This document summarizes mechanical engineering projects completed by the author, including rebuilding a Model T Ford Speedster with family members, designing an adapter to connect engine parts on a Honda motorcycle, and modeling a large aluminum component for a client. It also describes machining various precision and custom parts like spanner wrenches, load cell fixtures, and 3D printed supports. Graphs are included showing stress-strain curves from tensile tests on various materials. A multi-page section details the design, modeling, and construction of an alpha-style Stirling engine for a course project, including CNC milling of components, though the engine was ultimately unsuccessful.

1. Mechanical Engineer
Project Portfolio

2. My brother, my
father, and I rebuilt a
Model T Ford Speedster
together out of several
carcasses. These
velocity stacks help the
dual carburetors to look
nice and draw more air.
They actually have had a
significant effect so that
the timing needed to be
adjusted after
installation, and the
engine produces a
noticeably greater
amount of power.

4. Adapter
Rev 2
Adapter
Rev 3
1986
w/adapter
1985
I was given an ‘86 Honda CR250 with a
blown cylinder, and we had an ‘85 cylinder
available. The only difference between the
years is the (mostly ineffective) HPP
exhaust porting system.
I designed and machined an adapter and
the motorcycle runs beautifully.
Adapter
Installed
on
Cylinder

5. These pictures show the adapter connecting the cylinder to the
exhaust pipe.

6. Client needed a CAD model of a large
aluminum component to be quoted for
casting. Modeled with a fairly high degree
of accuracy in 6 hr.

7. Custom
Spanner
Wrenches
Tiny Links
~1/2” length
Load Cell
Fixture
SLA
Supports

8. Water-tight threaded Delrin components,
used for testing and show prototypes
I programmed and milled 10 each of all but
the top right piece. I used GibbsCam and a
Tormach mill to create these from another
student’s CAD models.
Macor blocks with silver printed
paths. Used in a BSU research
experiment on the behavior of
charged particles traveling through
cone-shaped orifices. I cut the
ceramic, drilled .02” holes, and
created cones.

9. 500
Stress Strain Curves of Tensile Specimens
450
400
350
Stress (psi)
300
250
A
B
200
C
D
150
E
Bandsaw 1
100
Bandsaw 2
Bandsaw 3
50
Exacto
0
0.00
0.05
0.10
0.15
0.20
Strain
0.25
0.30
0.35

10. As a part of the Thermal and Fluids Systems
course, our team
designed, thermodynamically modeled, and
built an alpha-style Stirling engine. We used
precision dampers for the piston/cylinder
components and I CNC milled the drivetrain
and manifold components.
The first flywheel (not shown) was too
small, so I created this monster out of a
square foot of aluminum. We cut the mounting
base to accommodate the size increase.

11. Sadly, our engine was unsuccessful. It could
not produce the power to sustain rotation from
the energy of the three tea candles. This was
likely due to the slack in the drive train, air
leakage, and the small working volume of the
air in the system. We tried many
modifications, but could not make it run.
If we could make another attempt we would:
• Use much more copper tubing and make
more passes over the heat source and the
heat sink
• Create a more rigid drive train with fewer
components
•Use a higher output heat source