Jeff, here are some renderings of that alloy end house I sent.

 The replaceable sheet metal wear surface is .090 4130 heat treated
 to Rockwell 64 and Blanchard ground on one side.

 What would it cost to make one of these out of billet.
 We could build up an engine and test it.
 The real market is one rotors where engine weight is critical.
 This should save up to 20 pounds.

 Paul Lamar

Paul

Talking 6061-t6?????  A day's worth of machining and set-up, really
more..I'd do it for you $350 plus material..deal...   Looks like 38
lbs(12x13x2.5) and 6061- billet is about $3.25/lb.

It will machine down to 12 to 15 lbs....

jeff

I deleted your SW jpg Jeff as it was too confusing since we are talking
about an aluminum billet end housing.

That is a bargain for an aluminum rear rotor housing. Racing Beat charges
$1300 and the coated wear surface is unproven. For a one rotor engine $350 would
be well worth it. If we get some interest in this I will do a front end
housing design as well. If one bought a new Mazda end
housing it would cost one about that. This means you can buy all the
parts for a 125 HP all aluminum one rotor Mazda based engine for less than
about 2 or 3 thousand dollars less the PSRU. Weight with PSRU would be well
under 200 pounds.

Can you cut down a stock 2 rotor E-shaft as well?

Paul Lamar


This is most interesting if it can be done.  I have been lurking
on this list for about 6 months trying to educate myself on a
previously unfamiliar topic.  I appreciate the ingenuity and
cooperative spirit shared on this list. I am learning....

I desire to use a rotary for my Kolb MKIII X, which I am
currently building, to stay away from the Rotax 912ULS (for all
the known reasons).  Short of Revolution Rotary I have not seen
a light enough solution in the 100 HP range.  Rev Rotary seems
as though they are moving towards a solution, but appear to
still be in the design stage. I like the idea of using standard
components from Mazda, with the custom but  affordable
reductions you are working on.

With what you are proposing, the scale appears to be sliding
towards substantial consideration.....

In my case, the ideal engine would be specifications nearly
identical to the Rotax 912ULS with lighter weight (with all
ancillary parts) and much lower cost.  Rotax prices are not
compatible with my pay grade...


Please keep us posted and thank you for all you are doing Sir.

Fran Losey


Well if Jeff can make them at that price the one rotor Mazda will
be a very competitive engine for a wide range of aircraft
that use the Rotax 912 and 914.  A turbo compound version would
be very competitive in the UAV engine market.

Paul Lamar