PEPPERELL 23 CUSTOM BUILD FROM SOLID

This project is a precursor to our production variant that will soon be coming to our store. As with all our machined from solid builds this one starts as a single block of 6061 T6 aluminium and is fully machined from start to finish with manual machines using our own purpose built tooling.

Here's where they start

First machining operation finished and onto the second op......

Second machine operation is now completed and we are moving onto the profile milling operation.

Here we have the first milling operation completed on all 5 cases.

Now we move back to the lathe to machine in the cylinder section of the case along with all the internal cylinder dimensions.

Now it's back onto the case fixture to rotary mill the last square bits off to finish up the crankcase to cylinder blend.

Here they are all finished and ready for the next parts to be made and fitted.

 

Next step is to manufacture all the crankshafts for these engines including the back plates, prop drivers and spinner nuts.

Here's the crankshafts all finished.

Fitted up and ready for the backplates and front ends.

Backplates are done first....................

now the prop drivers and spinner nuts................................

And here they are all ready for the next step.

Now we'll move onto making the back plate end caps and the drum valve.

Now we'll start on the N.V.A.'S

Here's all the needle valves made and ready to fit to the rest of the engines. Front induction engine is already done.

 

Now it's onto the cylinder liners and piston blanks.

Here we have 5 nicely finished cylinder liners all ready for final lapping.

Next up are the piston and contra piston blanks.

Here we have the 5 pistons and contra pistons all blanked out and ready for mounting up onto the tooling to carry out the final machining and fitting to the cylinder liners.

Here we have the 5 conrods and gudgeon pins ready for pre assembly onto the piston blanks to be then final machined and fitted to the cylinder liners.

Next step is to assemble the rods onto the piston blanks and carry out the final machining and fitting to the cylinder liner.

And here they all are fitted up and ready to start the final machining operation and lap to final size to fit the cylinder liner. The center piston is for the FRV version which has a slightly larger crank pin.

Here are all the cylinder assemblies finished and ready to install in the engines.

Now it's time to machine up the cylinder heads and compression screws.

here's the set of comp screws all ready to be fitted to the engines.