Ok Paul,

Housing weld went fine. When I tried to straiten the corner, it popped
right off, was only being held by about .05? of material.

Cleaned and welded the corner on, part is in slow cool down on the hot
plate now. I will have Tammy ship it to you ups ground today.

You will need to chamfer the bottom edge of the exhaust header to clear
the weld in that area, as cutting the weld would reduce the strength of
 the weld considerably. As long as an engine mount is not used on this
corner, this housing would work fine for your plane. The quality of the
cast iron in these is good, so there should not be a strength issue at
all. Just use a little silicon on the sealing surfaces.

Larry

Thanks Larry. It looks great.
-- 
Paul Lamar ...No rotor no motor.

Wow yes that does look great, could you give a little tutorial on how you
did that ?

John Gibbons


Cast iron welding 101
1. Chamfer the edges of the break about 1/8 inch all the way around on both
halves.

2. Clean the part until you would be willing to eat with it.

3. Preheat the part to above 500 deg F (do this slowly, I use a ceramic
digital controlled hot plate that can go to 600 deg C.) This can also be
done in a house oven, just don't show your wife.

4. Welded with a Miller Tig welder set at 200 amps using NiRod filler wire.
NiRod is a filler rod made specifically to weld cast iron.

5. As soon as the welding is complete, turn the hot plate back on and slowly
cool the part over several hours.

6. DO NOT heat or cool the part quickly! This is how to make many cracks.

7. Practice killing many junk parts before you work on your good part.....

Clean it up and your  done.
Larry

Larry,
Good stuff!
BTW the newer stationary gear and rotor gears have improved tip relief as
well. The same sort of mod used in performance vehicles.

Also I recently had my RX8 rotor fly-cut to accept 3mm apex seals. Although
the depth of the material is reduced in the RX8 rotors in the apex seal area
( by about 1.5mm from memory), there is still plenty for the deeper seals.
This may be something your willing to do for builders who wish to use the
higher 10:1 compression rotors - which have the new gears as well and are
half the price of new RX7 rotors.

Just a suggestion!
George (down under)


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