Stuart D-10 Dual Cylinder Marine Engine
United Kingdom - Manufacture date: 1978
Bore = 3/4", Stroke 3/4", Flywheel diameter = 1 5/8"
Style: Double Acting, dual cylinder,Vertical marine

Dimensions: 5 1/2" length x 4" width x 5 1/2" height

The Stuart D-10 Marine Engine

his engine was built by the talented, Lou who also built the Stuart H-9 engine in the collection. Lou does some very nice work and I've been very pleased with the engines I've purchased from him. I suspect Lou would be less than pleased with me if he knew the fate of this engine shortly after I received it. This engine was accidentally knocked off its shelf and the front cylinder tower was shattered. It sat on my work bench for nearly a year before I decided I, with nearly no tools, was going to repair it. Lou builds his engines with tolerances of ± 1/2 a thousandth of an inch so the decision to rebuild it was a bit daunting considering I'd only have a drill press to work the replacement casting. Lots of care and slow facing with a fine flat hone and a makeshift cylinder hone, along with constant checks with a micrometer went into the effort.

I had very serious doubts that this engine would ever run again since I'm no machinist and my available tools would certainly make one shake his head in dismay. Slowly the micrometer began to tell me things were coming together much better than I'd hoped. When the last surface polishing was done, the measurements all matched the original piece. Much to my surprise, once everything was assembled for a "final" test fitting, the engine turned smoothly with almost no resistance.

As I've mentioned, Lou takes a lot of pride in his work. The slide valve links and the connecting rods on this engine were hand contoured , rounded and tapered for an elegant realistic look. A lot of rounded sides, edges and ends were hand shaped to a perfect match throughout the drive train.

D-10 with polished flywheel, connecting rods
and slide valve links

Stuart Castings love
400, 1200 and 2500 grit paper
but take it to 3 microns and magic happens

The engine was originally an institutional green and with the raw casting, needed painting badly. Another disassembly ensued and the castings were stripped and prepared for a new coat of red paint. While the engine was apart, I broke out my trusty Dremel and jewelers rouge and set to work adding a high shine to Lou's already sleek brass work. The machined surfaces of the castings and flywheel were then hand polished using 400, 1200 and finally, 2500 grit paper. I learned that cast iron loves 2500 grit and takes a near mirrored stainless finish with very little effort.

All of the gaskets had to be replaced, but luckily an old steam collector suggested cutting them from a $1.00 bill. The rag paper and silk make a perfect gasket and stand up to cutting quite nicely. My confession to Lou and the results of my misadventure are shown here. Lou...its stored safely way from the edge this time.


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