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2019 in the workshop
 

2022 Exhaust header

22 September, 2022 - Machining the exhaust header One of the problems I've had over the years results from adding right and down thrust to the engine. &nbsp; When using a tuned pipe, these offsets throw the header out of alignment. <div style="Font-size:5.0pt" 22 September, 2022 - Machining the exhaust header Up until now, I've had to live with it. I've tried filing the header to correct the misalignment but this never worked for me. Since I have the equipment now, I decide to machine the offsets accurately on the mill. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I decide to use my 80th birthday indexing head to hold the header securely while I machine the surface. Here, I bring a .002" feeler gauge to rest against the low side. Notice the angle of the indexing head compared with the channels in the bed. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header Measuring the location of the left side at .002" to machine the header in the horizontal plane. This is an old header that I don't intend to use. <div style="Font-size:5.0pt"
07 November, 2022 - Machining the exhaust header I then measure the other side and it is about .020". This is just a guess it but seems to be less than necessary. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I set the indexing head to remove the misalignment in the vertical plane caused by adding down thrust to the engine. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header The 16mm spanner unlocks the indexing head itself so that I can add a few degrees to the vertical plane. The 10mm spanner unlocks the head to the bed so that I can adjust the horizontal plane. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header The tubing tends to crush and the header moves out of alignment. <div style="Font-size:5.0pt"
07 November, 2022 - Machining the exhaust header I re-secure the header and take a couple of light passes. Aligning the header in the chuck is quite easy as the bottom of the port shows if the mill is cutting square to the header. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I fit the newly machined header back onto the engine and fit the assembly back in the fuselage. It is almost properly aligned but I've dented the 19mm tubing. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I need to make a sleeve to properly support the header in the chuck of the indexing head so I get a piece of 25mm alloy and bore a 19mm hole in it. The header is a very nice fit in the bore. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I need to cut a slot in the 19mm I.D. sleeve so that it will compress slightly in the jaws of the chuck. &nbsp; Back in the mill, I drill a series of 5/64" holes 2mm apart. <div style="Font-size:5.0pt"
07 November, 2022 - Machining the exhaust header Then I clean out the slot with a 2.5mm end mill. I hold the end mill in a collet chuck to make sure that the end mill doesn't wander around. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I then take it back to the lathe and slice off the sleeve. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I fit the sleeve to another header which now holds it securely in the jaws of the chuck. <div style="Font-size:5.0pt" 07 November, 2022 - Machining the exhaust header I also add a little extra to the angle of the indexing head. The angle is qite obvious now. I measure these distances and lose the piece of paper on which I write them. <div style="Font-size:5.0pt"
07 November, 2022 - Machining the exhaust header The finished machining shows a bit of chatter. These marks sand out quite well with a piece of emery paper against a steel plate. End of this project &nbsp; Click to go to home page <div style="Font-size:5.0pt"    
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