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Return-Path: <13brv3@bellsouth.net> Received: from imf20aec.mail.bellsouth.net ([205.152.59.68] verified) by logan.com (CommuniGate Pro SMTP 4.1.4) with ESMTP id 2605363 for flyrotary@lancaironline.net; Fri, 26 Sep 2003 17:21:54 -0400 Received: from rad ([68.212.13.204]) by imf20aec.mail.bellsouth.net (InterMail vM.5.01.05.27 201-253-122-126-127-20021220) with ESMTP id <20030926212152.EGXA1781.imf20aec.mail.bellsouth.net@rad> for ; Fri, 26 Sep 2003 17:21:52 -0400 From: "Russell Duffy" <13brv3@bellsouth.net> To: "'Rotary motors in aircraft'" Subject: RE: [FlyRotary] Re: aluminum intake tubing? Date: Fri, 26 Sep 2003 16:21:53 -0500 Message-ID: <000f01c38474$353e6460$0201a8c0@rad> MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_0010_01C3844A.4C685C60" X-Priority: 3 (Normal) X-MSMail-Priority: Normal X-Mailer: Microsoft Outlook, Build 10.0.4510 Importance: Normal X-MimeOLE: Produced By Microsoft MimeOLE V6.00.2800.1165 In-Reply-To: This is a multi-part message in MIME format. ------=_NextPart_000_0010_01C3844A.4C685C60 Content-Type: text/plain; charset="us-ascii" Content-Transfer-Encoding: quoted-printable If you order from Burns and bent tubing, you will get it in the "O" condition or a slightly harder condition due to the cold work hardening = from bending. I found that heating them at 500F for 8 hours seems to harden = them a bit - they don't ding as easily as the "O" condition.=20 =20 I'm guessing this is something you have to do when your wife isn't home = :-)=20 =20 For intake runners, I generally use 1 3/8" OD 0.058 or .065 wall = thickness for the primary. I use 1 5/8" OD same wall thickness for secondaries. = I have used from 1 1/4" to 1 3/4" but I think the other diameters are = about optimum. =20 =20 What would you guess for a size when using only two runners from intake = to the TB? I was planning to match the size of the TB throats as much as possible, which will make the pipes about 2-1/8" ID. By coincidence, = that works out to almost exactly the same area as your two pipes combined. =20 =20 You can get the Burn's lengths and then added to the lenght. You can = do it by adding a short length (2"?) of the next larger diameter size as a = coupler so that both ends fit inside. However, its difficult to find a welder = that can weld thin tubing. I have had good success with brazing the thin = wall stuff.=20 =20 Finding a welder in my house that can do anything useful is a challenge. All I've managed to do with the new TIG machine is give myself a good sunburn. I was going to practice on some aluminum today, but found that just about all I have is 2024, which is effectively un-weldable. =20 =20 You can get pipe bends (Elbows) from RBWagner schedule 40 which has = walls of approx 0.12 ". It is much heavier but you can use it just for the bend = and then stick in straight light weight tubes from most of your runner = lenght.=20 =20 A dandy idea! More welding though. =20 =20 Just a few options. Me, I am currently making the mold for another = plastic intake part. This time it will be for the lower part of the intake, so = I can use inexpensive straight tubing with the bend in the plastic casting rather than keep paying for expensive pre-bent tubing. =20 So are you making these plastic parts strong enough to hold 10 psi when = you add the turbo :-) =20 Has anyone considered using really heavy hose for the runners, rather = than something ridged like aluminum, or fiberglass? It would have to be fuel resistant of course, which rules out silicone I believe. I'll have to = hit McMasters for 2" Viton hose :-) =20 Thanks for the info. =20 Cheers, Rusty =20 ------=_NextPart_000_0010_01C3844A.4C685C60 Content-Type: text/html; charset="us-ascii" Content-Transfer-Encoding: quoted-printable Message

If you order from = Burns and bent=20 tubing, you will get it in the "O" condition or a slightly harder = condition due=20 to the cold work hardening from bending. I found that heating them = at 500F=20 for 8 hours seems to harden them a bit - they don't ding as easily as = the "O"=20 condition.

I'm guessing this is something you have to do = when your=20 wife isn't home :-)

For intake runners, I generally = use 1 3/8" OD=20 0.058 or .065 wall thickness for the primary. I use 1 5/8" = OD same=20 wall thickness for secondaries. I have used from 1 1/4" to 1 = 3/4"=20 but I think the other diameters are about optimum.

What=20 would you guess for a size when using only two runners from intake = to the=20 TB? I was planning to match the size of the TB throats = as much=20 as possible, which will make the pipes about 2-1/8" ID. By=20 coincidence, that works out to almost exactly the same area as = your two=20 pipes combined.

You can get the Burn's lengths = and then=20 added to the lenght. You can do it by adding a short length (2"?) = of the=20 next larger diameter size as a coupler so that both ends fit = inside. =20 However, its difficult to find a welder that can weld thin tubing. = I have=20 had good success with brazing the thin wall stuff.

Finding a welder in my house that can do = anything useful is=20 a challenge. All I've managed to do with the new TIG machine is = give=20 myself a good sunburn. I was going to practice on some aluminum = today, but=20 found that just about all I have is 2024, which is effectively=20 un-weldable.

You can get pipe bends=20 (Elbows) from RBWagner schedule 40 which has walls of approx 0.12 = ". =20 It is much heavier but you can use it just for the bend and then stick = in=20 straight light weight tubes from most of your runner lenght.

A dandy idea! More welding = though. =20

Just a few options. Me, I am = currently making=20 the mold for another plastic intake part. This time it will be for = the=20 lower part of the intake, so I can use inexpensive straight tubing with = the bend=20 in the plastic casting rather than keep paying for expensive pre-bent=20 tubing.

So are you=20 making these plastic parts strong enough to hold 10 psi when you add the = turbo=20 :-)

Has anyone=20 considered using really heavy hose for the runners, rather than = something ridged=20 like aluminum, or fiberglass? It would have to be fuel resistant = of=20 course, which rules out silicone I believe. I'll have to hit = McMasters for=20 2" Viton hose :-)

Thanks for=20 the info.

Cheers,

Rusty

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