Mailing List flyrotary@lancaironline.net Message #41942
From: Ernest Christley <echristley@nc.rr.com>
Subject: Gatorade make a nice intake manifold
Date: Fri, 14 Mar 2008 09:51:04 -0400
To: Rotary motors in aircraft <flyrotary@lancaironline.net>
I cut up the stock manifold to get the mounting flange and the injector hardware.  The injector bosses themselves are pieces of 3/4"x.058" 4130 tube with a 5/8" washer welded to the bottom.

I drilled several holes in the flange around the runners and countersunk the engine side.  I then ran several strips of fiberglass tape through the holes and up the length of the runner.  Flox mixed with the balled up tip of the tape serve as an extra anchor.

The BMW throttle body is mounted on a .050" stainless steel plate with a fiber reinforced rubber mat for sealing.  The mat squeezes and holds the bolts so that I can tighten them and install the cotter pins.

I left a hole around the neck of the bottle in my initial layup.  Pulled the mold out through that then sealed it with another layup.  The hardest part of the mold to remove was the 3/4" nylon tubing that I used for the center runners.  I had to twist them with needle-nose pliers, then spray water between the tube and the runner wall.  Once I got water all the way through, it slipped out fairly easily.

http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifold1.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifold4.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifold6.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifold7.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifold8.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifold9.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifoldA.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifoldComplete1.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifoldComplete2.jpg
http://ernest.isa-geek.org/Delta/Pictures/EngineIntakeManifoldComplete3.jpg

Time-Warner limits my upstream bandwidth to 50kbps.  If everyone hits the site at once, it will be really slow.
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