Hi Paul,

Lots of progress over the last year.  Since the first disastrous running,
the engine has been completely rebuilt.  Part of the tear down involved a
weigh in, firewall forward.  Almost 280lbs!
That was a Lou Ross built single rotor 13b with stock parts and an Atkins
shaft, a Ross gear reduction 3.17:1 and some custom parts.  The claimed 120
hp was impossible.  Tear down revealed side ports untouched.  It is normally
aspirated.  The severe vibration was traced to inadequate balancing of the
rotor and counterweights.

I thought quite a while about throwing in the towel and going for the usual
O200 aircraft engine, a thought that recurs from time to time...
Nevertheless, we scrounged up some funds and ordered aluminum side housings
from Racing Beat.  I sent the center housing to Jeff for P porting.  The
housing was too old for a two inch port, as the bolt spacing did not allow
for it.  Jeff kindly sent a later model housing, ported and ready to go.
The newer housing dictated a new rotor.  I bought a high compression rotor
from Kevin at rotary resurrection.com.  The whole rotating assembly was then
shipped to Mazdatrix for a dynamic balance.  They said no way would it run
smoothly, as is (was.). After much effort, a well balanced assembly,
including flex plate, returned home.  Everything went back together with a
mix of Tracy's overhaul kit and stock Mazda apex seals.  Here are some
pictures:


I used RB's template to enlarge the exhaust port, slightly.


At this point, it weighed 68 lbs.

I machined everything that looked like it could lose weight.


120 lbs. to this point

Jeff kindly machined a hat piece which enabled the PSRU to house some thrust
bearings.  Great work, Jeff!

Later model parts do not play well with earlier ones, so new oil pump and
drive, new water pump, new lightweight alternator, modified engine mount,
new plumbing, radiator and oil cooler.

I did the water pump mod that Paul suggested, also modified/machined the
throttle body injector, the propeller hub (ivoprop requires an adapter for
the sae2 hub.  A little machining and electrical isolation negated this)

In the end, the only part used untouched or modified from the original
engine, is the main shaft.

Looks like all up weight, firewall forward, about 220lbs with an
electrically pitched Ivoprop and fluids.

I have many more photos.

It is running, finally.  But the cowling and intake air filter plumbing are
not yet completed.  Serious ground tests in the spring.  Hopefully flying by
summertime.

Lewis.


Nice work Lewis.

BTW I am listening to spectacular Maria Callas while I edit this stuff.
Do we have any other Maria Callas lovers on here ? :)

Paul Lamar

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