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Date: Mon, 17 Mar 2008 09:35:15 -0400
From: Ernest Christley <echristley@nc.rr.com>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>,
        Dwight Frye <dfrye@cisco.com>, Robert Edwards <rob@mgcarz.com>
Subject: Porting
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Porting an engine with a drill will destroy it.

Plain and simple.  No ifs, ands or buts.  I have a die grinder, but 
nothing more than a pancake compressor so actually using it is painful.  
I could buy a larger compressor, but then I have to find someplace to 
store it.  Having everything else I need to start the porting process, I 
improvised.  Chucked the parabolic bit into my drill and had at it.

4 hours, and only one oopsie, later, I had a nicely ported intake, and a 
drill with a chuck that wobbles like a drunken sailor.  I'm talking at 
least 1/2" of play at the tip of the chuck.  Fortunately, these drills 
are cheap at Northern Tool.  I can get them for $15 when they're on 
sale.  The extra handle gives you a lot to hold onto as you're grinding 
away; hence, the single oopsie.  You hate for tools to be considered 
disposable, but in this case it worked out really well.

http://ernest.isa-geek.org/Delta/Pictures/ EnginePortingTemplate.jpg
http://ernest.isa-geek.org/Delta/Pictures/EnginePortingIntermediateHousingRear.jpg  

http://ernest.isa-geek.org/Delta/Pictures/EnginePortingRearHousing.jpg
http://ernest.isa-geek.org/Delta/Pictures/EnginePortingIntermediateHousingFront.jpg  

http://ernest.isa-geek.org/Delta/Pictures/EnginePortingRearHousing2.jpg    
     
http://ernest.isa-geek.org/Delta/Pictures/EnginePortingFrontHousingOopsie.jpg 
<http://ernest.isa-geek.org/Delta/Pictures/EnginePortingFrontHousingOopsie.jpg>