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Single-cylinder 4-stroke engine v1

A 50 x 50 mm single-cylinder pushrod OHV four-stroke engine. It has a counterweighted crankshaft on two 6204 bearings, a 100 mm conrod, a three-groove piston, a finned cylinder and a two-valve head with springs and rockers. A gear-driven 2:1 camshaft (20T/40T, m1.5) with two lobes and tappets/pushrods drives the valves. The model is shown at TDC.

Files

STEP · AP214Exact solids for CAD/CAM STLMesh for 3D printing Drawing PDFA3, sections, hole & weld tables DXF flat patternsLaser / plasma cutting, zip

Flagged by the engineer

The camshaft lies close to the swept envelope of the crank webs and conrod. Check the full rotation for clearance.
Valve timing and gear tooth phase are not set.
S235 is unsuitable for a piston, liner or valves. Use aluminium alloy or cast iron and valve steel for a running engine.
No lubrication, piston rings or crankcase split are modelled. The crankcase must be split for assembly.

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Specification

Displacement	98 cm3
Bore x stroke	50 x 50 mm
Gear ratio	2 : 1 (20T/40T, m1.5)
Centre distance	45 mm
Rod ratio	100 mm / 4.0
Overall size	95 × 136.44 × 282 mm
Parts	35
Material	Steel (S235)
Mass (calculated)	9167.3 g
General tolerance	± 0.1 mm (ISO 2768-m)
Process	machining

Standard parts · purchasable

2×	Deep groove ball bearing 6204 ISO 15
4×	Socket head cap screw M8x35 ISO 4762
4×	Socket head cap screw M8x20 ISO 4762

Parts list

01	crankcase 72 × 120 × 115 mm · 3638.0 g
02	bearing_0 14 × 47 × 47 mm · 124.4 g
03	bearing_1 14 × 47 × 47 mm · 124.4 g
04	crankshaft 95 × 64 × 73 mm · 613.0 g
05	conrod 20 × 32 × 126 mm · 169.7 g
06	piston 49.8 × 49.8 × 50 mm · 351.1 g
07	gudgeon_pin 47.8 × 12 × 12 mm · 42.4 g
08	cylinder 80 × 100 × 95 mm · 1614.8 g
09	cylinder_head 80 × 100 × 30 mm · 1731.4 g
10	head_bolt_0 13 × 13 × 43 mm · 20.9 g
11	base_bolt_0 13 × 13 × 28 mm · 15.0 g
12	head_bolt_1 13 × 13 × 43 mm · 20.9 g
13	base_bolt_1 13 × 13 × 28 mm · 15.0 g
14	head_bolt_2 13 × 13 × 43 mm · 20.9 g
15	base_bolt_2 13 × 13 × 28 mm · 15.0 g
16	head_bolt_3 13 × 13 × 43 mm · 20.9 g
17	base_bolt_3 13 × 13 × 28 mm · 15.0 g
18	crank_gear 10 × 32.98 × 32.98 mm · 29.4 g
19	cam_gear 10 × 62.89 × 62.89 mm · 211.0 g
20	camshaft 80 × 20 × 25 mm · 106.1 g
21	valve_in 20 × 20 × 62 mm · 20.5 g
22	spring_in 14 × 14 × 24 mm · 5.1 g
23	retainer_in 16 × 16 × 2 mm · 2.7 g
24	tappet_in 10 × 10 × 15 mm · 9.2 g
25	pushrod_in 6 × 6 × 187 mm · 41.5 g
26	rocker_in 8 × 51 × 8 mm · 22.5 g
27	valve_ex 20 × 20 × 62 mm · 20.5 g
28	spring_ex 14 × 14 × 24 mm · 5.1 g
29	retainer_ex 16 × 16 × 2 mm · 2.7 g
30	tappet_ex 10 × 10 × 15 mm · 9.2 g
31	pushrod_ex 6 × 6 × 187 mm · 41.5 g
32	rocker_ex 8 × 51 × 8 mm · 22.5 g
33	rocker_shaft 56 × 8 × 8 mm · 22.1 g
34	pedestal_l 6 × 12 × 42 mm · 21.4 g
35	pedestal_r 6 × 12 × 42 mm · 21.4 g