Return-Path: Received: from smtpauth09.mail.atl.earthlink.net ([209.86.89.69] verified) by logan.com (CommuniGate Pro SMTP 4.3c3) with ESMTP id 881351 for flyrotary@lancaironline.net; Sun, 17 Apr 2005 20:36:48 -0400 Received-SPF: pass receiver=logan.com; client-ip=209.86.89.69; envelope-from=jerryhey@earthlink.net Received: from [65.176.136.39] (helo=earthlink.net) by smtpauth09.mail.atl.earthlink.net with asmtp (Exim 4.34) id 1DNKF4-0003kH-4T for flyrotary@lancaironline.net; Sun, 17 Apr 2005 20:35:59 -0400 DomainKey-Signature: a=rsa-sha1; q=dns; c=simple; s=test1; d=earthlink.net; h=Date:Subject:Content-Type:Mime-Version:From:To:In-Reply-To:Message-Id:X-Mailer; b=IJPXDnhi1/jf+i++mkNoROv+yFYpPLO3BccdlA2mtftfoSAgUagxqiaM3UdR3erT; Date: Sun, 17 Apr 2005 19:37:30 -0500 Subject: Re: [FlyRotary] Re: Apex Seal Groove Wear and Air Filters was Re: [FlyRotary]... Content-Type: multipart/alternative; boundary=Apple-Mail-8-185981206 Mime-Version: 1.0 (Apple Message framework v552) From: Jerry Hey To: "Rotary motors in aircraft" In-Reply-To: Message-Id: <0C469C16-AFA2-11D9-98A4-0003931B0C7A@earthlink.net> X-Mailer: Apple Mail (2.552) X-ELNK-Trace: 8104856d7830ec6b1aa676d7e74259b7b3291a7d08dfec7992bd326e509a26faf4d6fada35532f73350badd9bab72f9c350badd9bab72f9c350badd9bab72f9c X-Originating-IP: 65.176.136.39 --Apple-Mail-8-185981206 Content-Transfer-Encoding: quoted-printable Content-Type: text/plain; charset=ISO-8859-1; format=flowed Hi Ed, I did not use a hole saw. I did find a picture of someone=20 doing it with a hole saw and posted it. Maybe that is what you are=20 thinking of. You could drill the initial hole with a hole saw and=20 then finish off with a boring bar. In my case we (a machinist friend =20= and I ) made the throttle bodies first and then bored the holes to a=20 push fit. It would be a good idea to practice on a junk housing. You=20 will need a heavy angle plate to clamp the housing to. Just use a slow=20= feed. It is so easy confidence grows quickly. Gluing in the inserts=20= is no big deal either. A couple of grooves were cut in the inserts so=20= the epoxy would have a mechanical lock. If you go for the interference=20= fit, you will not have to worry about epoxy leaking through into the =20= housing. Timing: we set the timing by finding the center line of the housing=20 and then measuring from it to the center of the hole. This is easy to=20= do in the mill with digital read outs. The hole is parallel to a=20 line through the center of the housing and not perpendicular to the=20 housing. I did it this way so that 180 degree sweeps could be used. =20= By the way, you can buy 1.75 o.d./1.625 i.d. steel "combo bends" from=20= the Chassis Shop www.chassishop.com for $16.00. Two of them will do =20 your entire intake. If you want to do aluminum, you are on your own=20= as I never found exactly what I was looking for. Ed Klepeis made the=20 bell mouths and they are perfect. Jerry On Sunday, April 17, 2005, at 06:22 PM, Ed Anderson wrote: > Hey, Jerry > =A0 > I now have two turbo rotor housings that I feel free to try some PP=20 > stuff.=A0 I understand that you cut the hole with a hole saw.=A0 Did = you=20 > then clean it up with a boring bar or something similar or just ram=20 > the aluminum tube down the hole {:>)?=A0 Any prep to the hole other = than=20 > removing debris before putting the tube in it?=A0 I have your = dimensions=20 > but will await your reports on results before cutting. > =A0 > Ed A > > ----- Original Message ----- > From: Jerry Hey > To: Rotary motors in aircraft > Sent: Sunday, April 17, 2005 6:47 PM > Subject: [FlyRotary] Re: Apex Seal Groove Wear and Air Filters was Re:=20= > [FlyRotary]... > > Thomas, my set up will not produce 250 hp because I have the 2:17=20 > drive. However, I still do have some hp to play with. I could=20 > sacrifice 10 hp and still leave the airport vertically. Power Sport=20 > claims 215 hp without ram air so I should do somewhat better than=20 > that. I will consider your suggestions tomorrow when I have the engine=20= > in front of me, but at first glance they look good. Some kind of=20 > double plenum will be required, the first one supplied by ram air and=20= > housing the air filter and the second plenum feeding the bell mouths.=20= > Jerry > > > =A0 > --Apple-Mail-8-185981206 Content-Transfer-Encoding: quoted-printable Content-Type: text/enriched; charset=ISO-8859-1 Hi Ed, I did not use a hole saw. I did find a picture of someone doing it with a hole saw and posted it. Maybe that is what you are thinking of. You could drill the initial hole with a hole saw and then finish off with a boring bar. In my case we (a machinist friend=20= and I ) made the throttle bodies first and then bored the holes to a push fit. It would be a good idea to practice on a junk housing. You will need a heavy angle plate to clamp the housing to. Just use a slow feed. It is so easy confidence grows quickly. Gluing in the inserts is no big deal either. A couple of grooves were cut in the inserts so the epoxy would have a mechanical lock. If you go for the interference fit, you will not have to worry about epoxy leaking through into the housing. =20 Timing: we set the timing by finding the center line of the housing and then measuring from it to the center of the hole. This is easy to do in the mill with digital read outs. The hole is parallel to a line through the center of the housing and not perpendicular to the housing. I did it this way so that 180 degree sweeps could be used. =20= By the way, you can buy 1.75 o.d./1.625 i.d. steel "combo bends" from the Chassis Shop www.chassishop.com for $16.00. Two of them will do=20 your entire intake. If you want to do aluminum, you are on your own as I never found exactly what I was looking for. Ed Klepeis made the bell mouths and they are perfect. Jerry =20 On Sunday, April 17, 2005, at 06:22 PM, Ed Anderson wrote: ArialHey, = Jerry =A0 ArialI now have two turbo rotor housings that I feel free to try some PP stuff.=A0 I understand that you cut the hole with a hole saw.=A0 Did you then clean it up with a boring bar or something similar or just ram the aluminum tube down the hole {:>)?=A0 Any prep to the hole other than removing debris before putting the tube in it?=A0 I have your dimensions but will await your reports on results before cutting. =A0 ArialEd A ----- Original Message ----- From: 1999,1999,FFFFJerry = Hey To: 1999,1999,FFFFRotary motors in aircraft Sent: Sunday, April 17, 2005 6:47 PM Subject: [FlyRotary] Re: Apex Seal Groove Wear and Air Filters was Re: [FlyRotary]... Thomas, my set up will not produce 250 hp because I have the 2:17 drive. However, I still do have some hp to play with. I could sacrifice 10 hp and still leave the airport vertically. Power Sport claims 215 hp without ram air so I should do somewhat better than that. I will consider your suggestions tomorrow when I have the engine in front of me, but at first glance they look good. Some kind of double plenum will be required, the first one supplied by ram air and housing the air filter and the second plenum feeding the bell mouths. Jerry =A0 = --Apple-Mail-8-185981206--