Have worked alot on these rotors this week. Totally 32 times on 4 rotors in the machine.

http://i815.photobucket.com/albums/z...ps8f20b7aa.jpg

I bought a bunch of new rotors. How do I comfirm that they are 9.7:1-compression?
I have weight them, but all the newer rotors have the same weight. The 28cc in the comb-chamber are kind of tricky to check, or?

Your build up is awe-inspiring!

Today I get to play with the big boys :-)

http://www.build-threads.com/category/build-threads/

This is one of the best build threads ever. Thank you for sharing this.

Havn't done much lately, but have done some with the steering, the wattlink and finally some on the intermediate-plates.

This was a LEGO i designed :)
http://i815.photobucket.com/albums/z...ps101b2b3c.jpg
http://i815.photobucket.com/albums/z...ps5ec7ccbc.jpg
http://i815.photobucket.com/albums/z...ps1a6907d6.jpg

And this is how that goes in the car.
http://i815.photobucket.com/albums/z...psa46339c2.jpg

Here the intermediate-plate is prepared for the bearing
http://i815.photobucket.com/albums/z...psbf6d2517.jpg

Just staring at that front end.
Nice work.

Amazing build. I need access to some of those tools! Just the raw material for the engine would break my budget, haha. Can't wait to hear the startup video.

take a caliper and a flat piece of metal, mic the metal and zero out the gauge. lay the strip over the pocket and measure the depth of just the pocket and it should be very close to 10.85mm in depth and have a machined relief(the deeper the pocket is, obviously the lower the compression is). this is the measured depth for the 9.7:1 rotors.

turbo rotors also have a T stamp embossed into the oil relief vein area facing the center iron, n/a rotors have no T stamp, just a I and II for front and rear(which accompany the T on turbo rotors).

that said, the quickest and easiest method is just check the oil galley in the rotor for the T stamp(or lack thereof in this case) and make sure the rotor has a machined pocket for the series 5.

if you somehow managed to get renesis rotors they're a little less conspicuous with their scallops and thick side seal lands.

Neat!

Have lately spent some time with the porting of the engine. Most in SolidWorks, but also in reality.

http://i815.photobucket.com/albums/z...pseef2faf5.jpg

http://i815.photobucket.com/albums/z...ps3a4e40a0.jpg

http://i815.photobucket.com/albums/z...psf27ed9cf.jpg

http://i815.photobucket.com/albums/z...ps8de988fa.jpg

http://i815.photobucket.com/albums/z...ps29db07db.jpg

http://i815.photobucket.com/albums/z...psbd2b4b20.jpg

Thought I run with V-band instead of what is in the renderings. However, I must turning one half of the V-band myself, and it seems difficult to find the measure of it.
If anyone has seen it, or know how they should look like, I am receptive :-) Happy to metric! The tubes I intend to use is 50x2, ie 46mm internally.

An engineering marvel! very impressive!

Continued today with the trash-housing.
Did a test sleeve in the cnc-lathe. I am very satisfied with this. Have minor improvements to do with the real ones later.

http://i815.photobucket.com/albums/z...ps069d5938.jpg
http://i815.photobucket.com/albums/z...ps7bb28e13.jpg
http://i815.photobucket.com/albums/z...psb70cb47c.jpg

agreed ... and yet still i still find the words so bloody inadequate.

I have been thinking about the intake. I would want to have tapered runners, but because "someone" decided to lower the entire body over the frame, there isn't much space above the engine.
This means that I have to make a turn on 156.5grd pretty tight around the engine and land on the block. The options are to cast runners in plastic, carbon fiber or aluminum perhaps?

Today I continued to mod my intermediate irons for more bearings.
First I layed a the intermediate and clamped it. Then either front or rear iron onto to indicate the centrum.


http://i815.photobucket.com/albums/z...ps09c355ad.jpg

Machined two new very tight dowels. As tight as possible.
Even then you can move the plate 0.015mm in both directions. I alinged in the middle of the play.

http://i815.photobucket.com/albums/z...ps2627d198.jpg
http://i815.photobucket.com/albums/z...ps841dc37b.jpg


http://i815.photobucket.com/albums/z...psf1dd4655.jpg
http://i815.photobucket.com/albums/z...ps1557250e.jpg

The build continues.
Bought standard lock rings, but couldn't let them be standard.
Grinded them from 2.5 and 3mm with friendly tolerance to 2.00mm

http://i815.photobucket.com/albums/z...ps7ebc58c9.jpg

The it was time for the grooves. Did them +0.03 to +0.05mm in height to get the right feeling. They are easy to install, and sits solid when released.

http://i815.photobucket.com/albums/z...ps2d109a61.jpg
http://i815.photobucket.com/albums/z...ps4c11ad91.jpg
http://i815.photobucket.com/albums/z...psf479b4dc.jpg

Have modified an old front bearing for test.
http://i815.photobucket.com/albums/z...psmff4dxtp.jpg

A keyway as well.
http://i815.photobucket.com/albums/z...ps3kqu4mhb.jpg

First of all I'm very proud to annouce this link :)

http://www.build-threads.com/general...uilds-of-2013/

Back on topic.
Builded some new benches to work on, and then started to assembly the dummy again to put back in the car for some measurements.

http://i815.photobucket.com/albums/z...psedv4lubw.jpg
http://i815.photobucket.com/albums/z...ps3eg3dcbm.jpg
http://i815.photobucket.com/albums/z...psrb9gpxzy.jpg



Tonight I was out on the highway and meet a friendly truckdriver from Czech Republic. He had brought a 20B flexplate from hIGGI on the Rx7Club-forum. Thanks alot for that hIGGi!

http://i815.photobucket.com/albums/z...ps1dy1mdgw.jpg

Also got some V-band-clamps today. Perfect size. Small and tight, just like we want them.

http://i815.photobucket.com/albums/z...pssii2bnt5.jpg
http://i815.photobucket.com/albums/z...psvhzyo2rz.jpg

V-band might have vacuum leaks.

Nothing a recessed O'ring grove machined into the face with small O section O ring will not fix :hurray:
Easy solution did very similar on multiple similar joins in a physics lab when I was machinist there ;)

Notice that this is just a test-housing. The port insert are in steel in this one just to get the shape.

When satisfied, its going to be aluminium with o-rings :-)

Tegheim seriously 1 of the best threads ever!

I just read this whole thread from the beginning...all I can say is WOW!!! The thought and work going into this is incredible!

Not much is happening at the moment.

I shortened my steering rack at last. Cut 220mm of an let 200mm be left.

http://i815.photobucket.com/albums/z...pstlz5jltb.jpg

http://i815.photobucket.com/albums/z...pswkxtfpzt.jpg

http://i815.photobucket.com/albums/z...pssc78mnvv.jpg

http://i815.photobucket.com/albums/z...psg5vpzwdk.jpg

http://i815.photobucket.com/albums/z...psrtf6yiob.jpg

http://i815.photobucket.com/albums/z...psp3kljrne.jpg

http://i815.photobucket.com/albums/z...psvoir8yit.jpg

http://i815.photobucket.com/albums/z...psncvh8pca.jpg

http://i815.photobucket.com/albums/z...ps3wrozpxl.jpg




Took some M24-nuts and machined out the threads. Then put them over my 4-link rods for adjustments later on. Just a little work with the TIG, and they are ready for some paint.

http://i815.photobucket.com/albums/z...psneykjszn.jpg




Are going with these 15.99mm solid dowels straight through the engine. Better off than the OEM.

http://i815.photobucket.com/albums/z...ps0eipgunt.jpg

Bought some Ø10.0mm Chromemoly 4340-bars.
Cut them in correct lenght and cnc-turned M10x1 thread in both ends.
I use Grade 10-nuts and harderned washers to hold the engine in place.

http://i815.photobucket.com/albums/z...psvwlrj57y.jpg

http://i815.photobucket.com/albums/z...psmuuw7r2h.jpg

http://i815.photobucket.com/albums/z...psloahauuf.jpg

http://i815.photobucket.com/albums/z...psy5durtxe.jpg

Todays work was the peripheralport-sleeves.
Cut some Ø80mm alu and threaded them M65x2.



http://i815.photobucket.com/albums/z...ps4w2dnngw.jpg



http://i815.photobucket.com/albums/z...psezw7e12t.jpg



http://i815.photobucket.com/albums/z...psjamrjjcy.jpg



http://i815.photobucket.com/albums/z...psm4vfucdx.jpg



http://i815.photobucket.com/albums/z...pshm3outra.jpg



Next step is to machine the rotorhousings.

:o16:

Moment of truth, or point of no return for these housings...

http://i815.photobucket.com/albums/z...psdjppmt0m.jpg


The original "oil-nozzle" must be removed before milling or else my tool, or my housing will be broken.

http://i815.photobucket.com/albums/z...psrhrit5pr.jpg


Started with a M10-bolt and drilled a Ø4.2mm hole to allign the drill.
Threaded M5, and pulled it out with some washers and a M5-bolt.

http://i815.photobucket.com/albums/z...psa9zw6k7l.jpg
http://i815.photobucket.com/albums/z...psh62bcrn2.jpg
http://i815.photobucket.com/albums/z...psijncmurh.jpg


Machined a Ø63mm hole for the thread, and then removed all stuff the pointed out form the housing.

http://i815.photobucket.com/albums/z...psespnxl0k.jpg
http://i815.photobucket.com/albums/z...psrqejzihw.jpg


All done. Next step is the inserts!

http://i815.photobucket.com/albums/z...ps2ryiichx.jpg

Yesterday I continued with my Peripheral-inserts.
Because they are threaded into the housings there is imported to get the D-shape in the right angle to align with the pre-machined D-shape in the housings.
The D-shape closest to the housing are bigger than the round hole and the runners, so therefore I need to machine this with the inserts on the side.

I could have done a round hole in the center, and port the sleeves by hand. But I'm really not a "handyman" :) And CNC-port are in my opinion the coolest.

It worked out pretty well! I was really nervous when I mounted the first insert...

I very satisfied.

Next is to deside how to couple the inserts with the runners, and also how my runners will look like, size and lenght. Butterfly-throttles or slides.


http://i815.photobucket.com/albums/z...pspqmo0fsj.jpg

http://i815.photobucket.com/albums/z...psndvduva6.jpg

http://i815.photobucket.com/albums/z...pse37qcrlb.jpg

Rotar Cave!

Nice.

Also. Im sure you know what your doing but id like to remind you to check the clearance between the flywheel and the engine studs.

Just because it's quiet, doesn't mean it's dead :)

My old teacher called, he had found my website, and wanted to show his friends my build in person. Really fun! Cleaned up and made some coffee.

http://i815.photobucket.com/albums/z...ps9865baa1.jpg
http://i815.photobucket.com/albums/z...psa9e743b0.jpg

Have been thinking about the intake, and have some ideas of how it will be.

I want thin throttlebodys with no injectors, and also buttefly model.
Something like this...

http://i815.photobucket.com/albums/z...ps9382488d.jpg

Started on a prototype of aluminium...

http://i815.photobucket.com/albums/z...ps5dcd7956.jpg


The P-Port-inserts will have V-band to connect the runners, but I wanted a personal touch also.

http://i815.photobucket.com/albums/z...psjbj9gqjl.png

http://i815.photobucket.com/albums/z...psok2ujnvn.jpg

This is how the billet stainless v-band-clamps turned out today. Really happy with them.

http://i815.photobucket.com/albums/z...ps9dviskq5.jpg

All good things are four :-)

http://i815.photobucket.com/albums/z...psc3btr7dq.jpg


http://i815.photobucket.com/albums/z...pswwda1iq8.jpg





Yesterday I got some mandrels from www.mandrel-bends.com for the intake-

2" 16GA with tight CLR.

Today I did the V-band-flanges for the runners. With a groove to stay concentric and also a little groove on the other side to fix the pipe in. Only 2mm deep, but tight, so it holds there when trying out the parts. Easier to weld also.

http://i815.photobucket.com/albums/z...psqk3idhpi.jpg
http://i815.photobucket.com/albums/z...pscfmlo2jw.jpg
http://i815.photobucket.com/albums/z...psensjpkdd.jpg

http://i815.photobucket.com/albums/z...pskjcrwc9l.jpg

http://i815.photobucket.com/albums/z...psjofheor2.jpg

http://i815.photobucket.com/albums/z...psezwih1yc.jpg

http://i815.photobucket.com/albums/z...psoflvalbr.jpg

http://i815.photobucket.com/albums/z...ps92mdeofz.jpg

http://i815.photobucket.com/albums/z...ps5s2jxzym.jpg

Moar!:drool5:

Got up early today again. Lovely to start the day with some Engine-stuff... :)

http://i815.photobucket.com/albums/z...psbxwqkwpa.jpg

http://i815.photobucket.com/albums/z...ps1ihvw4kg.jpg

http://i815.photobucket.com/albums/z...ps9vo5iedi.jpg

http://i815.photobucket.com/albums/z...pswewwltrl.jpg

http://i815.photobucket.com/albums/z...psl7u33gp5.jpg

http://i815.photobucket.com/albums/z...pswpsw8qqp.jpg

http://i815.photobucket.com/albums/z...pscbr0fc0e.jpg

Please sir may I have another!

We need an update!

Long time no see, have done some small updates now and then on both Facebook and Instagram. I'm sorry, but it's so easy to throw in a picture and move on.

Lets do a throwback sunday.

I did a little test with my front fender. My wheels are to big, and the body is so much lower that I can't mount the fenders over the wheels today.
I let it sit there and sink in. The rear wheelarc will be a big challenge as well..
http://i815.photobucket.com/albums/z...ps7cc81736.jpg
http://i815.photobucket.com/albums/z...ps5f81ffa1.jpg

Then I moved on with the watt-link. Did some sheetmetal-parts in Solidworks.
http://i815.photobucket.com/albums/z...ps47960877.png

A friend of mine helped me with the lasercut and bending. Will be nice!
http://i815.photobucket.com/albums/z...ps130679c0.jpg
http://i815.photobucket.com/albums/z...pse6c74fa6.jpg

Back to the 4-rotor...

I havn't done much, but some small thing here and there.
Have done the first part of my new centerbearings.
http://i815.photobucket.com/albums/z...psxps85hai.jpg
http://i815.photobucket.com/albums/z...ps1gigqafj.jpg

The toleranses are tight! Need to demount to get all oil-windows in place.
http://i815.photobucket.com/albums/z...psgnq3fznx.jpg

Have also prepared the irons.
http://i815.photobucket.com/albums/z...psikg84dwf.jpg

Then I went through my rotors, and picked out these four. Close call without any mods yet. Only 20grams away.
http://i815.photobucket.com/albums/z...psgs5rkpb4.jpg

After some ultrasonicwashing. This is the rotor on the far left on the picture above.
http://i815.photobucket.com/albums/z...psryuawy7y.jpg

After a few seconds with a scotchbritepad by hand.
http://i815.photobucket.com/albums/z...psuxzr9y5p.jpg

Have bought two AutoVerdi-drysump-pumps.
One will GusFD3s use on his Rx3-20B, and the other will I keep.
http://i815.photobucket.com/albums/z...psyjgyidem.jpg

Sketched up the pump to get it into my assemblies in Solidworks
http://i815.photobucket.com/albums/z...psyw7rxfxm.jpg
http://i815.photobucket.com/albums/z...psnq4q5rwn.jpg

Started on the drysumppan and front cover that will be some billet-kind.
http://i815.photobucket.com/albums/z...pscbkrijin.jpg

Havn't desided if the pan will be billet or sheetmetal, the sheetmetal have some advantage, but billet is engine-porn :-)
Did a test with wellpapp of the sheetmetal-version.
Very tight and small, easy to fit AN-12 into.
http://i815.photobucket.com/albums/z...psx2fasen7.jpg

So, not much has happened, but still going in the right direction.

Can remind you of the facebook-page and instagram if you want instant updates without text :-)
But I'm trying to get better on updates here as well.

http://www.instagram.com/tegheim83
http://www.facebook.com/moosevilleperformance

Have you thought about getting two more front fenders, and stealing the wheel arches from those, to install in the back so that the arches match? The wheel openings on those cars were too small, it made the car look unbalanced and top heavy. Yours is a big improvement.

... but we love your descriptions of the toil and turmoil. :lol: