Don Dunbar wrote:

Hello Paul,

  Well the Renesis now has a new home. The mount is complete except
  for some small modification. This is a totally new mount as I have
  stayed with the standard sump as it is very light and there is no
  sense reinventing the wheel. I have tried to leave as much standard
  Mazda as possible. The front top mount is where the alternator was
  mounted, Mazda made these so strong you would think it was taking
  the full hp output. My intake manifold is under way and will show
  this on completion. The exhaust has also started with the flange
  being cut. I will have to find a way or a square tube to fit the
  rectangular exhaust port or it will be another fab job. The standard
  manifold cost $500 AUS. The problem with this is it faces the wrong
  direction and can't be rotated as the center holes and port don't
  line up.

--
Best regards,
 Don                          mailto:ddunbar@echidna.id.au

I see you welded the rubber bushings brackets to the bell house.
Very clean and simple way of handling the problem. Looks very good.
Now that the rotary is back in production basing the PSRU on the
stock bell housing looks a lot more viable.

Just use a 180 bend tail pipe and come out of the side of the cowl like
the real P51 Mustang. It would also look like a PT6 turbo prop engine.

Paul Lamar

Don,
I love the way you simplify everything down to the most minimum
requirements.
However my advice was that injection castings have a lot of silicone to help
with flow(of the metal) into the thin walls. This silicone inhibits the
successful welding of the material.

I know you have a hell of a lot more experience in this field than me - your
dealing with it (aluminium)all the time, in a major way. I on the other
hand, am a lot more reluctant to take chances on any old local welding.
Do you suggest any special technique.
George (down under)

Hi George,
Pressure casting is not quite as good to weld with Mig but don't attempt
to weld with TIG. In the past I have welded all types of aluminium and
the worst has always's been sand castings as the silica sand impregnates
the outer skin. This is the same with all casting's more so with sand. If
it is cleaned properly and welds good it is good.
In the past we used sand cast bulbous bows on our catamarans. We had
test bars poured and tested. We then welded them to 8083 H321 plate and
then tested the tensile and to our sunrise we had a 15% increase in
the cast part of the test piece in the weld effected areas.
I have welded all sorts of motor bike parts and many structural
components in cast form and I would always's use the mig.

--
Best regards,
 ddunbar                            mailto:ddunbar@echidna.id.au

To give you an idea of the kinds of larger aluminum things Don's company welds
here are a few pictures. No not the models. .the full size boats.

Paul Lamar
 
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