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The O ring is in the tightest part of the intake. Just past the floor drops away and the outer walls disapear into a big cavity. It has to kill velocity. The extra intakes I cut bypass the tight spot and add 25% of area. |
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Going into this project before I had it apart I knew cutting the transfer exits accurately would be one of the biggest challenges. I do a lot of 3 and 4 axis programing and machining with and without cadcam so I have a good idea of how to cut things to specifications. In the end I made a primative tool that works so well I can't believe its not common knowledge. I put two 3/16" holes through a 1/2" bar one 0 degrees for the main transfers and one at 30 degrees for the secondarys. It has set screws in the side to hold short pieces of round file. It works best if you pull to cut. Also grind the end square and sharp to shape the corners in the ducts. Its slow and tedious but makes it not just easy but the only way possible for me to cut full size corner to corner at the right angle or direction transfer exits. I have a fixture to hold the cylinders verticle in a vise. Spent weeks there.
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Another direction to approach the front secondary wall to blend it in. |
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I heated and bent a square coarse file to help blend around corners. The outer radius of the file is smaller than the smallest port outer corner and the inside radius is bigger than the biggest port inner corner. These move a lot of metal and its easy to take high spots off making long smooth corners in the ducts.
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I only raised the transfers enough to make them the same. I used jb weld to fill the low spots. |
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The file handle is flat against the main transfer outer wall up to the mark. It shows theres plenty of meat inside to cut and make a big arch the only problem is the cases are so thin you can't cut into them to get that big arch. Anybody know more about this?
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I like this better. I will make the radius on the blow hole larger. |
