Mystic IHC Mogul Engine – Part 2

Restoration of a 1916 1 HP IHC Mogul continues, including muffler and oiler work – Part 2 of 3

| August/September 2012

  • Mystic Mogul Engine
    The Mogul as it looked at time of purchase.
  • Exhaust Pipe
    Exhaust pipe as removed from engine.
  • Exhaust Connector
    Exhaust connector, showing weld around the remains of the elbow.
  • Remains of the Elbow After Welding
    Exhaust connector showing the remains of the elbow after grinding off the weld.
  • Starting to turn the body of the muffler.
    Starting to turn the body of the muffler.
  • Setting boring bar to cut the inside.
    Setting boring bar to cut the inside.
  • Using a profile tool to shape the bottom of the baffles.
    Using a profile tool to shape the bottom of the baffles.
  • Rounding the edge of the baffles using a homemade profile tool.
    Rounding the edge of the baffles using a homemade profile tool.
  • Turning the cap, center and baffles.
    Turning the cap, center and baffles.
  • The body with the turning finished.
    The body with the turning finished.
  • The outer sides of the body and cap.
    The outer sides of the body and cap.
  • The body and cap after brazing the four internal supports.
    The body and cap after brazing the four internal supports.
  • Spacers taped in place to position the lid when drilling bolt holes.
    Spacers taped in place to position the lid when drilling bolt holes.
  • Brazing the two top strips to the main body.
    Brazing the two top strips to the main body.
  • Rolling the first curve.
    Rolling the first curve.
  • The two sides completed.
    The two sides completed.
  • Finished guard in place.
    Finished guard in place.
  • The securing straps cut out and partially bent.
    The securing straps cut out and partially bent.
  • The extension tube braised in place on the old part.
    The extension tube brazed in place on the old part.
  • The finished parts.
    The finished parts.
  • Assembled muffler.
    Assembled muffler.
  • Broken breather washer.
    Broken breather washer.
  • Repaired breather valve.
    Repaired breather valve.
  • The broken oiler.
    The broken oiler.
  • Oiler parts with the jig.
    Oiler parts with the jig.
  • The repaired oiler.
    The repaired oiler.
  • The two parts on the jig and brazed together.
    The two parts on the jig and brazed together.
  • Skid with the engine removed.
    Skid with the engine removed.
  • The skid iron-work plans.
    The skid iron-work plans.
  • The skid after being cleaned and treated with linseed oil.
    The skid after being cleaned and treated with linseed oil.
  • The wheel template and central plug.
    The wheel template and central plug.
  • Test-fitting each spoke.
    Test-fitting each spoke.
  • Boring the axle hole in the hub.
    Boring the axle hole in the hub.
  • The finished wheel.
    The finished wheel.
  • The grooved axle block.
    The grooved axle block.
  • Starting to groove the axle blocks.
    Starting to groove the axle blocks.
  • Shaping the ends of the block.
    Shaping the ends of the block.
  • Finishing forming the bend of the bolt.
    Finishing forming the bend of the bolt.
  • Completed U bolt, buts, washers and block.
    Completed U bolt, buts, washers and block.
  • The support outline marked on wood.
    The support outline marked on wood.
  • Partially bent supports.
    Partially bent supports.
  • Heating iron in the brazing hearth.
    Heating iron in the brazing hearth.
  • The completed supports, bolts and plates
    The completed supports, bolts and plates
  • The core and outer lip before shaping.
    The core and outer lip before shaping.
  • The outer lip being sawn before shaping.
    The outer lip being sawn before shaping around the filing button, a hardened washer used as a guide when filing a radius.
  • The core and outer lip before shaping on Mogul.
    The core and outer lip before shaping.
  • The shaped inner clip and outer lip ready for brazing.
    The shaped inner clip and outer lip ready for brazing.
  • A clip for the inner lip after brazing.
    A clip for the inner lip after brazing.
  • The finished brake pieces.
    The finished brake pieces.
  • The completed brake attached to the skid.
    The completed brake attached to the skid.

  • Mystic Mogul Engine
  • Exhaust Pipe
  • Exhaust Connector
  • Remains of the Elbow After Welding
  • Starting to turn the body of the muffler.
  • Setting boring bar to cut the inside.
  • Using a profile tool to shape the bottom of the baffles.
  • Rounding the edge of the baffles using a homemade profile tool.
  • Turning the cap, center and baffles.
  • The body with the turning finished.
  • The outer sides of the body and cap.
  • The body and cap after brazing the four internal supports.
  • Spacers taped in place to position the lid when drilling bolt holes.
  • Brazing the two top strips to the main body.
  • Rolling the first curve.
  • The two sides completed.
  • Finished guard in place.
  • The securing straps cut out and partially bent.
  • The extension tube braised in place on the old part.
  • The finished parts.
  • Assembled muffler.
  • Broken breather washer.
  • Repaired breather valve.
  • The broken oiler.
  • Oiler parts with the jig.
  • The repaired oiler.
  • The two parts on the jig and brazed together.
  • Skid with the engine removed.
  • The skid iron-work plans.
  • The skid after being cleaned and treated with linseed oil.
  • The wheel template and central plug.
  • Test-fitting each spoke.
  • Boring the axle hole in the hub.
  • The finished wheel.
  • The grooved axle block.
  • Starting to groove the axle blocks.
  • Shaping the ends of the block.
  • Finishing forming the bend of the bolt.
  • Completed U bolt, buts, washers and block.
  • The support outline marked on wood.
  • Partially bent supports.
  • Heating iron in the brazing hearth.
  • The completed supports, bolts and plates
  • The core and outer lip before shaping.
  • The outer lip being sawn before shaping.
  • The core and outer lip before shaping on Mogul.
  • The shaped inner clip and outer lip ready for brazing.
  • A clip for the inner lip after brazing.
  • The finished brake pieces.
  • The completed brake attached to the skid.

This is the second in a three part series on Peter Rooke's restoration of a 1 HP IHC Mogul engine. You can read part 1 in Mystic IHC Mogul. 

Muffler

When I purchased the Mogul, it sported a straight piece of pipe as the exhaust and had part of an old union welded to the remains of the original muffler elbow.

The length of pipe was screwed into the union and it took a lot of heat from a gas torch and the combined use of a big vise and a large pipe wrench to part them.

I then sawed the elbow from the original muffler off the union before all the weld was ground away from it to leave the sad remains of the old and badly rust-pitted elbow.



Unable to scrounge any cast iron for this muffler, I purchased two pieces of cast iron so that the muffler could be rebuilt. Fortunately a friend had an original muffler on his Mogul, so I could take measurements to make an accurate copy.

The first part I turned was the main body, and as the supplier sent a bigger piece of cast iron than ordered and paid for, this would also include a spigot for part of the pipe to the elbow. After partially turning the faces of the cast iron, I bored a 1.4-inch hole through its center. I then turned the outer diameter to 4.375 inches, leaving a short length reduced to a diameter of 1.7 inches to form part of the inlet pipe.



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