Hello  Paul,

Here are four pictures of P-port and the in-housing  injection holders.
This housing is one of several scrap housings I am  machining to get the
entrance angle and component dimensions finalized.  These four pictures
are from last August's work and don't show the finished  bores yet.
The P-port will have an outer step bore similar to the injector  holders.
I am extremely happy with the hardness and toughness of the DEVCON  Al
product.  Only one trouble is the consistency is a little softer  than
taffy so as you can see, it is easy to end up with inclusions.   If you
work fast and use a technique like applying frosting on a cake,  then
good results can be obtained.  Any hole can be drilled out and  filled.
The company sells another slightly softer epoxy that pours.  I  assume it
has more solvent in it.

I was very happy with how the  injector area worked out and was able to
get the correct and final  dimensions with this one housing.  As for the
P-port area I had to add  about 6mm more along the bottom for the slide
throttle to be supported  correctly.  For this test work, adding epoxy is
not a problem as it  sticks to a preexisting epoxy when roughened up a
bit.  As you can see  it sticks well to prepared alumunim and is damm
near as hard.  It  machines VERY nice.

Can it done with your straight-in  approach?   Yes why not?  Bend up some
thin aluminum sheet  into the proper wedge profile.  Alodize it. Fix this
fence in place  with hot glue gun on the outside.  Epoxy should be made
extra high and  milled down to final dimensions. To save expensive epoxy
add a 40mm wooden  or plastic dowel in the area where the inlet will be
bored.   DO  NOT PREHEAT to make it easier to pour.  Follow the
directions for best  results.

Doug in Japan

That 12.5 degree tilt looks like a real  mechanical advantage.
I hope you can find a dyno over there to get some  good numbers
on the pros and cons of your version. BSFC and  HP.

Paul Lamar

This is the best idea I have seen in some time. Alternatively one injector
here and another in the runner further from the port.
But if this works, look at the much reduced fuel delivery pieces required.

After the doubts about Devcon Plastic aluminum, I used to build Power
Products 6.10 Cubic inch Kart engines. The side of the case
opposite the exhaust port was cut away and 6 bypass ports were drilled
through the cylinder at the same level as the stock side ports.
Childs modeling clay was rolled into passage molds and inserted into the
ports, and a dam was built around the area in cardboard,
held in place by additional clay. The bypass area was poured full of
Devcon. Once cured, the clay was flushed away in a cleaning tank.
The mirror smooth bypass ports put us ahead of the McCullough engined
Karts. Never a failure in the Devcon.

Lynn E. Hanover