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From: Lehanover@aol.com
Message-ID: <159.47e3057f.2f0eb684@aol.com>
Date: Thu, 6 Jan 2005 10:43:00 EST
Subject: Re: [FlyRotary] Re: P-Port stuff-  was Re: RV-3 engine rebuild 
To: flyrotary@lancaironline.net
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Check out Paul Yaw's web site at www.yawpower.com and in the pictures section 
he walks through a very nice Pport construction. He is an anal retentive when 
it comes to this stuff, and his products reflect that interest in detail. 

I have made one home built set of Pport housings, and they turned out real 
nice.
I cut the ports first then formed a length of exhaust tubing using heat and 
hammer to form the rectangular end to fit the port, and then cut through the 
outer water jacket to fit the round end of the exhaust tube. I left it stick out 
about an inch to give room to use two hose clamps when connecting the 
manifold tubes.

The entire void around the tube is filled with Devcon Plastic alumunum. All 
the way to the mating surface on both sides. File and sand dead smooth. This 
makes this area very stiff. No water can get through this area once you have 
finished. There is none in the factory Pport housing either. No water = no water 
leaks. I didn't know squat at the time and just copied the factory Pport 
timing. Not a good choice for an autocross car.
The side ports in the irons are filled with Devcon Plastic Steel.

The rotor housings are far more flexible than they should be. I would not 
weld anything to them. 

Lynn E. Hanover


<< As for the actual construction, aren't most of these PP inlets just epoxied
 in place?  It just seems hard to believe that it won't leak water at some
 point if you do that.  Is the rotor housing alloy weldable?  Can the port be
 TIG welded inside and out, rather than epoxied?  
 
 Should have the RV-3 engine home this weekend, but probably not apart until
 sometime next week.  
 
 Thanks,
 Rusty  >>