Ed Anderson wrote:

Hi Paul,

    Here's a few photo of latest progress on new intake system.  A minor set
back in that this was suppose to be the plastic plenum/throttle body
mount/injector bosses.  However, due to a little chemical process called
exothermal (you fiberglass guys know all about this I'm told) produced
bubbles in the plastic resin, so the casting is not usable - expect to make
a better mold and cast another one.

The front side will of course have holes cut to the tubes form the throttle
body and also throttle body mounting holes/studs.  The back side with the
ledge will have four fuel injection holes drilled (one for each runner) and
the fuel injectors and fuel rail mounted back there.  It will all set on the
pipes as seen (and No, I haven't yet cut the pipes to length{:>) ). There
will be a metal plate (shown but not cut to final size) that will hold the
pipes and plenum together by bolting the plate onto the bottom of the
casting.  I might just run a metal strap around the top and to the metal
plate on each side just to be safe.  A step size in the runner holes will
except an "O" ring around each tube and against the casting tube wall to
provide an air seal.

But, it looks like it will  weigh less than half of my old manifold system,
a lot cleaner and the fuel injectors away from the exhaust.  Waiting for
more resin to pour the second casting - we know about those things, don't we
{:>)  One of the photos Mvc-009.jpg shows the bubbles caused by the
exothermal reaction.

 Also, the casting does not look smooth yet, because I have some bondo type
filler stuff on it that I will sand down to a hopefully glass smooth
surface.  Also about 1" (or more) of the top of the throttle body flat plate
mounting area will come off.

Hopefully, I will have it completed this week and be flying with it within
another week.

Best Regards

Ed Anderson
Matthews, NC
RV-6A N494BW
eanderson@carolina.rr.com

Very very interesting Ed. 

Paul Lamar
 
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