I am going to try Doug's idea of putting epoxy on the outside
  to make a flat area for an O-ring outer seal. If it leaks
  in the future it can be more easily repaired. I'll buy the high
  price liquid aluminum Devcon product but I am willing to bet it
  is no better than JB Weld. I'll heat one puck of JB Weld and another
  of DEVCON in the oven at 500 F and see what happens. My money is
  on the JB Weld :)


  The welded SS tube to the liner will be retained.

  Paul Lamar
  --

  Paul,


  OK but that may not tell you much as in application if your intake port
  gets up to 500 degrees I think your engine will have bigger problems:)
  I take it you are concerned with thermal soak after the engine is shut
  down?  This could be a problem with an unshielded exhaust system nearby.
    I would be more concerned with comparing the compressive
  strength,hardness, thermal creep characteristic, and toughness.

  Are you going to retain the straight-in approach?  If so  the upper
wedge
  of epoxy will be about 15mm high.  I suggest you put a metal dam there.
  Best is a three side dam that conforms to the housing.  This was the
  next experiment I was going to try.  It can be one piece stainless that
  is bent.  Done properly it will look nice as well and of course can be
  milled as well.

  Doug in Japan

  Yes. I will keep the straight in approach.

  Paul Lamar

Paul,

Is there any merit to a .005" interference fit between an Al tube and the
rotor housing using LN2?

Joe Berki

You have to be careful you don't stretch or warp the housing. .005 inches
would  result in a major leak in the sides of the housing where the water O rings
are. IMHO it is not worth it. The SS tube tig welded to the liner and the
conformal  aluminum plate is straight forward and highly likely to work with easy
leak  repairs in the remote chance you even get a leak in the outer housing.

BTW a pound of Devcon pour came into today but I will probably use it
to make a casting pattern for the conformal aluminum plate. It was about
$56.  Larry has a new casting supplier he likes in Northern CA.

Paul Lamar

Paul,
Is the RX 8 motor that you dynoed the only motor that has the stainless tube
welded into the liner?  Just picked up a MAF sensor from a recycler off of a
Lincoln Town car.  I am running out of room under the cowl but will re- do
the airbox and filter setup.

Joe

It is the only one I know about. However we have had
23,000 hits on the youtube video and it has been
over a year so surely somewhere some one has built
another. If it did not work I am sure I would have heard
about it on youtube. It is easy to do and it is easy to test
on junk rotor housings.

Paul Lamar