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!