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Ed, $75.00? I put more than than in the trash can a couple of days ago. After wasting about $100.00 worth of aluminum tubing I got the job done perfectly with $38.00 worth of steel tubing. That is what I wanted to do originally but was talked into the aluminum. I have nothing against aluminum but in this case it was not the right choice. My original drawings called for 1.75 o.d. 1.625 i.d. steel tubing but even I forgot that in the rush to make a super cool aluminum intake. If we could have found a 2.5R sweep in 6061 with the right I.d, it would have been possible. Or better technique on my part would have made it possible. However, now that I have figured out the steel, I can build a complete runner in about 45 minutes. The next p port I build will benefit greatly from this experience. For sure there will be ONE i.d./o.d. throughout. Jerry
On Wednesday, April 6, 2005, at 07:34 PM, Ed Anderson wrote:
Jerry, looks like great progress. My two housings are panting with
anticipation.
By the way, next time I recommend you try RBWagner. The produce stail
railing and have almost any radius from 1" to 8" in tubes from 1" to 2 1/2"
in stainless or aluminum. I got my exhaust tubing from them because I
could select a number of different bends to get the configuration I wanted.
Only trouble is they have now raised their minimum order to $75. Stil might
be worth it to get exactly what you want.
Ed A
----- Original Message -----
From: "Jerry Hey" <jerryhey@earthlink.net>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
Sent: Wednesday, April 06, 2005 5:39 PM
Subject: [FlyRotary] P port runners
I made a little progress on the p port today and have the runners in
place though not finished welded. These are 21" long from the rotor
face. They are steel but the bell mouths are aluminum made by Ed
Klepeis. Eventually the bellmouths will be epoxied to the runners but
for todays photo session we went with hose and clamps. They were not
easy to make but if I had to make more, now that I have learned how, it
would not be a difficult process.
Originally, the throttle bodies had a 2 inch o.d. where they were to
butt up against the runners. The i.d. is 1.625. The sweep radius had
to be 2.5 inches so that the runners would lay low across the top of
the engine. A 3 inch R was way to high. The search for a sweep to fit
the above proved fruitless. Ed K. did find a 1.9 o.d. aluminum sweep
with a 1.61 i.d. which was close enough. However, this material was in
a very soft condition and I could not clamp it securely enough to saw
or part off, without distorting it beyond use. I am sure a real
machinist could have figured out a way, but it whipped me.
Finally I switched to a steel 1.75 o.d. x 1.625 i.d. x 2.5R which
made an excellent runner except that it did not match the throttle body
or the bell mouth. Collars had to be made to match the 1.75 to 2
inches at the throttle body and 1.75 to 1.9 at the bell mouth. These
were welded to the runner and I was nearly in business. At least on
the throttle body end I could use 2 inch i.d. hose and clamp it
together. I hoped it would work on the bell mouth but the 1.9 o.d.
was too small for the hose and I could not clamp securely. As I
said, they will be epoxied eventually.
The runners travel slightly downhill from the bell mouths. I did this
to created clearance for the Bells over the engine. Here are a couple
of photos. Next pics, hopefully, will be of the powder coated
finished product which will include the plenum, fuel rail and dual air
intakes (filtered or ram). Jerry
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