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From: "Bill Bradburry" <bbradburry@bellsouth.net>
To: "'Rotary motors in aircraft'" <flyrotary@lancaironline.net>
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Subject: RE: [FlyRotary] Re: Permanent Magnet Alternators
Date: Tue, 5 Oct 2010 16:11:16 -0400
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Where do you work, Ernest??  I am available most Fridays..  :>)

Bill B

-----Original Message-----
From: Rotary motors in aircraft [mailto:flyrotary@lancaironline.net] On
Behalf Of Ernest Christley
Sent: Tuesday, October 05, 2010 9:52 AM
To: Rotary motors in aircraft
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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