Both housings partially reefed through with 1 3/4" hole saw in drill press, after creating a jig to hold the housings steadily and repeatably. The holes ended up being within a few thousandths of each other, pretty good for a setup from the Lowest Bidder. Left housing has had three starter holes drilled through, housing on right has had starter holes turned into one big (little) fat hole.
I kept the aluminum chunks. They're kind of good-luck charms now.
You can just barely make out the horizontal scribe marks.
Rough port edges laid out with masking tape. Masking tape is easier to see than a scribe mark when there are chips everywhere.
A look down what will be the new intake port. This is not the tube that will be used, but it works for photo purposes. There's still a good deal of aluminum to move, but at this point it's better to sneak up on it than risk taking too much away.
(very) roughed out exhaust port. 12A exhaust ports are *narrow*.
These housings only have 120k on them. I've yet to pull apart a 2mm seal engine with housings anywhere near this bad.
Exhaust will end up almost double in height. I don't believe in opening the exhaust any earlier on a street engine, but it will still see some "attention".
More flaking goodness/grossness. Dig how the one housing has flaking exactly where the exhaust port is!
Tube will get welded in, in a fashion. (Will become clear later). Then, JB Weld will fill/seal the water jacket area, as well as finish up the transition from round port to square hole.
The numbers are hard to see, but shot-for opening is 80BTDC, closing is 60ABDC. (The hash marks start at 90BTDC/BDC, and go every ten degrees until TDC/90ABDC) I *wanted* 50ATDC closing, but it would have required either less than 1/2" between the port and the edge of the housing, or an earlier opening.
Update: Work done late March, finally extracted pictures from the camera.
Near housing: Other intake and exhaust port roughed in. First exhaust port 90% there. Sadly the pictures of the port itself didn't turn out well.
Two 1 3/4", 2" radius mandrel bends. Hmm, what to do, what to do.
No, they won't be this long on the engine, but it sure looks impressive, eh?
"The only thing side ports are good for is a place to store epoxy." They have already been sanded flush and the rest of the air-injection port (useless on an SA engine even in stock form) has been filled in.
Sharp edges on the rotor bowl radiused away. This should assist in getting combustion to the end-gasses. Don't worry, the shape itself has not been altered - it's just some strange collation of flash angle and sanding grain that makes the worked bowl look horribly warped.
Update April 30:
Short length of 1/2" all-thread, strategically shaped...
...threaded into a strategically tapped tension bolt hole...
...where it intersects the area where the intake sleeve will go...
...and the strategic shaping comes into play. Next comes the zap-zap with the MIG.
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modified June 13, 2005
Pete Remner aka peejay or sometimes ???