20601 Old State Road, Haubstadt, Indiana 47639
In early 1989 the Hercules Gas Engine Factory came back to life. As a part of the Hercules 75th anniversary celebration by the Southern Indiana Antique and Machine Club (SIAM) last June, it was decided to make commemorative toy engines for those who might be interested in buying a souvenir.
The major responsibility for the project fell on yours truly. We debated about having someone make them for us, but after a while it was decided that the club would tackle it. When you've never done such a thing before, it can be an interesting and challenging experience. After much discussion, it was decided to make a 1/8 scale of the Hercules 1 1/2 HP model E engine. A 98 mile roundtrip was made to Grandview Aluminum Products at Grandview, Indiana to show Harold Banks what we wanted and to find out how to go about it. A toy engine from another source was taken along to illustrate what we had in mind. Mr. Banks explained the casting process and the pattern requirements.
First it required a pattern to make additional casting patterns from so it could be set up to cast parts for four engines at a time (thus lowering the cost). Two 1/2 inch thick aluminum pieces were acquired and glued together with a piece of paper in between so the two halves could be split apart. Numerous measurements and drawings were made from a full size 1 1/2 HP engine. The process of sawing, milling, filing, grinding, filling and sanding took place until a suitable pattern was made for the main body. All surfaces required at least one degree or more of relief so the casting sand would release from the patterns. A Webster magneto pattern was made and Steve Elpers made them for the flywheel and muffler.
Off we went to Grandview to find out the next step. Some of the patterns needed more work so back to the home shop we went. Then we went back to Grandview and had additional patterns made from the originals. It took another trip back to Grandview to pick them up. We also got instructions on how to mount them on the plate for the sand molding process. The additional patterns were cleaned and slicked up and mounted on a 15 x 26 x 3/8 inch thick aluminum plate. The foundry has a process to put on the lettering. We had 'Hercules Evansville, IN' and '1914 -75 Years - 1989' put on the sides of the base.
Back to Grandview we went. 100 were cast and they called to come and get them. It turned out that the two pattern halves of one main casting were misaligned enough on the plate to make quite an offset in the finished casting. That left just 75 good main castings. At this point two things happened. Several club members started cleaning up the castings, boring holes and preparing the parts to be fitted together. The misaligned patterns were taken off the plate and modified to make the main body for 1/8 scale 1 1/2 HP model E Economy engines. It was then decided to have another 200 castings made. 50 would be Economy and the other 150 Hercules. So, it was back to Grandview again.
By mid-April the last trip to Grandview was made and the assembly preparations got into high gear. Some 25 of the club members worked at various times during the next month on the parts in my shop. We tried all kinds of filing and sanding techniques to clean up parts. Holes had to be bored for the flywheel shaft, the muffler, the magneto mounting and the oiler. An adapter was made for the lathe to accept the flywheels so the hole could be bored and the rim turned in one operation. The oilers were turned out of 3/16 inch brazing rod on a small lathe. The pulley blanks were cut from 1/2 inch aluminum rod and then machined.
All Hercules parts except the shafts, muffler, magneto and oiler were painted Hunter Green and the Economy parts IHC Red. The mufflers and magnetos were painted Satin Black. Before painting, all were stamped with a number on the base. After painting, the raised letters on the base were sanded so the bare aluminum showed through. As the parts were assembled, a liquid locking compound was applied to hold the pieces in place. Before assembly several efforts were made to find a way to put on the stripes. Finally yours truly took a paint striper with a 1/64 inch wheel and tried it out. Guess who ended up striping all 266 of them?
About 125 3 x 5 walnut blocks were made. All Economys and about 75 of the Hercules were mounted on them. Even though premium priced, they sold first. In all, 52 Economys, 213 Hercules and one Jaeger were made and all were sold.