Saving Old Seagulls

Had an idea to try and design and 3D print a 1:4 scale featherweight so have started this thread to document progress, it may interest someone!

I’m not going for exact replica (bolts, chamfers etc), just as close as I can get without spending days on my laptop. Did the featherweight gearbox tonight, I’m quite happy with it. Although sanding and priming will help with surface imperfections, I am going to play around with smaller nozzle sizes and layer heights soon to try and help.
As I said, not going to be worrying too much about the smaller details, just having a bit of fun!
Ed

Looks good, nice roller bearing

Had another hour free today, not done any finishing work but it’s coming together..
Spinning prop!

Wow that looks awesome! Would you mind to share the STL files? Just for personal use.

Will put the STLs together once it’s all done, no problem.

More progress today.
Forgot to add the tiller arm mount to the crankcase rookie error! Haven’t tried carb yet but I’m working on the transom bracket at the moment, quite fiddly.

As a first attempt I’m quite happy with it, done with a .4 mm nozzle with fast print speed, was really just to test tolerances. Got some .2 nozzles in the post so second attempt should have a nicer finish, thumb screws in the transom bracket, spinning flywheel and moving tiller arm.
Anyway this is what I’ve ended up with: Transom bracket works the same way as the real thing, side to side, up and down and tilt with retaining hook.

Mk1 tiller arm and carb, throttle assembly is printed in 5 pieces, a lot more definition to be had once printed on .2 as these are .4, but it’s coming together! Sourced some 1.5 mm rubber cord for the throttle cabling which should do the trick.

Nice.
It is a lot of work drawing up all of the bits. Im still working on the crank for my 1/3 scale.

Decided to make the exhaust tubes out of stainless, think it’s going to look much better when it’s done! Attention to detail is key I think, so I’m going back and designing plug caps, ht lead connections on the base plate etc. Definitely a lot of work, mainly trial and error! Picture of the first attempt stainless exhaust attached to block:

Fuel tank and flywheel next

That's remarkable work, love the detail! You could make a copy of a marston block like that to use as a pattern to cast in aluminium. Just thinking out loud

Adrian we've looked into that, long & hard, a working cylinder is a major task.
5 sand cores & the required moulds.
Cast iron liner with all the ports in the right location, & the integral base retaining flange & a very complicated multi part core.
And several fixtures for machining the base, bore, internal chamber head, the inlet & exhaust ports.
Don't forget CAD drawings for all of this.
The negative side is far less spares for your next restoration!

Not saying it would be easy, but certainly doable, I don’t want to hijack the thread.