Though the process may seem
impossible without a professional
manufacturing setup, it is possible
to build a diesel engine from
scratch at home. Having an
understanding of how engines work
is helpful for this process. A
rudimentary diesel engine does
not need to function in exactly the
same way a car's diesel engine
does and may not require parts
such as a glow plug . There are
several different designs and
approaches to building a diesel
engine from scratch, each requiring
a unique set of materials and
approaches.
Tools
Because metal is the common
denominator of all scratch-built
engines, most of these projects
require access to metalworking
equipment. This can include lathe
tools fitted with special
metalworking parts. Keep in mind
that the same lathe tools used for
woodworking projects may not work
properly for metalworking tasks.
Techniques
Some diesel engine projects use
casting techniques to make some
of the engine parts, including
pistons or the engine block. Cast
iron is one example of a cast metal
material that is useful for some
diesel engine constructions. Those
who do not have casting
experience may not want to add
another complex step to the
construction process and should
instead opt for a project that does
not require this approach.
Getting to Know Diesel
Engine Parts
Different diesel engines have
various constructions and may even
have slightly different parts, but
there are certain diesel engine
components that serve essential
functions and are typically present.
Parts such as pistons are likely to
vary in size and number depending
on the size and function of the
engine.
Engine Block
The engine block contains most of
the engine parts, and depending
on the engine design, the engine
block functions as a sort of housing
for the entire mechanism. It is
possible to cast this part of the
engine with poured metal and a
mold. Alternatively, use a lathe
and carve the engine block shape
out of a blank aluminum bar .
Cylinders
Most engine blocks contain
cylinders, which provide space for
the pistons to move. These
cylinders are, as the name
indicates, cylindrical in shape.
There are a few different
arrangement configurations for the
cylinders, including a simple
horizontal, inline arrangement
where all of the pistons line up in
a vertical orientation.
Pistons
Pistons are the main moving parts
of an engine. They typically move
in an up-and-down fashion. Most
pistons use a single piece of
material, but it is plausible to
connect two separate pieces so
long as they firmly attach through
a technique such as welding.
Crankshaft
The pistons connect to the
crankshaft, which rotates in a
circular fashion. This circular
turning motion drives the pistons
in their up-and-down movement.
Most of the time, crankshafts
consist of a single long piece of
metal and a larger flat end piece.
An additional set of parts, the
connecting rods, connect the
pistons to the crankshaft.
Fuel Injector
The fuel injector sprays the diesel
fuel into the engine's combustion
chambers. A combination of
pressure and heat causes the fuel
to combust, providing the driving
energy force of the basic internal
combustion engine.
Constructing and
Assembling The Parts
The parts of a diesel engine, in
addition to other parts that help
the engine move, such as fuel
pumps and a variety of different
hoses, fit together in a logical
progression. The engine block is
the housing for the crankshaft and
the pistons. The crankshaft drives
the pistons, and it draws its power
from the diesel fuel provided by
the fuel injector.
It is possible to construct all of
these parts using a lathe or other
metalworking tools. However, this
is a very advanced project, and
only the most avid engineering
enthusiasts want to actually
construct a working diesel engine
completely from scratch.
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