Mark out and drill the tube holes in the bottom, and then the flue hole, for which a series of small holes must be made close together inside the circumference and united with a fret saw. Work the hole out carefully till the flue, which should be slightly tapered at the end, can be driven through an eighth of an inch or so. The flue hole in the top should be made a good fit, full size.

Rivet a collar, x (Fig. 80, a), of strip brass 1/4 inch above the bottom of the flue to form a shoulder. Another collar, y (Fig. 80, c), is needed for the flue above the top plate. Put the ends and flue temporarily in place, mark off the position of y, and drill half a dozen 5/32-inch screw holes through y and the flue. Also drill screw holes to hold the collar to the boiler top.

The steam-pipe is a circle of 5/16-inch copper tube, having one end closed, and a number of small holes bored in the upper side to collect the steam from many points at once. The other end is carried through the side of the boiler.



Assembling.—The order of assembling is:—Rivet in the bottom; put the steam-pipe in place; rivet in the top; insert the flue, and screw collar y to the top; expand the bottom of the flue by hammering so that it cannot be withdrawn; insert the stays and screw them up tight; silver-solder both ends of the flue, the bottom ends of the stays, and the joint between bottom and barrel. The water-tubes are then inserted and silver-soldered, and one finishes by soft-soldering the boiler top to the barrel and fixing in the seatings for the water and steam gauges, safety-valve, mud-hole, filler, and pump-if the last is fitted.

The furnace is lined with a strip of stout sheet iron, 7 inches wide and 19-1/4 inches long, bent round the barrel, which it overlaps for an inch and a half. Several screws hold lining and barrel together. To promote efficiency, the furnace and boiler is jacketed with asbestos—or fire-clay round the furnace—secured by a thin outer cover. The enclosing is a somewhat troublesome business, but results in much better steaming power, especially in cold weather. Air-holes must be cut round the bottom of the lining to give good ventilation.

A boiler of this size will keep a 1 by 1-1/2 inch cylinder well supplied with steam at from 30 to 40 lbs. per square inch.

A Horizontal Boiler.



The boiler illustrated by Fig. 81 is designed for heating with a large paraffin or petrol blow-lamp. It has considerably greater water capacity, heating surface—the furnace being entirely enclosed—and water surface than the boiler just described. The last at high-water level is about 60, and at low-water level 70, square inches.

The vertical section (Fig. 82) shows 1/16-inch barrel, 13 inches long over all and 12 inches long between the end plates, and 6 inches in diameter. The furnace flue is 2-1/2 inches across outside, and contains eleven 1/2-inch cross tubes, set as indicated by the end view (Fig. 83), and 3/4 inch apart, centre to centre. This arrangement gives a total heating surface of about 140 square inches. If somewhat smaller tubes are used and doubled (see Fig. 84), or even trebled, the heating surface may be increased to 180-200 square inches. With a powerful blow-lamp this boiler raises a lot of steam.

Tubing the Furnace Flue.—Before any of the holes are made, the lines on which the centres lie must be scored from end to end of the flue on the outside. The positions of these lines are quickly found as follows:—Cut out a strip of paper exactly as long as the circumference of the tube, and plot the centre lines on it. The paper is then applied to the tube again, and poppet marks made with a centre punch opposite to or through the marks on the paper. Drive a wire-nail through a piece of square wood and sharpen the point. Lay the flue on a flat surface, apply the end of the nail to one of the poppet marks, and draw it along the flue, which must be held quite firmly. When all the lines have been scored, the centring of the water tubes is a very easy matter.



The two holes for any one tube should be bored independently, with a drill somewhat smaller than the tube, and be opened to a good fit with a reamer or broach passed through both holes to ensure their sides being in line. Taper the tubes—2-7/8 inches long each—slightly at one end, and make one of the holes a bit smaller than the other. The tapered end is passed first through the larger hole and driven home in the other, but not so violently as to distort the flue. If the tubes are made fast in this way, the subsequent silver-soldering will be all the easier.



The Steam Dome.—The large holes—2 inches in diameter—required for the steam dome render it necessary to strengthen the barrel at this point. Cut out a circular plate of metal 4 inches across, make a central hole of the size of the steam dome, and bend the plate to the curve of the inside of the barrel. Tin the contact faces of the barrel and "patch" and draw them together with screws or rivets spaced as shown in Fig. 85, and sweat solder into the joint. To make it impossible for the steam dome to blowout, let it extend half an inch through the barrel, and pass a piece of 1/4-inch brass rod through it in contact with the barrel. The joint is secured with hard solder. Solder the top of the dome in 1/8 inch below the end of the tube, and burr the end over. The joint should be run again afterwards to ensure its being tight.



The positions of stays and gauges is shown in Fig. 83.

Chimney.—This should be an elbow of iron piping fitting the inside of the flue closely, made up of a 9-inch and a 4-inch part. The last slips into the end of the flue; the first may contain a coil for superheating the steam.

A Multitubular Boiler.



Figs. 86 and 87 are respectively end and side elevations of a multitubular boiler having over 600 square inches of heating surface—most of it contributed by the tubes—and intended for firing with solid fuel.

The boiler has a main water-drum, A, 5 inches in diameter and 18 inches long, and two smaller water-drums, B and C, 2-1/2 by 18 inches, connected by two series of tubes, G and H, each set comprising 20 tubes. The H tubes are not exposed to the fire so directly as the G tubes, but as they enter the main drum at a higher point, the circulation is improved by uniting A to B and C at both ends by large 1-inch drawn tubes, F. In addition, B and C are connected by three 3/4-inch cross tubes, E, which prevent the small drums spreading, and further equalize the water supply. A 1-1/2-inch drum, D, is placed on the top of A to collect the steam at a good distance from the water.

Materials.—In addition to 1-1/2 feet of 5 by 3/32 inch solid-drawn tubing for the main, and 3 feet of 2-1/2 by 1/16 inch tubing for the lower drums, the boiler proper requires 22-1/2 feet of 1/2-inch tubing, 19 inches of 3/4-inch tubing, 2-1/4 feet of 1-inch tubing, 1 foot of 1-1/2-inch tubing, and ends of suitable size for the four drums.



CONSTRUCTION.



The centres for the water-tubes, G and H, should be laid out, in accordance with Fig. 88, on the tops of B and C and the lower part of A, along lines scribed in the manner explained on p. 207. Tubes H must be bent to a template to get them all of the same shape and length, and all the tubes be prepared before any are put in place. If the tubes are set 7/8 inch apart, centre to centre, instead of 1-1/4 inches, the heating surface will be greatly increased and the furnace casing better protected.

Assembling.—When all necessary holes have been made and are of the correct size, begin by riveting and silver-soldering in the ends of the drums. Next fix the cross tubes, E, taking care that they and B and C form rectangles. Then slip the F, G, and H tubes half an inch into the main drum, and support A, by means of strips passed between the G and H tubes, in its correct position relatively to B and C. The E tubes can now be pushed into B and C and silver-soldered. The supports may then be removed, and the a and H tubes be got into position and secured. Drum D then demands attention. The connecting tubes, KK, should be silver-soldered in, as the boiler, if properly made, can be worked at pressures up to 100 lbs. per square inch.

The casing is of 1/20-inch sheet iron, and in five parts. The back end must be holed to allow A, B, and C to project 1 inch, and have a furnace-door opening, and an airway at the bottom, 5 inches wide and 1 inch deep, cut in it. The airway may be provided with a flap, to assist in damping down the fire if too much steam is being raised. In the front end make an inspection opening to facilitate cleaning the tubes and removing cinders, etc.

The side plates, m m, are bent as shown in Fig. 86, and bolted to a semicircular top plate, n, bent to a radius of 6 inches. A slot, 1-1/2 inches wide and 11-1/2 inches long, must be cut in the top, n, to allow it to be passed over drum D; and there must also be a 3 or 3-1/2 inch hole for the chimney. A plate, p, covers in D. A little plate, o, is slipped over the slot in n, and asbestos is packed in all round D. The interior of the end, side, and the top plates should be lined with sheet asbestos held on by large tin washers and screw bolts. To protect the asbestos, movable iron sheets may be interposed on the furnace side. These are replaced easily if burnt away. The pieces m m are bent out at the bottom, and screwed down to a base-plate extending the whole length of the boiler.

The fire-bars fill the rectangle formed by the tubes B, El, and E2. A plate extends from the top of E2 to the front plate of the casing, to prevent the furnace draught being "short circuited."

Boiler Fittings.



Safety Valves.—The best all-round type is that shown in Fig. 89. There is no danger of the setting being accidentally altered, as is very possible with a lever and sliding weight. The valve should be set by the steam gauge. Screw it down, and raise steam to the point at which you wish the safety valve to act, and then slacken off the regulating nuts until steam issues freely. The lock nuts under the cross-bar should then be tightened up. In the case of a boiler with a large heating surface, which makes steam quickly, it is important that the safety-valve should be large enough to master the steam. If the valve is too small, the pressure may rise to a dangerous height, even with the steam coming out as fast as the valve can pass it.



Steam Gauges.—The steam gauge should register pressures considerably higher than that to be used, so that there may be no danger of the boiler being forced unwittingly beyond the limit registered. A siphon piece should be interposed between boiler and gauge (Fig. 90), to protect the latter from the direct action of the steam. Water condenses in the siphon, and does not become very hot.



Water Gauges should have three taps (Fig. 91), two between glass and boiler, to cut off the water if the glass should burst, and one for blowing off through. Very small gauges are a mistake, as the water jumps about in a small tube. When fitting a gauge, put packings between the bushes and the glass-holders, substitute a piece of metal rod for the glass tube, and pack the rod tightly. If the bushes are now sweated into the boiler end while thus directed, the gauge must be in line for the glass. This method is advisable in all cases, and is necessary if the boiler end is not perfectly flat.

Pumps.—Where a pump is used, the supply should enter the boiler below low-water level through a non-return valve fitted with a tap, so that water can be prevented from blowing back through the pump. As regards the construction of pumps, the reader is referred to p. 164 and to Chapter XXII.

Filling Caps.—The filling cap should be large enough to take the nozzle of a good-sized funnel with some room to spare. Beat the nozzle out of shape, to give room for the escape of the air displaced by the water.

The best form of filling cap has a self-seating ground plug, which, if properly made, is steam-tight without any packing. If needed, asbestos packing can easily be inserted between plug and cap.

Mud-holes.—All but the smallest boilers should have a mud-hole and plug in the bottom at a point not directly exposed to the furnace. In Fig. 82 it is situated at the bottom of the barrel. In Figs. 86 and 87 there should be a mud-hole in one end of each of the three drums, A, B, and C. The plug may be bored at the centre for a blow-off cock, through which the boiler should be emptied after use, while steam is up, and after the fire has been "drawn." Emptying in this way is much quicker than when there is no pressure, and it assists to keep the boiler free from sediment.



Steam Cocks.-The screw-down type (Fig. 92) is very preferable to the "plug" type, which is apt to leak and stick.

Testing Boilers.—The tightness of the joints of a boiler is best tested in the first instance by means of compressed air. Solder on an all-metal cycle valve, "inflate" the boiler to a considerable pressure, and submerge it in a tub of water. The slightest leak will be betrayed by a string of bubbles coming directly from the point of leakage. Mark any leaks by plain scratches, solder them up, and test again.



The boiler should then be quite filled with cold water, and heated gradually until the pressure gauge has risen to over the working pressure. There is no risk of an explosion, as the volume of the water is increased but slightly.

The third test is the most important and most risky of all-namely, that conducted under steam to a pressure well above the working pressure.

In order to carry out the test without risk, one needs to be able to watch the steam-gauge from a considerable distance, and to have the fire under control. My own method is to set the boiler out in the open, screw down the safety-valve so that it cannot lift, and raise steam with the help of a blow-lamp, to which a string is attached wherewith to pull it backwards along a board. If the boiler is to be worked at 50 lbs., I watch the steam gauge through a telescope until 100 lbs. is recorded, then draw the lamp away. After passing the test, the boiler, when pressure has fallen, say, 20 lbs., may safely be inspected at close quarters for leaks.

This test is the only quite satisfactory one, as it includes the influence of high temperature, which has effects on the metal not shown by "cold" tests, such as the hydraulic.

Do not increase your working pressure without first re-testing the boiler to double the new pressure to be used.

Fuels.—For very small stationary boilers the methylated spirit lamp is best suited, as it is smell-less, and safe if the reservoir be kept well apart from the burner and the supply is controllable by a tap or valve. (See Fig. 104.)



For medium-sized model boilers, and for small launch boilers, benzoline or petrol blow-lamps and paraffin stoves have become very popular, as they do away with stoking, and the amount of heat is easily regulated by governing the fuel supply. Fig. 94 is a sketch of a blow-lamp suitable for the horizontal boiler shown on pp. 204, and 206, while Fig. 95 shows a convenient form of paraffin stove with silent "Primus" burner, which may be used for a horizontal with considerable furnace space or for vertical boilers. In the case of all these liquid fuel consumers, the amount of heat developed can be increased by augmenting the number of burners. Where a gas supply is available its use is to be recommended for small stationary boilers.

Solid Fuels.—The chief disadvantages attaching to these are smoke and fumes; but as a solid fuel gives better results than liquid in a large furnace, it is preferred under certain conditions, one of them being that steam is not raised in a living room. Charcoal, coke, anthracite coal, and ordinary coal partly burned are the fuels to use, the fire being started with a liberal supply of embers from an open fire. Every solid-fuel boiler should have a steam-blower in the chimney for drawing up the fire; and if a really fierce blaze is aimed at, the exhaust from the engine should be utilized for the same purpose.



XIX. QUICK BOILING KETTLES.

[Transcriber's note: Do not use lead solder on articles associated with human or animal consumption.]

The principles of increasing the area of heating surface in model boilers may be applied very practically to the common kettle. The quick-boiling kettle is useful for camping out, for heating the morning tea water of the very early riser, and for the study "brew," which sometimes has to be made in a hurry; and, on occasion, it will be so welcome in the kitchen as to constitute a very useful present to the mistress of the house.

As the putting in of the tubes entails some trouble, it is worth while to select a good kettle for treatment. Get one that is made of thick tinned sheet iron (cast-iron articles are unsuitable), or even of copper, if you are intent on making a handsome gift which will last indefinitely. The broad shallow kettle is best suited for tubing, as it naturally has a fair heating surface, and its bottom area gives room for inserting plenty of tubes. Also, the tubes can be of good length. Let us, therefore, assume that the kettle will be of at least 8 inches diameter.

In Figs. 96 (a) and 96 (b) are shown two forms of fire-tube kettles (a and b) and two of water-tube (c and d). For use over a spirit or Swedish petroleum stove the first two types are most convenient; the third will work well on a stove or an open fire; and the last proves very efficient on an open fire. One may take it that, as a general rule, areas of heating surface being equal, the water-tube kettle will boil more quickly than the fire-tube.

Fire-tube Kettles.

The tubing of Figs. 96 (a) and 96 (b) presents a little difficulty in each case. The straight tube is the more difficult to insert, owing to the elliptical shape of the ends; whereas the bent tube requires only circular holes, but must be shaped on a template.

The tubing used for (a) should have at least 5/8-inch internal diameter, for (b) 1/2 inch, and be of thin copper. Hot gases will not pass willingly through tubes much smaller than this, in the absence of induced or forced draught.

For convenience in fitting, the tubes should run at an angle of 45 degrees to the bottom and side of the kettle, as this gives the same bevel at each end. Find the centre of the bottom, and through it scratch plainly four diameters 45 degrees apart. From their ends draw perpendiculars up the side of the kettle.



Now draw on a piece of paper a section of the kettle, and from what is selected as a convenient water-level run a line obliquely, at an angle of 45 degrees, from the side to the bottom. Measuring off from this diagram, you can establish the points in the side and bottom at which the upper and longer side of the tubes should emerge. Mark these off.

Next bevel off a piece of tubing to an angle of 45 degrees, cutting off roughly in the first instance and finishing up carefully with a file till the angle is exact. Solder to the end a piece of tin, and cut and file this to the precise shape of the elliptical end. Detach by heating, scribe a line along its longest axis, and attach it by a small countersunk screw to the end of a convenient handle.

Place this template in turn on each of the eight radii, its long axis in line with it, being careful that the plate is brought up to the marks mentioned above, and is on the bottom corner side of it. Scratch round plainly with a fine steel point.

To remove the metal for a tube hole, it is necessary to drill a succession of almost contiguous holes as near the scratch as possible without actually cutting it. When the ring is completed, join the holes with a cold chisel held obliquely. Then file carefully with a round file, just not cutting the scratch. As the side of the hole nearest to the bottom corner should run obliquely to enable the tube to pass, work this out with the file held at an angle.

As soon as a pair of holes (one in the bottom, the other in the side) have been made, true up the side hole until a piece of tubing will run through it at the correct angle. Then bevel off the end to 45 degrees and pass the tube through again, bringing the bevel up against the bottom hole from the inside. If it is a trifle difficult to pass, bevel off the edge slightly on the inside to make a fairly easy driving fit. (Take care not to bulge the bottom of the kettle.) Mark off the tube beyond the side hole, allowing an eighth of an inch extra. Cut at the mark, and number tube and hole, so that they may be paired correctly later on.

When all the tubes are fitted, "tin" the ends with a wash of solder before returning them to their holes. If there is a gap at any point wide enough to let the solder run through, either beat out the tube from the inside into contact, or, if this is impracticable, place a bit of brass wire in the gap. Use powdered resin by preference as flux for an iron kettle, as it does not cause the rusting produced by spirit of salt. If the latter is used, wipe over the solder with a strong ammonia or soda solution, in order to neutralize the acid.

As the hot gases may tend to escape too quickly through large tubes, it is well to insert in the upper end of each a small "stop," x—a circle of tin with an arc cut away on the bottom side. To encourage the gases to pass up the tubes instead of along the bottom, a ring of metal, y, may be soldered beyond the bottom holes, if an oil or spirit stove is to be used. This ring should have notches cut along the kettle edge, so as not to throttle the flame too much.



As the tubes for these require bending to shape in each case, the three types may be grouped together. The tubes of c and d, which require bending to somewhat sharp curves, may be of 3/8-inch internal diameter. In the last two cases the direction of the water travel is shown. The up-flow end, which projects farther through the bottom than the down-flow, is nearer the centre, where, if a gas stove is used, the heat is more intense than at the circumference of the bottom. (Note.-If type c is for use on a three-support stove, increase the number of tubes to 9, equally spaced, 40 degrees apart, so that the kettle may be adjusted easily.)

The copper tubing should be annealed or softened by heating to a dull red and plunging in cold water. Cut a wooden template of the exact outline of the inside line of the shape that the tube is to assume, and secure this firmly to a board. Fill the tube with melted resin, to prevent, as much as possible, "buckling" or flattening on the curves. The tube must be kept up to the template by a stop of hard wood, at the end at which bending commences. Don't cut the tube into lengths before bending, as short pieces are more difficult to handle. When a piece sufficient for a tube has been bent, cut it oft, and remove the resin by heating.

The fitting of the tubes is an easy matter, as the holes are circular. Pair off a tube with its holes and number it. A fluted reamer will be found invaluable for enlarging them to the correct size. Tin all tubes at points where they are to be attached to the kettle.

In Fig. 96 (c) and (d) care should be taken to make all the tubes project the same distance, so that the kettle may be level when resting on them.



XX. A HOT-AIR ENGINE.

The pretty little toy about to be described is interesting as a practical application to power-producing purposes of the force exerted by expanding air. It is easy to make, and, for mere demonstration purposes, has an advantage over a steam-engine of the same size in that it can be set working in less than a minute, and will continue to act as long as a small spirit flame is kept burning beneath it; it cannot explode; and its construction is a simpler matter than the building of a steam-engine.



Principles of the Hot-air Engine.—Fig. 97 gives a sectional view of the engine. The place of what would be the boiler in a steam-engine of similar shape is taken by an air chamber immediately above the lamp, and above that is a chamber through which cold water circulates. In what we will call the heating chamber a large piston, known as the displacer, is moved up and down by a rod D and a connecting rod CR1. This piston does not touch the sides of the chamber, so that the bulk of the air is pushed past it from one end of the chamber to the other as the piston moves. When the displacer is in the position shown—at the top of its stroke—the air is heated by contact with the hot plate C, and expands, forcing up the piston of the power cylinder, seen on the left of the engine. (The power crank and the displacer crank are, it should be mentioned, set at right angles to one another.) During the second half of the power stroke the displacer is moved downwards, causing some of the air to pass round it into contact with the cold plate D. It immediately contracts, and reduces the pressure on the power piston by the time that the piston has finished its stroke. When the power piston has reached the middle of its downward stroke, the displacer is at its lowest position, but is halfway up again when the power piston is quite down. The air is once again displaced downwards, and the cycle begins anew. The motive power is, therefore, provided by the alternate heating and cooling of the same air.

Construction.—The barrel and supports were made out of a single piece of thin brass tubing, 2-7/16 inch internal diameter and 5-5/8 inch long. The heating end was filed up true, the other cut and filed to the shape indicated in Fig. 98 by dotted lines. The marking out was accomplished with the help of a strip of paper exactly as wide as the length of the tube, and as long as the tube's circumference. This strip had a line ruled parallel to one of its longer edges, and 2-1/2 inches from it, and was then folded twice, parallel to a shorter edge. A design like the shaded part of Fig. 98 was drawn on an end fold, and all the four folds cut through along this line with a pair of scissors. When opened out, the paper appeared as in Fig. 98.



We now—to pass into the present tense—wrap this pattern round the tube and scratch along its edges. The metal is removed from the two hollows by cutting out roughly with a hack saw and finishing up to the lines with a file.

The next things to take in hand are the displacer rod D and the guide tube in which it works. These must make so good a fit that when slightly lubricated they shall prevent the passage of air between them and yet set up very little friction. If you cannot find a piece of steel rod and brass tubing which fit close enough naturally, the only alternative is to rub down a rod, slightly too big to start with, until it will just move freely in the tube. This is a somewhat tedious business, but emery cloth will do it. The rod should be 3-3/8 inches, the tube 2-1/8 inches, long. I used rod 3/16 inch in diameter; but a smaller rod would do equally well.



The two plates, A and B, are next prepared by filing or turning down thin brass[1] discs to a tight fit. (Note.—For turning down, the disc should be soldered centrally to a piece of accurately square brass rod, which can be gripped in a chuck. I used a specially-made holder like that shown in Fig. 99 for this purpose.)

[Footnote 1: Thin iron plate has the disadvantage of soon corroding.]

When a good fit has been obtained, solder the two discs together so that they coincide exactly, and bore a central hole to fit the guide tube tightly. Before separating the plates make matching marks, so that the same parts may lie in the same direction when they are put in position. This will ensure the guide tube being parallel to the barrel.

The power cylinder is a piece of brass tubing 2 inches long and of 7/8-inch internal diameter. The piston is of 7/8-inch tubing, fitting the cylinder easily, and thick enough to allow a shallow packing recess to be turned in the outside. Brass washers turned or filed to size form the ends of cylinder and piston. The connecting rod CR2 is a piece of strip brass, 3-3/16 inches long, between centres of holes. This had better be cut off a bit long in the first instance, and be fitted to the little stirrup which attaches its lower end to the piston. The drilling of the crank pinhole should be deferred till the cylinder and crank are in position.



Putting in the Water-chamber Discs.—Clean the inside of the barrel thoroughly with sandpaper; also discs A and B round the edges and the central holes. Disc A is forced in from the crank end a little further down than it is to be finally, and then driven up from below until at all points its lower side is exactly three inches from the bottom edge of the barrel. Disc B is then forced up 1-1/2 inches from the bottom end. The guide tube— which should have been cleaned—having been driven into place, solder is run all round the joints. If the barrel is heated over a spirit lamp, this operation is performed very quickly. ("Tinol" soldering paste is recommended.) Before soldering in B, drill a small hole in the barrel between A and B to allow the air to escape.

Attaching the Cylinder.—Scratch a bold line through the centre of one of the crank holes to the bottom of the barrel, to act as guide. Drill a 5/32-inch hole in the barrel on this line just below plate B, and a similar hole in the bottom of the cylinder. (The cylinder end should be put in position temporarily while this is done to prevent distortion.) Flatten down the cylinder slightly on the line of the hole, so that it may lie snugly against the barrel, and clean the outside of the barrel. Lay the cylinder against the barrel with the holes opposite one another, and push a short piece of wood through to exclude solder from the holes and keep the holes in line. Half a dozen turns of fine wire strained tightly round cylinder and barrel will hold the cylinder in place while soldering is done with a bit or lamp. The end of the cylinder should then be made fast.

The Displacer.—This is a circular block of wood—well dried before turning—5/8 inch thick and 3/32 inch less in diameter than the inside of the barrel. The rod hole in it should be bored as truly central as possible. A hole is drilled edgeways through the block and through the rod to take a pin to hold the two together. To prevent it splitting with the heat, make a couple of grooves in the sides to accommodate a few turns of fine copper wire, the twisted ends of which should be beaten down flush with the outside of the block. The bottom of the block is protected by a disc of asbestos card held up to the wood by a disc of tin nailed on.

The Crank Shaft and Crank.—The central crank of the crank shaft—that for the displacer—has a "throw" of 1/4 inch, as the full travel of the displacer is 1/2 inch. If the bending of a rod to the proper shape is beyond the reader's capacity, he may build up a crank in the manner shown in Fig. 101. Holes for the shaft are bored near the tops of the supports, and the shaft is put in place. After this has been done, smoke the shaft in a candle flame and solder two small bits of tubing, or bored pieces of brass, to the outside of the supports to increase the length of the bearing. The power-crank boss is a 1-1/2-inch brass disc. This crank has a "throw" of 1/2 inch.



Connecting Rods.—Put a piece of card 1/16 inch thick in the bottom of the cylinder and push the piston home. Turn the power crank down and mark off the centre of the hole for the crank pin in the connecting rod CR2. Solder a piece of strip brass on each side of the rod at this point; measure again, and drill.

The top of the displacer rod D is now filed flat on two sides and drilled. Slip a ring 1/16 inch thick over the rod and push the rod upwards through the guide tube till the displacer can go no farther. Turn the displacer crank up and measure from the centre of the hole in the rod to the centre of the crank. The top of the connecting rod should be filed to fit the under side of the crank, against which it should be held by a little horseshoe-shaped strap pinned on. (Fig. 102). (Be sure to remove the ring after it has served its purpose.)

The Water Circulation.—The water chamber is connected by two rubber tubes with an external tank. In Fig. 97 the cooling water tank is shown, for illustrative purposes, on the fly-wheel side of the engine, but can be placed more conveniently behind the engine, as it were. Two short nozzles, E1 and E2, of 1/4-inch tube are soldered into the water chamber near the top and bottom for the rubber pipes to be slipped over, and two more on the water tank. For the tank one may select a discarded 1 lb. carbide tin. Cut off the top and solder on a ring of brass wire; make all the joints water-tight with solder, and give the tin a couple of coatings of paint inside and outside.



Closing the Hot-air Chamber.—When all the parts except the lamp chamber have been prepared, assemble them to make sure that everything is in order. The lower end of the hot-air chamber has then to be made air-tight. Soldering is obviously useless here, as the heat of the lamp would soon cause the solder to run, and it is impossible to make a brazed joint without unsoldering the joints in the upper parts of the engine. I was a bit puzzled over the problem, and solved it by means of the lower part of an old tooth-powder box stamped out of a single piece of tin. This made a tight fit on the outside of the barrel, and as it was nearly an inch deep, I expected that if it were driven home on the barrel and soldered to it the joint would be too near the water chamber to be affected by the lamp. This has proved to be the case, even when the water is nearly at boiling point. If a very close-fitting box is not procurable, the space between box and barrel must be filled in with a strip of tin cut off to the correct length.

The Lamp Chamber.—Cut out a strip of tin 4 inches wide and 1 inch longer than the circumference of the lower end of the hot-air chamber. Scratch a line 1/2 inch from one of the sides, a line 3/4 inch from the other, and a line 1/2 inch from each of the ends.

A lamp hole is cut in the centre, and ventilation holes 1 inch apart, as shown in Fig. 103. If the latter holes are made square or triangular (base uppermost), and the metal is cut with a cold chisel so as to leave the side nearest the edge unsevered, the parts may be turned up to form supports for the barrel.



The slit lower side of the plate is splayed out into a series of "feet," by three or more of which, the chamber is secured to the base. Bend the plate round the barrel and put the two screws and bolts which hold the ends in place, and tighten them until the barrel is gripped firmly. Screw the engine to its base, fit on the rubber water connections, and fasten down the tank by a screw through the centre of the bottom. The screw should pass through a brass washer, between which and the tank should be interposed a rubber washer to make a water-tight joint.

The Lamp.—The lamp shown in Fig. 104 was made out of a truncated brass elbow, a piece of 5/16-inch brass tube, and a round tin box holding about 1/3-pint of methylated spirit. A tap interposed between the reservoir and burner assists regulation of the flame, and prevents leakage when the lamp is not in use.

Running the Engine.—The power and displacer cranks must be set exactly at right angles to one another, and the first be secured by soldering or otherwise to the crank shaft. The fly wheel will revolve in that direction in which the displacer crank is 90 degrees ahead of the other.



The packing of the piston should be sufficiently tight to prevent leakage of air, but not to cause undue friction. When the packing has settled into place, an occasional drop of oil in the cylinder and guide tube will assist to make the piston and slide air-tight.

The engine begins to work a quarter of a minute or so after the lamp is lit, and increases its speed up to a certain point, say 300 revolutions per minute. When the water becomes very hot it may be changed. The power might be applied, through demultiplying gear, to a small pump drawing water from the bottom of the tank and forcing it through the water chamber and a bent-over stand pipe into the tank again. This will help to keep the water cool, and will add to the interest of the exhibit by showing "work being done."



XXI. A WATER MOTOR.

FIG. 105 is a perspective view of a simple water motor which costs little to make, and can be constructed by anybody able to use carpenter's tools and a soldering iron. It will serve to drive a very small dynamo, or do other work for which power on a small scale is required. A water supply giving a pressure of 40 lbs. upwards per square inch must be available.

We begin operations by fashioning the case, which consists of three main parts, the centre and two sides, held together by brass screws. For the centre, select a piece of oak 1 inch thick. Mark off a square, 7 inches on the side; find the centre of this, and describe a circle 5 inches in diameter. A bulge is given to the circle towards one corner of the square, at which the waste-pipe will be situated.

Cut out along the line with a keyhole saw. Then saw out the square of wood. A 5/8-inch hole is now bored edgeways through the wood into the "bulge" for the escape, and in what will be the top edge is drilled a 1/4-inch hole to allow air to enter.



Cut out the sides, and screw them on to the centre at the four corners, taking care that the grain runs the same way in all three pieces, so that they may all expand or contract in the same direction. Plane off the edges of the sides flush with the centre.

The parts should now be separated, after being marked so that they can be reassembled correctly, and laid for a quarter of an hour in a pan of melted paraffin wax, or, failing this, of vaseline, until the wood is thoroughly impregnated. Reassemble the parts, and put in the rest of the holding screws, which should have their heads countersunk flush with the wood.



For the shaft select a piece of steel rod 5/32 inch in diameter, and 3 or 4 inches long; for the bearings use two pieces, 3/4 inch long each, of close-fitting brass tube. Now take a drill, very slightly smaller in diameter than the bearings, and run holes right through the centres of, and square to, the sides. Both holes should be drilled at one operation, so that they may be in line.

With a wooden mallet drive the bearings, which should be tapered slightly at the entering end, through the sides. Push the shaft through them. If it refuses to pass, or, if passed, turns very unwillingly, the bearings must be out of line; in which case the following operation will put things right. Remove the bearing on the pulley side, and enlarge the hole slightly. Then bore a hole in the centre of a metal disc, 1 inch in diameter, to fit the bearing; and drill three holes for screws to hold the disc against the case. Rub disc and bearing bright all over.

Replace the bearing in its hole, slip the disc over it, and push the shaft through both bearings. Move the disc about until the shaft turns easily, mark the screw holes, and insert the screws. Finally, solder the bearing to the disc while the shaft is still in place.

The wheel is a flat brass disc 4 inches in diameter. Polish this, and scratch on one side twelve equally spaced radii. At the end of each radius a small cup, made by bending a piece of strip brass 1/4 inch wide and 1/2 inch long into an arc of a circle, is soldered with its extremities on the scratch. A little "Tinol" soldering lamp (price 1s. 6d.) comes in very handy here.

To fix the wheel of the shaft requires the use of a third small piece of tubing, which should be turned off quite square at both ends. Slip this and the wheel on the shaft, and make a good, firm, soldered joint. Note.— Consult Fig. 107 for a general idea of the position of the wheel, which must be kept just clear of the case by the near bearing.



The nozzle should be a straight, tapered tube of some kind—the nose of a large oil can will serve the purpose. The exit must be small enough to allow the water to leave it at high velocity; if too large, the efficiency of the wheel will be diminished. To the rear end of the nozzle should be soldered a piece of brass tubing, which will make a tight fit with the hose pipe leading from the water supply. A few small brass rings soldered round this piece will prevent the hose blowing off if well wired on the outside.

Now comes the boring of the hole for the nozzle. Fig. 106 shows the line it should take horizontally, so that the water shall strike the uppermost bucket just below the centre; while Fig. 107 indicates the obliquity needed to make the stream miss the intervening bucket. A tapered broach should be used to enlarge the hole gradually till the nozzle projects sufficiently. If the line is not quite correct, the tip should be bent carefully in the direction required. One must avoid distorting the orifice, which should be perfectly circular; clean it out with a small twist drill of the proper size.

A brass elbow, which may be purchased for a few pence, should be driven into the waste hole, and a small shield be nailed under the air hole. A couple of screwed-on cross pieces are required to steady the motor sideways and raise the elbow clear of the ground.

The motor may be geared direct to a very small dynamo, if the latter is designed to run at high speeds. If a geared-down drive is needed, a small pulley—such as is used for blinds, and may be bought for a penny—should be attached to the shaft, and a bootlace be employed as belt. Avoid overloading the wheel, for if it is unable to run at a high speed it will prove inefficient.



Lubrication.—The water will keep the bearings cool, but the bearings should be well lubricated. The most convenient method of effecting this is to bore holes in the bearings, and from them run small pipes to an oil reservoir on the top of the case (as in Fig. 70), where they are fed on the siphon principle through strands of worsted.

Alternative Construction.—If an all-metal case is preferred, the reader might utilize the description given of a steam turbine on pp. 170-178. The details there given will apply to water as well as steam, the one exception being that a nozzle of the kind described above must be substituted for the steam pipe and small ports.



XXII. MODEL PUMPS.

Every steam boiler which has to run for long periods and evaporate considerable quantities of water should be in connection with a pump capable of forcing water in against the highest pressure used. On a previous page (p. 158) we have described a force pump driven directly off the crank shaft of an engine. As the action of this is dependent on the running of the engine, it is advisable, in cases where the boiler may have to work an engine not provided with a pump of its own, to install an independent auxiliary pump operated by hand or by steam, and of considerable capacity, so that in an emergency water may be supplied quickly.



Making a Hand pump.—Fig. 109 shows the details of a hand pump which is easy to make. The barrel is a length of brass tubing; the plunger a piece of brass or preferably gun-metal rod, which fits the tube closely, but works easily in it. The gland at the top of the barrel, E, is composed of a piece, D, of the same tubing as the barrel, sliding in a collar, C, soldered to E. The bottom of D and top of E are bevelled to force the packing against the plunger. The plates A and B, soldered to D and C respectively, are drawn together by three or more screws. A brass door-knob makes a convenient top for the plunger. When the knob touches A, the bottom of the plunger must not come lower than the top of the delivery pipe, lest the water flow should be impeded and the valve, V, injured. Round off the end of the plunger, so that it may be replaced easily and without disarranging the packing if pulled out of the pump.

The valves are gun-metal balls, for which seats have been prepared by hammering in steel cycle balls of the same size. Be careful to select balls considerably larger than the bore of the pipes on which they rest, to avoid all possibility of jamming. An eighth of an inch or so above the ball, cross wires should be soldered in to prevent the ball rising too far from its seat.



A convenient mounting for a hand pump is shown in Fig. 110. The plate, F, of the pump is screwed to a wooden base resting on a framework of bent sheet zinc, which is attached to the bottom of a zinc water tray. The delivery pipe, G, will be protected against undue strains if secured by a strap to the side of the wooden base.

The same pump is easily adapted to be worked by a lever, which makes the work of pumping easier. Fig. 111 gives details of the top of the plunger and the links, B. A slot must be cut in the plunger for the lever, A, to pass through, and the sides bored for a pivot pin. The links are straddled (see sketch of end view) to prevent the back end of the lever wobbling from side to side.



A Steam Pump.—The pump illustrated in Fig. 112 belongs to what is probably the simplest self-contained type, as no fly wheel, crank, or eccentric is needed for operating the valve.

The steam cylinder and the pump are set in line with one another (in the case shown, horizontally), and half as far apart again as the stroke of the cylinder. The plunger is either a continuation of the piston rod, or attached to it.



An arm, S, fixed at right angles to the piston rod, has a forked end which moves along the rod. This rod is connected with the slide valve through the rocking arm, R1 and the rod, R2. On it are two adjustable stops, T1 T2, which S strikes alternately towards the end of a stroke, causing the valve to shift over and expose the other side of the piston to steam pressure. The absence of the momentum of a fly wheel makes it necessary for the thrust exerted by the piston to be considerably greater than the back pressure of the water, so that the moving parts may work with a velocity sufficient to open the valve. If the speed falls below a certain limit, the valve opens only part way, the speed falls, and at the end of the next stroke the valve is not shifted at all.

The diameter of the plunger must be decided by the pressure against which it will have to work. For boiler feeding it should not exceed one-third that of the piston; and in such case the piston rod and plunger may well be one.

A piston valve, being moved more easily than a box valve, is better suited for a pump of this kind, as friction should be reduced as much as possible.

CONSTRUCTION.

The cylinder will not be described in detail, as hints on making a slide-valve cylinder have been given on earlier pages. The piston rod should be three times as long as the stroke of the cylinder, if it is to serve as pump plunger; and near the pump end an annular groove must be sunk to take a packing.

The pump, if designed to work horizontally, will have the valves arranged like the pump illustrated in Fig. 65; if vertically, like the pump shown in Fig. 109. Both suction and delivery pipes should be of ample size, as the pump works very fast. The pump is mounted on a foot, F, made by turning up the ends of a piece of brass strip, and filing them to fit the barrel.

The bed can be fashioned out of stout sheet brass or zinc. Let it be of ample size to start with, and do not cut it down until the pump is complete. Rule a centre line for cylinder and pump, and mount the cylinder. Pull out the piston rod plunger as far as it will go, and slip the pump barrel on it. The foot of the pump must then be brought to the correct height by filing and spreading the ends until the plunger works quite easily in the pump, when this is pressed down firmly against the bed. When adjustment is satisfactory, mark the position of the foot on the bed, solder foot to barrel, and drill and tap the foot for the holding-down screws. Don't forget that the distance between pump and cylinder gland must be at least 1-1/3 times the stroke.

The valve motion can then be taken in hand. Cut off for the guides, G1 G2, two pieces of stout brass strip, 2-1/2 inches long and 3/4 inch wide. Lay them together in a vice, and bore the holes (Fig. 113) 1-1/4 inches apart, centre to centre, for the 1/8-inch rods, R1 R2. The feet are then turned over and a third hole bored in G1, midway between those previously made, to take the end of the support, PP, of the rocking lever.



Screw G1 G2 down to the bedplate, 3/4 inch away from the cylinder centre line. G1 is abreast of the mouth of the pump, G2 about half an inch forward of the end of the cylinder.

The striker, S, is a piece of brass strip soldered to 1/2 inch of tubing fitting the piston rod. (See Fig. 113.) Its length is decided by running a rod through the upper holes in G1 G2, allowance being made for the notch in the end. The collar is tapped for two screws, which prevent S slipping on the piston rod. The rods for R1 R2 are now provided with forks, made by cutting and filing notches in bits of brass tubing. The notches should be half as deep again as the rocking lever is wide, to give plenty of room for movement. Solder the forks to the rods, and put the rods in place in the guides, with the forks as far away from G1 as the travel of the slide valve. Then measure to get the length of the rocking lever support. One end of this should be filed or turned down to fit the hole drilled for it; the other should be slotted to fit the lever accurately.

The rocking lever, RL, which should be of steel, is slotted at each end to slide on the pins in the forks, and bored for the pivot pin, which, like those in the forks, should be of hardened steel wire. Assemble the rocking lever in its support and the rod forks, and solder on the support.

To the back end of R2 solder a steel plate, A, which must be bored for the pin in the valve fork, after the correct position has been ascertained by careful measurement.

The stops, T1 T2, are small, adjustable collars, kept tightly in place on R1 by screws.

Setting the Striker.—Assemble all the parts. Pull out the piston rod as far as it will go, and push the slide valve right back. Loosen the striker and the forward stop, and slide them along in contact until the striker is close to the pump. Tighten up their screws. Then push the piston rod fully in, draw the valve rod fully out, and bring the rear stop up against the striker, and make it fast. Each stop may now be moved 1/16 inch nearer to a point halfway between them to cause "cushioning" of the piston, by admitting steam before the stroke is quite finished.

A pump made by the author on this principle, having a 1-1/4 inch stroke and a 1/2-inch bore, will deliver water at the rate of half a gallon per minute against a head of a few feet.

Note.—To steady the flow and prevent "water hammer," a small air-chamber should be attached to the delivery pipe.

An Alternative Arrangement.—If the reader prefers a steam pump which will work at slow speeds, and be available, when not pumping, for driving purposes, the design may be modified as shown diagrammatically in Fig. 114. The striker becomes a cross head, and is connected by a forked rod passing on each side of the pump with the crank of a fly wheel overhanging the base. The valve is operated in the ordinary manner by an eccentric on the crankshaft. The steadying effect of the fly wheel and the positive action of the valve make it possible to use a larger pump plunger than is advisable with the striking gear. With a pump piston of considerably greater diameter than the piston rod, the pump may be made double-acting, a gland being fitted at the front end for the piston rod to work through, and, of course, a second set of valves added.



A SUGGESTION.

For exhibition purposes a small, easily running, double-action pump might be worked by the spindle of a gramophone. A crank of the proper throw and a connecting rod must be provided. Both delivery pipes feed, through an air-chamber, a fountain in the centre of a bowl, the water returning through an overflow to the source of supply, so that the same water may be used over and over again.



XXIII. KITES.

Plain Rectangular Box Kites.—The plain box kite is easy to make and a good flier. Readers should try their hands on it before attempting more complicated models.

Lifting pressure is exerted only on the sides facing the wind, but the other sides have their use in steadying the kite laterally, and in holding in the wind, so that they justify their weight.

Proportions of Box.—Each box has wind faces one and a third times as long as the sides, and the vertical depth of the box is about the same as its fore and aft dimensions. That is, the ends of the boxes are square, and the wind faces oblong, with one-third as much area again as the ends. Little advantage is to be gained from making the boxes proportionately deeper than this. The distance between the boxes should be about equal to the depth of each box.

CONSTRUCTION.

After these general remarks, we may proceed to a practical description of manufacture, which will apply to kites of all dimensions. It will be prudent to begin on small models, as requiring small outlay.

Having decided on the size of your kite, cut out two pieces of material as wide as a box is to be deep, and as long as the circumference of the box plus an inch and a half to spare. Machine stitch 5/8 inch tapes along each edge, using two rows of stitching about 1/8 inch from the edges of the tape. Then double the piece over, tapes inside, and machine stitch the ends together, three quarters of an inch from the edge. Note.—All thread ends should be tied together to prevent unravelling, and ends of stitching should be hand-sewn through the tape, as the greatest strain falls on these points.

The most convenient shape for the rods is square, as fitting the corners and taking tacks most easily. The sectional size of the rods is governed by the dimensions of the kite, and to a certain extent by the number of stretchers used. If four stretchers are employed in each box, two near the top and two near the bottom, the rods need not be so stout as in a case where only a single pair of central stretchers is preferred.

Lay the two boxes flat on the floor, in line with one another, and the joins at the same end. Pass two rods through, and arrange the boxes so that the outer edges are 1/2 inch from the ends of the rods. (These projections protect the fabric when the kite strikes the ground).

Lay the rods on one corner, so that the sides make an angle of 45 degrees with the floor, pull the boxes taut—be careful that they are square to the rods—and drive three or four tacks through each end of the box into the rods. Then turn them over and tack the other sides similarly. Repeat the process with the other rods after measuring to get the distances correct.

The length of the stretchers is found approximately by a simple arithmetical sum, being the square root of the sum of the squares of the lengths of two adjacent sides of the box. For example, if each box is 20 by 15 inches, the diagonal is the square root of (20 squared plus 15 squared) = square root of 625 = 25 inches. The space occupied by the vertical rods will about offset the stretch of the material, but to be on the safe side and to allow for the notches, add another half-inch for small kites and more proportionately for large ones. It is advisable to test one pair of stretchers before cutting another, to reduce the effect of miscalculations.

The stretcher notches should be deep enough to grip the rods well and prevent them twisting, and one must take care to have those on the same stretcher exactly in line, otherwise one or other cannot possibly "bed" properly. A square file is useful for shaping the notches.

Ordinarily stretchers do not tend to fall out, as the wind pressure puts extra strain on them and keeps them up tight. But to prevent definitely any movement one may insert screw eyes into the rods near the points at which the stretchers press on them, and other eyes near the ends of the stretchers to take string fastenings. These attachments will be found useful for getting the first pair of stretchers into position, and for preventing the stretchers getting lost when the kite is rolled up.

The bridle is attached to four eyes screwed into the rods near the tops of the boxes. (See Fig. 118.) The top and bottom elements of the bridle must be paired off to the correct length; the top being considerably shorter than the bottom. All four parts may be attached to a brass ring, and all should be taut when the ring is pulled on. The exact adjustment must be found by experiment. In a very high wind it is advisable to shorten the top of the bridle if you have any doubt as to the strength of your string, to flatten the angle made by the kite with the wind.



Diamond Box Kites.—In another type of box kite the boxes have four equal sides, but the boxes are rhombus-shaped, as in Fig. 116, the long diagonal being square to the wind, and the bridle attached at the front corner.

For particulars of design and construction I am much indebted to Mr. W. H. Dines, F.R.S., who has used the diamond box kite for his meteorological experiments to carry registering meteorographs several thousands of feet into the air.

The longitudinal sticks used at the corners have the section shown in Fig. 115. They are about four times as wide at the front edge, which presses against the fabric, as at the back, and their depth is about twice the greater width. This shape makes it easy to attach the shorter stretchers, which have their ends notched and bound to prevent splitting.



Fig. 117 is a perspective diagram of a kite. The sail of each box measures from top to bottom one-sixth the total circumference of the box, or, to express the matter differently, each face of the box is half as long again as its depth. The distance separating the boxes is equal to the depth of a box.

The sides of a box make angles of 60 degrees and 120 degrees with one another, the depth of the space enclosed from front to back being the same as the length of a side. With these angles the effective area of the sails is about six-sevenths of the total area. Therefore a kite of the dimensions given in Fig. 117 will have an effective area of some thirty square feet.



The long stretchers pass through holes in the fabric close to the sticks, and are connected with the sticks by stout twine. Between stretcher and stick is interposed a wedge-shaped piece of wood (A in Fig. 115), which prevents the stick being drawn out of line. This method of attachment enables the boxes to be kept tight should the fabric stretch at all—as generally happens after some use; also it does away with the necessity for calculating the length of the stretchers exactly.

The stretchers are tied together at the crossing points to give support to the longer of the pair.

The dotted lines AB, AC, AD, EM, and EN in Fig. 117 indicate ties made with wire or doubled and hemmed strips of the fabric used for the wings. AB, running from the top of the front stick to the bottom of the back stick, should be of such a length that, when the kite is stood on a level surface, the front and back sticks make right angles with that surface, being two sides of a rectangle whereof the other two sides are imaginary lines joining the tops and bottoms of the sticks. This tie prevents the back of the kite drooping under pressure of the wind, and increases the angle of flight. The other four ties prevent the back sails turning over at the edges and spilling the wind, and also keep them flatter. This method of support should be applied to the type of kite described in the first section of this chapter.

String Attachment.—A box kite will fly very well if the string is attached to the top box only. The tail box is then free to tilt up and trim the kite to varying pressures independently of the ascent of the kite as a whole. When the bottom box also is connected to the string it is a somewhat risky business sending a kite up in a high wind, as in the earlier part of the ascent the kite is held by the double bridle fairly square to the wind. If any doubt is entertained as to the ability of the string to stand the pressure, the one-box attachment is preferable, though possibly it does not send the kite to as great a height as might be attained under similar conditions by the two-box bridle.



When one has to attach a string or wire to a large kite at a single point, the ordinary method of using an eye screwed into the front stick is attended by obvious risks. Mr. Dines employs for his kites (which measure up to nine feet in height) an attachment which is independent of the front stick. Two sticks, equal in length to the width of the sail, are tacked on to the inner side of the sail close to the front stick. Rings are secured to the middle of the sticks and connected by a loop of cord, to which the wire (in this case) used for flying the kite is made fast.

A Box Kite with Wings.—The type of kite shown in Fig. 118 is an excellent flyer, very easy, to make and very portable. The two boxes give good longitudinal stability, the sides of the boxes prevent quick lateral movements, and the two wings projecting backwards from the rear corners afford the "dihedral angle" effect which tends to keep the kite steadily facing the wind. The "lift," or vertical upward pull, obtained with the type is high, and this, combined with its steadiness, makes the kite useful for aerial photography, and, on a much larger scale, for man-lifting.

The materials required for the comparatively small example with which the reader may content himself in the first instance are:

8 wooden rods or bamboos, 4 feet long and 1/2 inch in diameter. 4 yards of lawn or other light, strong material, 30 inches wide. 12 yards of unbleached tape, 5/8 inch wide. 8 brass rings, 1 inch diameter.

The Boxes.—Cut off 2 yards 8 inches of material quite squarely, fold down the middle, crease, and cut along the crease. This gives two pieces 80 by 15 inches.

Double-stitch tape along the edges of each piece.

Lay the ends of a piece together, tapes inside, and stitch them together half an inch from the edge. Bring a rod up against the stitching on the inside, and calculate where to run a second row of stitching parallel to the first, to form a pocket into which the rod will slip easily but not loosely. (See Fig. 119, a.)

Remove the rod and stitch the row.

Now repeat the process at the other end of the folded piece. The positions of the other two rod pockets must be found by measuring off 15 inches from the inner stitching of those already made. (Be careful to measure in the right direction in each case, so that the short and long sides of the box shall be opposite.) Fold the material beyond the 15-inch lines to allow for the pockets and the 1/2-inch "spare," and make the two rows of stitching.



Repeat these operations with the second strip of material, and you will have prepared your two boxes, each measuring, inside the pockets, 15 by about 20 inches. (See Fig. 119.) Now cut out the wings in accordance with the dimensions given in Fig. 120. Each is 47-1/2 inches long and 15 inches across at the broadest point. It is advisable to cut a pattern out of brown paper, and to mark off the material from this, so arranging the pattern that the long 47-1/2-inch side lies on a selvedge. [The edge of a fabric that is woven so that it will not fray or ravel.]



Double stitch tapes along the three shorter sides of each wing, finishing off the threads carefully. Then sew the wings to what will be the back corners of the boxes when the kite is in the air—to the "spares" outside the rod pockets of a long side.

Take your needle and some strong thread, and make all corners at the ends of pockets quite secure. This will prevent troublesome splitting when the kite is pulling hard.

Sew a brass ring to each of the four wing angles, AA, BB, at the back, and as many on the front of the spares of the rod pockets diagonally opposite to those to which the wings are attached, halfway up the boxes. These rings are to take the two stretchers in each box.

Slip four rods, after rounding off their ends slightly, through the pockets of both boxes, and secure them by sewing the ends of the pockets and by the insertion of a few small tacks. These rods will not need to be removed.

The cutting and arrangement of the stretchers and the holes for the same require some thought. Each stretcher lies behind its wing, passes in front of the rod nearest to it, and behind that at the corner diagonally opposite. (See Fig. 119.) The slits through which it is thrust should be strengthened with patches to prevent ripping of the material.

Two persons should hold a box out as squarely as possible while a stretcher is measured. Cut a nick 3/8 inch deep in one end of the stretcher, and pass the end through the fabric slits to the ring not on the wing. Pull the wing out, holding it by its ring, and cut the stretcher off 1 inch from the nearest point of the ring. The extra length will allow for the second nick and the tensioning of the material. Now measure off the second stretcher by the first, nick it, and place it in position. If the tension seems excessive, shorten the rods slightly, but do not forget that the fabric will stretch somewhat in use.



Make the stretchers for the second box, and place them in position. The wings ought to be pretty taut if the adjustments are correct, but should they show a tendency to looseness, a third pair of stretchers of light bamboo may be inserted between the other two, being held up to the rods by loops of tape. In order to be able to take up any slackness, the wing end of each stretcher may be allowed to project a couple of inches, and be attached by string to the near ring, as described on p. 271. The bridle to which the flying string is attached is made up of four parts, two long, two short, paired exactly as regards length. These are attached to eyes screwed into the front rods three inches below the tops of the boxes. Adjustment is made very easy if a small slider is used at the kite end of each part. These sliders should be of bone or some tough wood, and measure 1 inch by 3/8 inch. The forward ends of the bridle are attached to a brass ring from which runs the flying string.

It is advisable to bind the stretchers with strong thread just behind the notches to prevent splitting, and to loosen the stretchers when the kite is not in use, to allow the fabric to retain as much as possible of its elasticity.

The area of the kite affected by wind is about 14 square feet; the total weight, 1-1/2 lb. The cost of material is about 2s.

The experience gained from making the kite described may be used in the construction of a larger kite, six or more feet high, with boxes 30 by 22 by 22 inches, and wings 24 inches wide at the broadest point. If a big lift is required, or it is desired to have a kite usable in very light breezes, a second pair of wings slightly narrower than those at the back may be attached permanently to the front of the boxes, or be fitted with hooks and eyes for use on occasion only. (Fig. 121.) In the second case two sets of stretchers will be needed.



Note.—If all free edges of boxes and wings are cut on the curve, they will be less likely to turn over and flap in the wind; but as the curvature gives extra trouble in cutting out and stitching, the illustrations have been drawn to represent a straight-edged kite.

Kite Winders.—The plain stick which small children flying small kites on short strings find sufficient for winding their twine on is far too primitive a contrivance for dealing with some hundreds of yards, may be, of string. In such circumstances one needs a quick-winding apparatus. A very fairly effective form of winder, suitable for small pulls, is illustrated in Fig. 122.

Select a sound piece of wood, 3/8-inch thick, 5 inches wide, and about 1 foot long. In each end cut a deep V, the sides of which must be carefully smoothed and rounded with chisel and sandpaper. Nail a wooden rod, 15 inches long and slightly flattened where it makes contact, across the centre of the board, taking care not to split the rod, and clinch the ends of the nails securely. The projecting ends of the rods are held in the hands while the string runs out. The projecting piece, A, which must also be well secured, is for winding in. The winding hand must be held somewhat obliquely to the board to clear the spindle. Winding is much less irksome if a piece of tubing is interposed between the spindle and the other hand, which can then maintain a firm grip without exercising a braking effect.

This kind of winder is unsuited for reeling in a string on which there is a heavy pull, as the hands are working at a great disadvantage at certain points of a revolution.



A far better type is shown in Figs. 123 and 124. Select a canister at least 6 inches in diameter, and not more than 6 inches long, with an overlapping lid. Get a turner to make for you a couple of wooden discs, 3/8 inch thick, and having a diameter 2 inches greater than that of the tin. Holes at least 3/8 inch across should be bored in the centre of each. Cut holes 1 inch across in the centre of the lid and the bottom of the canister, and nail the lid concentrically to one disc, the canister itself to the other. Then push the lid on the tin and solder them together. This gives you a large reel. For the spindle you will require a piece of brass tubing or steel bar 1 foot long and large enough to make a hard driving fit with the holes in the wood. Before driving it in, make a framework of 3/4-inch strip iron (Fig. 123), 3/32 or 1/8 inch thick, for the reel to turn in. The width of this framework is 1 inch greater than the length of the reel; its length is twice the diameter of the canister. Rivet or solder the ends together. Halfway along the sides bore holes to fit the spindle.

Make a mark 1 inch from one end of the spindle, a second l/8 inch farther away from the first than the length of the reel. Drill 3/16-inch holes at the marks. Select two wire nails which fit the holes, and remove their heads. Next cut two 1/4-inch pieces off a tube which fits the spindle. The reel, spindle, and framework are now assembled as follows:



Push the end of the spindle which has a hole nearest to it through one of the framework holes, slip on one of the pieces of tubing, drive the spindle through the reel until half an inch projects; put on the second piece of tubing, and continue driving the spindle till the hole bored in it shows. Then push the nails half-way through the holes in the spindle, and fix them to the ends of the reel by small staples. A crank is made out of 1/2-inch wood (oak by preference) bored to fit the spindle, to which it must be pinned. A small wooden handle is attached at a suitable distance away. If there is any fear of the wood splitting near the spindle, it should be bound with fine wire. An alternative method is to file the end of the spindle square, and to solder to it a piece of iron strip in which a square hole has been made to fit the spindle. The crank should be as light as is consistent with sufficient strength, and be balanced so that there shall not be unpleasant vibration when the string runs out fast, and of course it must be attached very securely to the spindle.

What will be the front of the framework must be rounded off on the top edge, which has a wire guide running parallel to it (Fig. 123) to direct the string on to the reel; and into the back are riveted a couple of eyes, to which are attached the ends of a cord passing round the body, or some stationary object.



A pin should be provided to push into a hole at one end of the reel and lock the reel by striking the framework, and it will be found a great convenience to have a brake for controlling the reel when the kite is rising. Such a brake is easily fitted to the side of the frame, to act on the left end of the reel when a lever is depressed by the fingers. There should be a spring to keep it off the reel when it is not required. The diagrams show where the brake and brake lever are situated.

Note.—To obtain great elevations a fine wire (piano wire 1/32 inch in diameter) is generally used, but to protect the user against electric shocks the wire must be connected with an "earthed" terminal, on the principle of the lightning conductor.



XXIV. PAPER GLIDERS.

In this chapter are brought to your notice some patterns of paper gliders which, if made and handled carefully, prove very satisfactory. Gliders are sensitive and "moody" things, so that first experiments may be attended by failure; but a little persistence will bring its reward, and at the end of a few hours you will, unless very unlucky, be the possessor of a good specimen or two.

The three distinguishing features of a good glider are stability, straightness of flight, and a small gliding angle. If the last is as low as 1 in 10, so that the model falls but 1 foot vertically while progressing 10 feet horizontally, the glider is one to be proud of.

Materials.—The materials needed for the gliders to be described are moderately stout paper—cream-laid notepaper is somewhat heavy for the purpose—and a little sealing wax or thin sheet metal for weighting.



Model "A."—Double a piece of paper 8 inches long and 2-1/2 inches wide, and cut out, through both folds, the shape shown in Fig. 126. Flatten the piece and fold the "head" inwards four times on the side away from the direction in which the paper was folded before being cut out. Flatten the folds and fix to the centre a little clip formed by doubling a piece of thin metal 3/16 by 1/2 inch. Make certain that the wings are quite flat, and then, holding the glider between thumb and first finger, as shown in Fig. 127, push it off gently. If the balance is right, it will fly quite a long way with an undulating motion. If too heavy in front, it will dive; if too light, it will rise suddenly and slip backwards to the ground. The clip or the amount of paper in the head must be modified accordingly. This type is extraordinarily efficient if the dimensions, weighting, and shape are correct, and one of the easiest possible to make.

Model "B."—The next model (Fig. 128), suggesting by its shape the Langley steam-driven aeroplane, has two sets of wings tandem. Double a piece of paper and cut out of both folds simultaneously a figure of the shape indicated by the solid lines in the diagram. The portion A is square, and forms the head weight; B indicates the front planes, C the rear planes. Bend the upper fold of each pair into the positions B1, C1, marked by dotted lines. Their front edges make less than a right angle with the keel, to ensure the wings slanting slightly upwards towards the front when expanded.

The model is now turned over, and the other wings are folded exactly on top of their respective fellows. Then the halves of the head are folded twice inwards, to bring the paper into as compact a form as possible. It remains to open out the wings at right angles to the keel, and then raise their tips slightly so that the two planes of a pair shall make what is called a "dihedral" angle with one another.



Before launching, look at your model endways and make sure that the rear planes are exactly in line with those in front. It is essential that they should be so for straight flight. Then grip the keel at its centre between finger and thumb and launch gently. Mark how your glider behaves. If it plunges persistently, trim off a very little of the head. If, on the contrary, it settles almost vertically, weight must be added in front. The position of the weight is soon found by sliding a metal clip along the keel until a good result is obtained.

Note that if the leading edges of the front wings are bent slightly downwards the glider may fly much better than before.

A good specimen of this type is so stable that if launched upside down it will right itself immediately and make a normal flight.

Model "C."—This is cut out of doubled paper according to the solid lines of Fig. 128. The three sets of planes are bent back in the manner already described, but the front planes are given a somewhat steeper angle than the others. This type is very stable and very fairly efficient.

General Remarks.—Always pick up a glider by the keel or middle, not by one of the wings, as a very little distortion will give trouble.

The merits of a glider depend on length, and on straightness of flight; so in competition the launching height should be limited by a string stretched across the room, say 6 feet above the floor. If the room be too short for a glider to finish its flight, the elevation at which it strikes the wall is the measure of its efficiency.

Out-of-door flights are impracticable with these very frail models when there is the slightest breeze blowing. On a perfectly calm day, however, much better fun can be got out of doors than in, owing to the greater space available. A good glider launched from a second-floor window facing a large lawn should travel many yards before coming to grass.

Large gliders of the types detailed above can be made of very stout paper stiffened with slips of cane or bamboo; but the time they demand in construction might perhaps be more profitably spent on a power-driven aeroplane such as forms the subject of the next chapter.



XXV. A SELF-LAUNCHING MODEL AEROPLANE. By V. E. Johnson, M.A.

This article deals not with a scale model—a small copy of some full-sized machine—but with one designed for actual flight; with one not specially intended to create records either of length or duration, but which, although small details must perforce be omitted, does along its main lines approximate to the "real thing."

Partly for this reason, and partly because it proves a far more interesting machine, we choose a model able to rise from the ground under its own power and make a good flight after rising, assuming the instructions which we give to have been carefully carried out. It is perhaps hardly necessary to add that such a machine can always be launched by hand when desired.

Before entering into special details we may note some broad principles which must be taken into account if success is to attend our efforts.

Important Points.—It is absolutely essential that the weight be kept down as much as possible. It is quite a mistake to suppose that weight necessarily means strength. On the contrary, it may actually be a cause of weakness if employed in the wrong place and in the wrong way. The heavier the machine, the more serious the damage done in the event of a bad landing. One of the best and easiest ways of ensuring lightness is to let the model be of very simple construction. Such a model is easier to build and more efficient when constructed than one of more complicated design. Weigh every part of your model as you construct it, and do not be content until all symmetrically arranged parts which should weigh the same not only look alike but do actually balance one another. (Note.—The writer always works out the various parts of his models in grammes, not ounces.) If a sufficiently strong propeller bearing weighing only half a gramme can be employed, so much the better, as you have more margin left for some other part of the model in which it would be inadvisable to cut down the weight to a very fine limit.

Details.—To pass now to details, we have four distinct parts to deal with:—

1. The framework, or fuselage.

2. The supporting surfaces, consisting of the main plane, or aerofoil, behind, and the elevator in front.

3. The propellers.

4. The motor, in this case two long skeins of rubber; long, because we wish to be able to give our motor many turns, from 700 to, say, 1,000 as a limit, so that the duration of flight may be considerable.



The Backbone.—For the backbone or central rod take a piece of pitch pine or satin walnut 52 inches long, 5/8 inch deep, and 1/2 inch broad, and plane it down carefully until it has a T-shaped section, as shown in Fig. 129, and the thickness is not anywhere more than 1/8 inch. It is quite possible to reduce the thickness to even 1/16 inch and still have a sufficient reserve of strength to withstand the pull of 28 strands of 1/16-inch rubber wound up 1,000 times; but such a course is not advisable unless you are a skilful planer and have had some experience in model-making.

If you find the construction of the T-shaped rod too difficult, two courses are open—

(l) To get a carpenter to do the job for you, or

(2) To give the rod the triangular section shown in Fig. 129, each side of the equilateral triangle being half an inch long.



The top of the T or the base of the triangle, as the case may be, is used uppermost. This rod must be pierced in three places for the vertical masts employed in the bracing of the rod, trussing the main plane, and adjusting the elevator. These are spaced out in Fig. 130, which shows a side elevation of the model. Their sectional dimensions are 1/16 by 1/4 inch; their respective lengths are given in Fig. 130. Round the front edges and sharpen the rear.

In Fig. 130 is shown the correct attitude or standing pose necessary to make the model rise quickly and sweep boldly up into the air without skimming the ground for some 10 to 20 yards as so many models do. E is the elevator (7 by 3 inches); A the main plane (5-1/2 by 29 inches); W the wheels; and RS the rear skid, terminating in a piece of hooked steel wire. The vertical bracing of these masts is indicated. The best material to use for the purpose is Japanese silk gut, which is very light and strong. To brace, drill a small, neat hole in the mast and rod where necessary, pass through, and tie. Do the same with each one.

To return to the central mast, which must also form the chassis. This is double and opened out beneath as shown in Fig. 131, yz being a piece similar to the sides, which completes, the triangle x y z and gives the necessary rigidity. Attach this piece by first binding to its extremities two strips of aluminium, or by preference very thin tinned iron, Tl and T2. Bend to shape and bind to xy, xz as shown in Fig. 131.



The Wheels and Chassis.—WW are the two wheels on which the model runs. They are made of hollow brass curtain rings, 1 inch in diameter, such as can be bought at four a penny. For spokes, solder two strips of thin tinned iron to the rings, using as little solder as possible. (Fig. 132.) To connect these wheels with the chassis, first bind to the lower ends of xy, xz two strips of thin tinned iron, T3 and T4, after drilling in them two holes of sufficient size to allow a piece of steel wire of "bonnet pin" gauge to pass freely, but not loosely, through them. Soften the wire by making it red hot and allowing it to cool slowly, and solder one end of this wire (which must be quite straight and 5-1/4 inches long) to the centre of the cross pieces or spokes of one wheel. Pass the axle through the holes in the ends of xy, xz, and solder on the other wheel. Your chassis is then finished.

The rear skid (RS in Fig. 130) is attached to the central rod by gluing, and drilling a hole through both parts and inserting a wooden peg; or the upright may be mortised in. On no account use nail, tack, or screw. Attach the vertical masts and the horizontal ones about to be described by gluing and binding lightly with thread, or by neatly glued strips of the Hart's fabric used for the planes.

Horizontal Spars, etc.—To consider now the horizontal section or part plan of the model, from which, to avoid confusion, details of most vertical parts are omitted. Referring to Fig. 133, it will be seen that we have three horizontal masts or spars—HS1, 4 inches; HS2, 6 inches; and HS3, slightly over 12 inches long. The last is well steamed, slightly curved and left to dry while confined in such a manner as to conform to the required shape. It should so remain at least twenty-four hours before being fixed to the model. All the spars are attached by glue and neat cross bindings. If the central rod be of triangular instead of T section, the join can be made more neatly. The same remarks apply to the two 9 and 10 inch struts at the propeller end of the rod, which have to withstand the pull of the rubber motor on PPl. These two pieces will have a maximum strength and minimum weight if of the T section used for the rod. If the work is done carefully, 1/4 inch each way will be sufficient.

Main Plane and Elevator.—The framework of each plane is simply four strips of satin walnut or other suitable wood, 1/4 inch broad and 1/16 inch or even less in thickness for the main plane, and about 1/16 by 1/16 inch for the elevator. These strips are first glued together at the corners and left to set. The fabric (Hart's fabric or some similar very light material) is then glued on fairly tight—that is, just sufficiently so to get rid of all creases. The main plane is then fixed flat on to the top of the central rod by gluing and cross binding at G and H. (A better but rather more difficult plan is to fasten the rectangular frame on first and then apply the fabric.) The same course is followed in dealing with the elevator, which is fixed, however, not to the rod, but to the 4-inch horizontal spar, HS1, just behind it, in such a manner as to have a slight hinge movement at the back. This operation presents no difficulty, and may be effected in a variety of ways. To set the elevator, use is made of the short vertical mast, M1. A small hole is pierced in the front side of the elevator frame at Z, and through this a piece of thin, soft iron wire is pushed, bent round the spar, and tied. The other end of the wire is taken forward and wrapped three or four times round the mast M1, which should have several notches in its front edge, to assist the setting of the elevator at different angles. Pull the wire tight, so that the elevator shall maintain a constant angle when once set. H H1 is a piece of 25 to 30 gauge wire bent as shown and fastened by binding. It passes round the front of the rod, in which a little notch should be cut, so as to be able to resist the pull of the twin rubber motors, the two skeins of which are stretched between H H1 and the hooks formed on the propeller spindles. If all these hooks are covered with cycle valve tubing the rubber will last much longer. The rubber skeins pass through two little light wire rings fastened to the underside ends of HS2. (Fig. 133.)

The front skid or protector, FS, is made out of a piece of thin, round, jointless cane, some 9 inches in length, bent round as shown in Fig. 134, in which A B represents the front piece of the T-shaped rod and x y z a the cane skid; the portion x y passing on the near side of the vertical part of the T, and z a on the far side of the same. At E and F thread is bound right round the rod. Should the nose of the machine strike the ground, the loop of cane will be driven along the underside of the rod and the shock be minimized. So adjust matters that the skid slides fairly stiff. Note that the whole of the cane is on the under side of the top bar of the T.



Bearings.—We have still to deal with the propellers and their bearings. The last, TN and TNl (Fig. 133), are simply two tiny pieces of tin about half a gramme in weight, bent round the propeller spar HS3 at B and B1. Take a strip of thin tin 1/4 inch wide and of sufficient length to go completely round the spar (which is 1/4 by 1/8 inch) and overlap slightly. Solder the ends together, using a minimum amount of solder. Now bore two small holes through wood and tin from rear to front, being careful to go through the centre. The hole must be just large enough to allow the propeller axle to run freely, but not loosely, in it. Primitive though such a bearing may seem, it answers admirably in practice. The wood drills out or is soon worn more than the iron, and the axle runs quite freely. The pull of the motor is thus directed through the thin curved spar at a point where the resistance is greatest—a very important matter in model aeroplane construction. To strengthen this spar further against torsional forces, run gut ties from B and Bl down to the bottom of the rear vertical skid post; and from B to B1 also pass a piece of very thin piano wire, soldered to the tin strips over a little wooden bridge, Q, like a violin bridge, on the top of the central rod, to keep it quite taut.