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From: "Ed Anderson" <eanderson@carolina.rr.com>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
References: <list-4493735@logan.com>
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Subject: Re: [FlyRotary] Re: Permanent Magnet Alternators
Date: Tue, 5 Oct 2010 10:14:13 -0400
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I was getting worry, Ernest about the "level" to which you were descending 
to produce components - I figured next you would start building an electric 
ore furnance to smart smelting your own aluminum for you casting efforts 
{:>)

Personally I think you are better off machining it out of know quality plate 
aluminum - as you have undoubted found out consistency can be difficult to 
achieve with large castings of aluminum - and therefore strength and hidden 
flaws can be of concern - particularly when used as a motor mount.

We all want you to stop goofing off and fire up that engine - its been - 
what three years or more since I flew up and blessed your engine assembly 
{:>) - and still no engine start?  Get busy, Ernest and stopped getting 
diverted by undoubtedly interesting - but time consuming side projects. 
There's way too many projects and  only so much time (and money) to build 
and airplane{:>)

Ed

Edward L. Anderson
Anderson Electronic Enterprises LLC
305 Reefton Road
Weddington, NC 28104
http://www.andersonee.com
http://www.eicommander.com


--------------------------------------------------
From: "Ernest Christley" <echristley@att.net>
Sent: Tuesday, October 05, 2010 9:51 AM
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
Subject: [FlyRotary] Re: Permanent Magnet Alternators

> Kelly Troyer wrote:
>> Todd and Ernest,
>>  Anything to report on your Permanent Magnet Alternator installations 
>> ??...............
>>
>
> I spent last Saturday trying to cast an aluminum mount for my rotor.  I'm 
> really not happy with the sheet metal mount I built.  I've been practicing 
> casting, and I've made several parts, including a couple of crank angle 
> sensor mounts (1/4" of aluminum makes for a really stiff mount).
>
> It turns out that the difficulty of metal casting is proportional to the 
> cube of the parts size.  Right now, I have a chunk of aluminum the size of 
> a one-gallon paint can stuck in my furnace.  I ran out of fuel just as the 
> last ingot was starting to melt, and after that disaster I discovered a 
> small hole had formed in my crucible and was slowly filling the bottom of 
> the furnace.
>
> That's when I decided that I would just order a 12"x12"x2" 6061-T3 
> aluminum plate and machine it.  I started down the path of a casting 
> before I bought my 12" lathe, but the machining makes more sense anyway.
>
> This is the last major part I need before moving on to an engine start, so 
> the delay kinda sucks, but at least I have a new skill.  I'm going to 
> apply it to making tap handles for the kegs that we use at work during our 
> Friday Beer Bash.
>
> --
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