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Stirling Engine Kit Assembly Instruction





Finished engine


The parts in the kit

Warning! Engine contains sharp edges, handle with care!





Step 1:

Drop The displacer into the displacer cylinder. The nylon wire should be facing up. Check that it can move up and down freely.

Drop the displacer into the displacer cylinder
  
Drop the displacer into the displacer cylinder
 
 
 
Thread the nylon wire through the tiny hole.
  Step 2:

Thread the fine nylon wire through the tiny hole in the top can. It's quite a small hole, and it may seem that it's not big enough.



 ! DO NOT ATTEMPT TO MAKE THE
HOLE BIGGER! IT IS THE RIGHT SIZE
 

The top can is pushed down at a bit of an angle
  


Push down on the un-cut edge of the top can

Step 3:

 Pull the nylon wire all of the way through. Rest the top can on top of the displacer cylinder, so that it is tipped forward slightly. Push down on the back edge to fit the top can in place. It should only be pushed down a small amount, 3 or 4 mm. Do not push above the cut out in the can, this will crush the can!

 

Seal around the join between the two cans.



 Step 4:

Seal around where the two cans meet
using general purpose silicone sealant.
Bolt on the L bracket

Step 5:

Bolt on the 40mm angle bracket using
the M4 x 12 machine screws.
Push the tube onto the bottle cap






Step 6:
 Push the silicone tube into the hole
nearest the edge of the bottle cap.
Bolt the bottle cap into place

Step 7:
Bolt the diaphragm holder to the angle
bracket using the M4 x 12 machine screw and
small washers.
 
Seal around the tube





Step 8:
Seal around the tube and bolt using silicone sealant.

  
Bolt and washer
Step 9:

Prepare one of the M4 x 12 machine
screws with a large washer, ready for the
diaphragm
 
Pierce a hole in the balloon

Step 10:
Punch a hole through the diaphragm
using a bradawl.

  
Assemble the diaphragm

Step 11:

Thread the bolt and washer through the
hole, add the other large washer onto the other
side and tighten the nut. It should be tight to seal
the joint.
Insert the crankshaft step 1

  
Insert the crankshaft step 2
 
Insert the crankshaft step 3


 Step 12:
Thread the crankshaft through the
bearing holes. You'll need to squeeze the can to
fit it into place.

Diagram of the displacer connection

 
Fix the nylon wire into the terminal block

 Step 13:

The nylon wire must be fixed into the
brass connector on the crankshaft. It must be
fixed so that it pulls the displacer to the top of
it's cylinder. If this doesn't happen, the engine
will not work. 
Slide on a pice of heatshrink
 		 Step 14:

Fix the flywheel in place, tighten the
small locking screw to prevent it slipping on the
crankshaft.

Slide a piece of heat-shrink onto the diaphragm
side of the crankshaft
Fit the diaphragm into place
 

Step 15 :

Fit the diaphragm over the diaphragm
holder.
 
 
Step 16:
Measure the distance between the diaphragm and crankshaft. Bend the diaphragm con
rod as shown, so that it will connect between the diaphragm and crankshaft. The bend in the
crankshaft allows for easy to adjustment.

Fit the diaphragm con rod into place
 


Step 16:

Fit the diaphragm con rod into place as
shown.
 
Last pice of heatshrink in place.
 Step 17:

To stop the con rod sliding off the
crankshaft, slid on another piece of heat-shrink.
Heat the heat-shrink up using a small flame, it
will shrink, securing it to the crankshaft
   

Running the engine:

Oil all of the points using a light machine oil.
Heat the bottom of the can using a candle flame, or by placing it in a cup
of boiling water.
Fill the cooling jacket with cold water.
Turn the flywheel to start the engine. The direction of rotation may very, so
try both ways.
The engine must turn freely
The engine must be sealed properly. The only air leak should be around the
nylon wire.