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Date: Thu, 30 Jun 2005 09:13:12 -0400
From: Ernest Christley <echristley@nc.rr.com>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] Machining help needed
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Jerry Hey wrote:

> I need to find someone to finish the bores on my injector bosses or 
> tell me how to do it.   Final i.d.should be .540 to .545 in.    The 
> bosses are .45 in high and are bored and reamed to .5312.  Material is 
> 6061.   I tried using a boring bar but could not maintain the 
> tolerances.  I bought adjustable hand reamers but they were not the 
> right tool for the job.  I considered trying to sand the bore to the 
> correct size using a flapper but have not tried it  yet.  
> Suggestions?  Volunteers?     Jerry  
>
>

1) Chuck the adjustable hand reamer in the lathe.  Just run it slow.  I 
have a 1" adjustable that I had to turn the end down on so that I could 
do this to true up the inside of some tubes.

2) Start with a short piece of 5/8"x.035 tube.  Take the blade out of a 
plumber's cutting tool and replace it with something blunt.  Use it just 
like a cutter to make internal ridges.  You can run just one ridge and 
seal it with clamping pressure, or you can run two ridges and then 
scream like a banshee when you want to get the &$%^ injector back out.

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