Why Opposed Piston Internal Combustion Engines Are Great

Converting the ignition of a fuel-air mixture into usable mechanical energy lies at the core of a dizzying number of internal combustion engines developed over the course of more than century. Although typical piston engines with a cylinder head and valve-train are the most common by far, and even rotary engines are quite well-known, the opposed-piston engine design is significantly more obscure. In a recent video by [driving 4 answers], this type of engine is covered and why it’s actually a pretty nifty ICE design with many benefits.

Achates opposed-piston design. (Source: driving 4 answers, YouTube)
Achates opposed-piston design. (Source: driving 4 answers, YouTube)

Above all, the design is mechanically far more simple, as it omits all the valves and timing-related hardware of the typical four-stroke ICE. Each ignition event pushes against two pistons at the same time, allowing for more of the kinetic energy to be converted into usable power, as well as enabling largely vibration-free operation in a more compact package, especially in the case of the Asender design that eliminates the second crankshaft of the Achates design. This makes the Asender rather similar to the 1914 Simpson’s design.

Despite these many advantages, opposed-piston engines have mostly led a quiet life in industrial and military applications, including tanks, submarines and airplanes. This is where the video also sees their continued use, but as a 2021 article in Autoweek suggests, we might be seeing more of these engines in everywhere from trucks to cars as well. Even if it’s only in hybrid cars where it would be in a generator role, there are many reasons why this ICE design would fit right into certain roles.

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You Wouldn’t Download A Combustion Engine

Although 3D printing it a great tool for making all sorts of things, the nature of the plastics used in most desktop FDM printers means it isn’t the first tool most would think of to build an internal combustion engine. [Alexander] is evidently not most people, as he’s on his third generation 3D printed engine.

There are 3D printed pumps to distribute coolant water and oil, plus some clever engineering in the head to make sure they don’t mix — a problem with a previous iteration. As you probably guessed, the engine isn’t fully printed. Assembling it requires add-on hardware for things like bearings, belts, and filters.

But it’s still impressive just how much of this beast is actually made of plastic. Not even fancy engineering plastic, either — there are a few CF-Nylon parts, but most of it is apparently good old ASA and ABS.

If you’re looking for “cheats”, the plastic engine block does get a stainless steel sleeve, and the head is CNC’d aluminum, but we hesitate to call anything that gets a homemade engine running a “cheat”. It’s hard enough using all the ‘right’ materials. Just like another 3D printed engine we featured, the carb is also an off-the-shelf component.

Still, it’s the dancing bear all over again: it’s not how well it runs that impresses, but the fact that it runs at all. We’ve also seen hackers use 3D printing to make steam engines, hot-air Stirling engines, and electric motors— all with varying amounts of non-printed parts.

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Two four-cylinder engines mechanically linked and exhausting into a trombone.

Franken-engine Plays Its Own Swan Song At 15k RPM

Back during WWII, Chrysler bodged five inline-6 engines together to create the powerful A57 multibank tank engine. [Maisteer] has some high-revving inline-4 motorcycle engines he’s trying to put together too, but unlike 1940s Chrysler, he also has a trombone… and a lot more RPMs to deal with.

The Chrysler flatheads were revving at a few thousand RPM– their redline was almost certainly in the three-thousand range. [Maisteer] is working at 15,000 RPM, which is where the real challenge of this build lies: the trombone in the image is just for fun. He wanted to use a heavy chain to link the crankshafts, but at that rotational speed, a heavy chain becomes really heavy— or at least, it feels a force many times its weight due to centrifugal force. The lietmotief of this video is a quote by an automotive engineer to the effect that chains don’t work over 10,000 RPM.

That leads to a few problems for the intrepid “not an engineer” that take most of the video to deal with and ultimately doom the engine linkage– for now. Not before he gets an iconic 8-cylinder sound out (plus some fire) out of a trombone, though. Of particular note is the maker-type workflow Hackaday readers will appreciate: he 3D scans the engines, CADs up parts he needs and sends away to have them CNC’d and SLS printed.

Hacking motorcycle engines into cars is nothing new. Hacking them together into franken-engines is something we see less often.

Thanks to [Keith Olson] for the tip! Remember, if you want to toot your own horn– or toot about someone else’s project, for that matter–the tips line is always open.

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Run A Lawnmower On Diesel With Hot Bulb Hack

If you’re into automotive hacks and don’t watch [Robot Cantina], you are missing out. This hack has [Jimbo] taking a break from automotive hacking to butcher a poor, innocent Tecumseh lawnmower to run diesel fuel (or anything else) by converting the motor into a hot bulb engine. (Video embedded below.)

The secret is a long stack of anti-fouling adapters, which are essentially extension tubes that move the spark plug out of the combustion chamber to keep it from getting crudded up in an engine that’s burning too much oil. In this case, burning is what’s happening inside the anti-fouling adapters: by stacking seven of them, [Robot Cantina] is able to create a hot-bulb– volume that stays hot enough between strokes to induce spontaneous combustion of the fuel-air mix.

Hot-bulb engines were popular for certain tractors (the Lanz Bulldog being the most famous) and stationary engines from the late 19th century until Rudolf Diesel’s eponymous invention drove them out of their niche completely sometime after WWII.

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A Two-Stroke Engine Made From Scratch Using Basic Hardware Store Parts

A working DIY two-stroke in all of its glory, with the flywheel removed. (Credit: Camden Bowen)
A working DIY two-stroke in all of its glory, with the flywheel removed. (Credit: Camden Bowen)

How hard could it to be to build a two-stroke internal combustion engine (ICE) from scratch? This is a challenge that [Camden Bowen] gladly set for himself, while foregoing such obvious wastes of time like first doing an in-depth literature study on the topic. That said, he did do some research and made the design in OnShape CAD before making his way over to the hardware store to make some purchases.

As it turns out, you can indeed build a two-stroke engine from scratch, using little more than some metal piping and other parts from the hardware store. You also need a welder and a lathe, with [Camden] using a Vevor mini-lathe that totally puts the ‘precision’ in ‘chatter’. As building an ICE requires a number of relatively basic parts that have to move with very little friction and with tight tolerances, this posed some challenges, but nothing that some DIY spirit can’t fix.

In the case of the very flexible boring bar on the lathe, improvising with some sturdy metal stock welded to a short boring bar resolved that, and precision was achieved. Together with an angle grinder, [Camden] was then able to manufacture the crank case, the cylinder and crank shaft and all the other pieces that make up an ICE. For the carburetor he used a unit off Amazon, which turned out to have the wrong throat size at 19 mm, but a 13 mm version worked. Ultimately, the first ICE constructed this way got destroyed mostly by running it dry and having the starter fluid acting as a solvent, but a full rebuild fixed all the issues.

This second attempt actually ran just fine the first time around, with oil in the crank case so that the poor engine wasn’t running dry any more. With a 40:1 fuel/oil mixture the little engine idles and runs as well as a two-stroke can, belching blue smoke and making a ruckus. This answers the question of whether you can build a two-stroke ICE with basic machining skills and tools, but of course the question that’s now on everyone’s lips is whether a four-stroke one would be nearly as ‘easy’. We wait with bated breath.

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Ford Patent Wants To Save Internal Combustion

There’s no doubt the venerable internal combustion engine is under fire. A recent patent filing from Ford claims it can dramatically reduce emissions and, if true, the technology might give classic engines a few more years of service life, according to [CarBuzz].

The patent in question centers on improving the evaporative emission system’s performance. The usual evaporative emission system stores fuel fumes in a carbon-filled canister. The canister absorbs fuel vapor when under high pressure. When the engine idles and pressure in the cylinder drops, the canister releases fumes, which are combusted with ordinary fuel/air mixture.

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Dad Builds Frickin’ Tank For His Son

We gotta love hacker Dads and Moms for being so awesome. Sooner or later, their kids get to play with some amazing toy that every other kid on the block is jealous of. [Meanwhile in the Garage aka MWiG] is one of those super hacker Dads who built a frickin’ Tank for his son (video, embedded below.). But it’s so much fun driving that beast around that we suspect Dad is going to be piloting it a lot more than the kid. The tank features metal tracks, differential steering, a rotating turret, periscopes and a functional paintball gun with camera targeting.

Building a tank, even if it’s a mini replica, needs an engine with a decent amount of torque. [MWiG] first tried reviving an old ATV engine, but it did nothing more than sputter and die. It went to the scrap heap after donating its rear transmission and axle. [MWiG] managed to get an old Piaggio scooter with a 250cc / 22 hp engine. The scooter gave up its engine, electricals and the instrument cluster before being scrapped. Looking at the final build, and the amount of metal used, we are left wondering how the puny 22 hp engine manages to drive the tank. We guess it’s the right amount of gearing for the win.

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