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Thread: A big aluminum spark plug!

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    bobs409's Avatar
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    A big aluminum spark plug!

    For the man who has everything, a big aluminum spark plug! Got the idea and had to have one.

    I opted to use the old style R45 AC plug that used the 13/16 socket as the model. It has more of a fat stubby look unlike the thin 5/8 variety. Using a digital caliper, I made countless measurements of the real plugs width and spacing's and multiplied each of those by 53%. The reason I went with 53% is so the hex area would finish up at 1-1/4 and that was the magic number. This was machined from a piece of 1-1/2 round stock a little over 4 inches long.

    The side electrode was made separately and installed at the end into a #50 hole using JB weld for aluminum. Everything else was done on a mill and lathe.

    It helps to have a sketch sheet with the measurements laid out as there are so many ways to screw up! Luckily I had no troubles but there is a lot of math so it's best to prepare that ahead of time. (I would occasionally double check my measurements as I made them too)

    The first pic shows the finished plug and below that I'll put in some shots of how it progressed.

    A big aluminum spark plug!-dscn7381.jpgA big aluminum spark plug!-dscn7342.jpgA big aluminum spark plug!-dscn7348.jpgA big aluminum spark plug!-dscn7354.jpgA big aluminum spark plug!-dscn7359.jpgA big aluminum spark plug!-dscn7366.jpgA big aluminum spark plug!-dscn7367.jpgA big aluminum spark plug!-dscn7371.jpgA big aluminum spark plug!-dscn7377.jpg

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    PJs (01-31-2017)

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    PJs
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    Great project Bobs409. It definitely covers a lot of operations and tool options. Reproducing it to scale can be challenging too with the excellent details of the ceramic neck. Well Done and a beautiful reproduction, Congratulations! Curious about the tool you used to hollow out the electrode area...custom ground?
    ‘‘Always do right. This will gratify some people and astonish the rest.’’
    Mark Twain

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    bobs409 (01-31-2017)

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    Thanks! I actually made a separate piece for that area and it's pressed in. I only tell those that ask. lol

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    PJs (02-01-2017)

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    very nice model!!!


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