Rolls royce merlin build

[Mustangboy]

Hi all
Im building a full scale 3D printed rolls / packard merlin engine not sure if anyone apart from the master Tom Kay has done a engine but heres my attempt so far. Crankcase completed this far 3 weeks of solid printing.
Cheers
Jamie

 

[Engineman]

Very impressive! Any rough cost of making all the pieces?

Eng

 

[Mustangboy]

Very impressive! Any rough cost of making all the pieces?

Eng

So far its cost around £90 in PLA plastic and glue for the crankcase the time I've completed the whole engine should be under £500 in plastic/paint/filler/glues fingers crossed

 

[Vic Balshaw]

My word, what a mammoth task you have set. Judging by printing time for the crank case, it's not going to be a quick build. Will look forward to your progress reports.

 

[Mustangboy]

My word, what a mammoth task you have set. Judging by printing time for the crank case, it's not going to be a quick build. Will look forward to your progress reports.

Thanks il keep the build thread going. not going to be a quick project but love a challenge

 

[Engineman]

So far its cost around £90 in PLA plastic and glue for the crankcase the time I've completed the whole engine should be under £500 in plastic/paint/filler/glues fingers crossed

Thanks for the reply! I have to say, your crankcase looks good. I have worked with real display engines and, although the real thing is great, you can't get a half worth having Merlin for many, many times that! I have a feeling that there could be a market for this, possibly as an unbuilt "kit" because the time/cost of build and finish would be considerable.
One advantage is that genuine parts, like magneto's, could be incorporated in a build.
You say, Rolls/Packard, but it would be good to know which engine in particular is modelled here? Also, I can imagine interest in 1/2 or 1/4 scale kits, and a whole host of other engines!
Cheers

Eng

 

[Mustangboy]

Thanks for the reply! I have to say, your crankcase looks good. I have worked with real display engines and, although the real thing is great, you can't get a half worth having Merlin for many, many times that! I have a feeling that there could be a market for this, possibly as an unbuilt "kit" because the time/cost of build and finish would be considerable.
One advantage is that genuine parts, like magneto's, could be incorporated in a build.
You say, Rolls/Packard, but it would be good to know which engine in particular is modelled here? Also, I can imagine interest in 1/2 or 1/4 scale kits, and a whole host of other engines!
Cheers

Eng

This engine is going to be a -7 packard. Ive built a half real, half printed one (-7) already came out great. That crankcase was real and cost 2000 on its own they are increasing hard to get hold of now. A kit could be done just takes quite some time to print but very achievable. Heres a pic of my half and half engine.
Cheers

 

[Engineman]

Very nice. I should have guessed from your moniker, mind you, could have been a -3 or a -9 I suppose.

Eng

 

[frankv]

Wow... very impressive.

I'm new here, and considering starting design of a "working" scaled down Merlin V12, similar to the Haynes V8 or more likely this EJ20.

So, I'm interested in what Merlin 3D model your build is based on... am I right in assuming this is the Rob McCune one that's on GrabCad?

FWIW, on the Internet I've also found a Packard Merlin 62 and what I think is a Rolls Royce Merlin XX.

My main difficulty atm is that the Packard models are done in SolidWorks with a few converted to IGES (I use OnShape, which can import STEP or IGES files, but not SolidWorks), and the XX is just STL files.

 

[Mustangboy]

Wow... very impressive.

I'm new here, and considering starting design of a "working" scaled down Merlin V12, similar to the Haynes V8 or more likely this EJ20.

So, I'm interested in what Merlin 3D model your build is based on... am I right in assuming this is the Rob McCune one that's on GrabCad?

FWIW, on the Internet I've also found a Packard Merlin 62 and what I think is a Rolls Royce Merlin XX.

My main difficulty atm is that the Packard models are done in SolidWorks with a few converted to IGES (I use OnShape, which can import STEP or IGES files, but not SolidWorks), and the XX is just STL files.

Thanks. Yes this crankcase is the Rob Mc Cune one with a few little mods but the rest of the engine has been done with scans and cad drawings from either me or Tom Kay a ton of time has gone into it before ive started printing anything. So far i have 95% of the engine including internals worked out but there maybe real parts incorporated as i have a few parts spare from a last build. Theres a few complete models files out there but the scaling and details are not great for a full size build. Ive been using solidworks and autocad 360 both work great. Il be print all the large parts first then the internals will be done later, maybe build a cut away version.
Cheers

 

[rrmerlin60]

Jamie

I might be the "Master" but you are the new stud. Superb work, and your overall speed has me in awe. Keep up the great work.

And let me know when you need the carburetor files for printing.

Cheers,Tom.

 

[frankv]

So far i have 95% of the engine including internals worked out but there maybe real parts incorporated as i have a few parts spare from a last build. Theres a few complete models files out there but the scaling and details are not great for a full size build.

Do you have a good model of the cylinder head casting that you could share? The IGES file for the one I'm looking at has faulty topology. I've fixed a few of the errors, but the head casting itself is one of the corrupted parts.

 

[Mustangboy]

Little Christmas update on the build. crankcase is done and painted, reduction case, lower crankcase and cylinders are all done and painted. Now printing the left cylinder head. Have a great Christmas!

 

[Wurger]

 

[Gnomey]

Great work so far!

 

[Mustangboy]

Heres another little update. Heads, valve covers, inlet manifolds and wheelcase printed. Starting to look like a merlin now

 

[rochie]

Wow fantastic job !

 

[Vic Balshaw]

Not only a fantastic job but good spray work out in the open.

 

[Wurger]

 

[Crimea_River]

Amazing work. Looks like the real deal.