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Date: Thu, 26 Oct 2006 10:45:56 -0400
From: Ernest Christley <echristley@nc.rr.com>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] Re: Rotary Roundup
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wrjjrs@aol.com wrote:

>  Steve,
> Reaming will usually produce a better finish than boring. Carefull 
> boring CAN produce a good finish but it is much slower.
> Bill Jepson
>  

Another way to skin this cat, that most likely won't help Steve, unless 
he want to make a new rail from scratch.

Replace the cutting bit in a tube cutter with a washer or a cutting 
blade that has the edge ground off.  Use a bolt through the blade's hole 
to chuck it in a drill and run it against a grinder.  You want a nice 
rounded blade to avoid stress risers.  Run dulled cutter it around a 
1/2"x.035 tube to make an internal swage.  You can dial down to the 
perfectly sized ID.  Make another swage just a little higher on the tube 
with a diameter just a couple thousandths smaller.  The O-ring now has a 
nice trap inside of a very smooth 4130 steel tube.

-- 
         ,|"|"|,              Ernest Christley       |
----===<{{(oQo)}}>===----    Dyke Delta Builder      |
        o|  d  |o        http://ernest.isa-geek.org  |