove so snap ring keep in place. In this way crankshaft can be shortend little too short that transmission offset is not that critical, sleeve is kept in place without touching the crank end. https://cimg5.ibsrv.net/gimg/www.off...a16c5341f4.jpg A, B, C and D in their place https://cimg3.ibsrv.net/gimg/www.off...35e61aaa9b.jpg A, B and C clutch drums in. https://cimg9.ibsrv.net/gimg/www.off...0b89b30b3a.jpg https://cimg8.ibsrv.net/gimg/www.off...9eb0a9d8e6.jpg 2/3 planetaries, they are big, six satellites with biggest bearing pins. https://cimg7.ibsrv.net/gimg/www.off...6e0039fc4d.jpg Brake E, its piston return springs and intermediate ring between E and F. https://cimg5.ibsrv.net/gimg/www.off...7d46520694.jpg Brake F and last planetary with output shaft, its 70mm diameter, not going to snap easily. I had to change tapered roller bearing to ball bearing, it's not good but should be fine. There will be no axial load because all gears are straight cut gears. https://cimg6.ibsrv.net/gimg/www.off...a0d82b4696.jpg Cut down back housing, splitbox will fit straight to this part. Brake F piston is also inside of back housing. Hope you like to see detailed real transmission build, I think this have not done ever before to speedboat. Fabio Buzzi maybe have use some big multispeed transmission but who knows. Weismann have done also their million dollar special billet transmissions that looks awesome! |
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