X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Received: from zproxy.gmail.com ([64.233.162.207] verified) by logan.com (CommuniGate Pro SMTP 4.3.4) with ESMTP id 990856 for flyrotary@lancaironline.net; Fri, 10 Jun 2005 00:35:55 -0400 Received-SPF: pass receiver=logan.com; client-ip=64.233.162.207; envelope-from=wdleonard@gmail.com Received: by zproxy.gmail.com with SMTP id 34so297059nzf for ; Thu, 09 Jun 2005 21:35:10 -0700 (PDT) DomainKey-Signature: a=rsa-sha1; q=dns; c=nofws; s=beta; d=gmail.com; h=received:message-id:date:from:reply-to:to:subject:in-reply-to:mime-version:content-type:references; b=CpDYKKNJJE0d5Uxc9sVfN5AcUHDgyT30V1GlzRjqbweOpV7B66eKL1i1TjcQElOjDX5N0lzJHh6VVYA6fqvZJm9oi0sIHI+LO7QII70sSOiSmNvXnF6cA/Gmgz2p+EtmQHJVA5TL5FUSxRshm4BdtrlAz2FLOIlaFUZIrKqmyNo= Received: by 10.36.19.10 with SMTP id 10mr952815nzs; Thu, 09 Jun 2005 21:35:10 -0700 (PDT) Received: by 10.36.9.4 with HTTP; Thu, 9 Jun 2005 21:35:10 -0700 (PDT) Message-ID: <1c23473f05060921353babe40f@mail.gmail.com> Date: Thu, 9 Jun 2005 21:35:10 -0700 From: David Leonard Reply-To: David Leonard To: Rotary motors in aircraft Subject: Re: [FlyRotary] RX-8 Six port manifold In-Reply-To: Mime-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_Part_2933_33166383.1118378110803" References: ------=_Part_2933_33166383.1118378110803 Content-Type: text/plain; charset=ISO-8859-1 Content-Transfer-Encoding: quoted-printable Content-Disposition: inline On 6/9/05, Bill Dube wrote:=20 >=20 > I've been thinking about how to make a manifold for my six-port. Tell me > what you think of this. >=20 > I plan to chop off the stock manifold a bit past the injectors and > just before the secondary valves. (I may reconsider and cut just after th= e > secondary valves.) I plan to fly-cut that area flat and make some sort of > flange. Perhaps I'll weld on an aluminum flange. >=20 > I'll carefully measure out the position of the openings in the > truncated flange and then CAD up a manifold that will emulate the stock > manifold in the "full-power" configuration, but I will make it hug the to= p > of the engine. I plan to just CAD up the inside surface of the manifold. > Next, I'll define a "web" surface that joins all the tubes at their > midpoint. I'll then CNC machine two blocks of foam, one for the bottom an= d > then one for the top. (Split at the web.) >=20 > I'll coat the resultant foam plugs with epoxy fiberglass or > whatever to make a smooth, hard surface. Next, spray on mold release and > lay up some carbon fiber (perhaps with Kevlar) on these plugs. Once I > manage to separate the parts from the plugs, I should be able to epoxy th= e > two webs together, trim it up, and have a complete manifold. >=20 > Alternatively, I could lay up the carbon fiber / Kevlar directly > on the foam, then carve and dissolve the foam away, but I'm not sure if= =20 > the > surface finish would be acceptable. >=20 > If it works well, I can CNC a more durable mold (like aluminum) > and then make duplicates. >=20 > Bill Dube' >=20 >=20 > >> Homepage: http://www.flyrotary.com/ > >> Archive: http://lancaironline.net/lists/flyrotary/List.html >=20 Bill, That would be awesome. We really need a good manifold like that.=20 Go Bill, Go Bill Go Bill. --=20 Dave Leonard Turbo Rotary RV-6 N4VY http://members.aol.com/_ht_a/rotaryroster/index.html http://members.aol.com/vp4skydoc/index.html ------=_Part_2933_33166383.1118378110803 Content-Type: text/html; charset=ISO-8859-1 Content-Transfer-Encoding: quoted-printable Content-Disposition: inline

On 6/9/05, B= ill Dube <bdube@al.noaa.gov= > wrote:

I've been thinking about how to = make a manifold for my six-port. Tell me
what you think of this.

        I plan to chop off the stoc= k manifold a bit past the injectors and
just before the secondary valves= . (I may reconsider and cut just after the
secondary valves.)  = ;I plan to fly-cut that area flat and make some sort of
flange. Perhaps I'll weld on an aluminum flange.

  &nb= sp;     I'll carefully measure out the position of= the openings in the
truncated flange and then CAD up a manifold that wi= ll emulate the stock
manifold in the "full-power" configuratio= n, but I will make it hug the top
of the engine. I plan to just CAD up the inside surface of the manifold= .
Next, I'll define a "web" surface that joins all the tubes a= t their
midpoint. I'll then CNC machine two blocks of foam, one for the = bottom and
then one for the top. (Split at the web.)

   &nbs= p;    I'll coat the resultant foam plugs with epoxy fib= erglass or
whatever to make a smooth, hard surface.  Next, spr= ay on mold release and
lay up some carbon fiber (perhaps with Kevlar) on= these plugs. Once I
manage to separate the parts from the plugs, I should be able to epoxy = the
two webs together, trim it up, and have a complete manifold.

=         Alternatively, I could lay = up the carbon fiber / Kevlar directly
on the foam, then carve and dissolve the foam away, but I'm not sure if= the
surface finish would be acceptable.

    =     If it works well, I can CNC a more durable mold (li= ke aluminum)
and then make duplicates.

        Bill Dube'

<= br>>>  Homepage:  http://www.flyrotary.com/
>>  Archive: &= nbsp; http:/= /lancaironline.net/lists/flyrotary/List.html

Bill,

That would be awesome. We really need a good manifold like that.=

Go Bill, Go Bill Go Bill.

--
Dave Leonard
Turbo Rotary R= V-6 N4VY
http://members.aol.com/_ht_a/rotaryroster/index.html
http://members.aol.com/vp4skydoc/index.html

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