KeithB
Resident Half Fast Machinist
Here is some pictures of a couple of the air intake rings I was machining. These start out as a solid 5-1/4" piece of round stock. It gets cut into slabs, then the center gets cut out using a hole saw in the big radial arm drill. The core of the Large ring is big enough to use to make the Small ring so we use a smaller holesaw to core it out also. In effect we end up with two short pieces of tubing. Aluminum tubing is outrageously expensive, doing it our way utilizes a less expensive starting material and reduces waste because we can use the cores of the Extra Large to make the Mediums, and the cores of the Large to make the Small.
The only thing visible after assembly is the front radius and bore, which gets finished after machining with medium grit Scotchbrite pads to give a brushed metal look. The ring gets embedded in the fiberglass engine cowling that our customer makes, two rings of one size and one of a different size. Different size engine require different size rings to match the required airflow.
Small (3-1/2" OD) and Large (5-1/4" OD) air inlet rings
The front of the Small ring
The back of the Small ring.
The only thing visible after assembly is the front radius and bore, which gets finished after machining with medium grit Scotchbrite pads to give a brushed metal look. The ring gets embedded in the fiberglass engine cowling that our customer makes, two rings of one size and one of a different size. Different size engine require different size rings to match the required airflow.
Small (3-1/2" OD) and Large (5-1/4" OD) air inlet rings
The front of the Small ring
The back of the Small ring.