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From: "Jack Ford" <jackoford@theofficenet.com>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>,
	"kevin lane" <n3773@comcast.net>
References: <list-767624@logan.com>
Subject: Re: [FlyRotary] hand router milling
Date: Wed, 2 Mar 2005 19:15:29 -0800
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Thank you sir.

Jack Ford


----- Original Message ----- 
From: "kevin lane" <n3773@comcast.net>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
Sent: Wednesday, March 02, 2005 5:37 PM
Subject: [FlyRotary] hand router milling


> a regular carbide bit for wood cuts well.  the secret is to get the larger
> diameter bit , otherwise they constantly clog up.  I believe I used one
that
> cut like 1" dia.  The 1/2" bits for like mortising hinges won't work.
Also,
> cut in the direction that the bit wants to travel and it is easier to take
a
> small amount with each pass.  For the wells that I routered, I cut them
down
> to the full depth, but remained maybe 1/8 to 1/4" inside my lines.  Then I
> worked to the finish cut line at full depth.   WEAR GLASSES!  What? Huh?
Oh
> yes, and ear protection!  I machined the 1/2" plate to shape on the
outside
> similarly after cutting it close first with a bandsaw with like a 6
> tooth/inch blade.  The engine mount plate took a good chunk of a Saturday
to
> make, but they run $500 to buy.  The plate ran $75.  I used the oil pan as
a
> template for the bolt holes.  My first engine mount plate I made these
wood
> templates, which was a bunch of work and not that necessary.  We're
building
> 1 airplane, right? (no, you couldn't afford me to make you one too! :-)  I
> did use a mill to cut the engine mount pockets.  We had started to use the
> mill to make all of the plate and decided I could do it by hand much
faster.
> Kevin Lane  Portland, OR
> e-mail-> n3773@comcast.net
> web-> http://home.comcast.net/~n3773
> (browse w/ internet explorer)
> ----- Original Message ----- 
> From: "Jack Ford" <jackoford@theofficenet.com>
> To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
> Sent: Wednesday, March 02, 2005 2:24 PM
> Subject: [FlyRotary] Re: 20B exhaust (so far)
>
>
> > Hey Kevin,
> >
> > What kind of bit are you using in that router? How deep can you cut
> > (Aluninum, I assume)?
> >
> > Sounds like a poor man's end mill.
> >
> > Jack Ford
> >
> >
> > ----- Original Message ----- 
> > From: "kevin lane" <n3773@comcast.net>
> > To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
> > Sent: Wednesday, March 02, 2005 1:56 PM
> > Subject: [FlyRotary] Re: 20B exhaust (so far)
> >
> >
> >> Todd - my first engine mounting plate had the exhaust even closer.  I
> >> bite
> >> the bullet and fabricated another one which moved the block forward
3/4",
> >> which also solved a water pump/fire wall clearance problem and the
> >> starter
> >> nose clearance too. I am getting pretty good at freehanding a router to
> >> machine the plates.  I even have pockets up front routered out for
weight
> >> savings, all done free hand (just go 1/16th" at a time, and keep your
> > mouth
> >> closed! chips go everywhere).
> >>     Thanks for the info.  I have some welding curtain material I use
for
> >> protection which seems to work well.  I wrapped my Lycoming starter in
it
> >> since a cross over pipe comes close.
> >> Kevin Lane  Portland, OR
> >> e-mail-> n3773@comcast.net
> >> web-> http://home.comcast.net/~n3773
> >> (browse w/ internet explorer)
> >> ----- Original Message ----- 
> >> From: "Bartrim, Todd" <Steve.Bartrim@canfor.com>
> >> To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
> >> Sent: Wednesday, March 02, 2005 11:58 AM
> >> Subject: [FlyRotary] Re: 20B exhaust (so far)
> >>
> >>
> >> Hi Kevin;
> >> My exhaust didn't work out exactly as I'd envisioned it and as a
> >> result the pipe is almost touching 2 of my mount struts where it passes
> >> between them. I was quite concerned about heat damaging the mount, so I
> >> kept a very close eye on this area. However it really hasn't been an
> >> issue. The paint on the mount hasn't discoloured at all so I haven't
> >> been too concerned, however I still check it often. When I first
> >> received the EM2, I attached one of my spare CHT thermocouples to the
> >> mount to monitor it and while I can't recall the temp, I know it was
low
> >> enough that I stopped worrying about it. I should've logged it.
> >>
> >> Todd
> >>
> >>
> >>
> >> this is a good point and I admit to have not thought it through yet.  I
> >> have made two engine mount plates so far because the first one had the
> >> exhaust almost touching the exhaust, maybe 1/8" clearance.  I will have
> >> to come up with some type of shield however.  I hope, also, to
introduce
> >> some fresh air flow over them also.
> >> Kevin Lane  Portland, OR
> >>
> >> >
> >> > I'm curious if you're planning some kind of heat shield for that
mount
> >>
> >> > strut that runs between the exhaust pipes... or maybe several layers
> >> of
> >> > exhaust tape... something to keep some of that heat away anyhow?
> >> Looks
> >> > scary to me, especially when you consider that those exhaust tubes
> >> will
> >> > likely be glowing red at full throttle.  Just a thought.
> >> >
> >> >  <Marv>
> >>
> >>
> >> >>  Homepage:  http://www.flyrotary.com/
> >> >>  Archive:   http://lancaironline.net/lists/flyrotary/List.html
> >>
> >>
> >> >>  Homepage:  http://www.flyrotary.com/
> >> >>  Archive:   http://lancaironline.net/lists/flyrotary/List.html
> >>
> >
> >
> >>>  Homepage:  http://www.flyrotary.com/
> >>>  Archive:   http://lancaironline.net/lists/flyrotary/List.html
>
>
> >>  Homepage:  http://www.flyrotary.com/
> >>  Archive:   http://lancaironline.net/lists/flyrotary/List.html
>