Why would we WANT side exhaust ports? We don't care about emissions.

 

Well, since mazda probably won't release a crate renisis, we could make our own


It may not have the brap brap idle and bad gas mileage, but it might have the better power levels & gas milage. And be more reliable then a bridgeport.


All we would need would be the lighter rotors to rev it to the correct efficiancy range for the ports.


-Zach

 

Haha, I got a kick out of that avatar!!! If your uncle was my uncle I would be trying to get some injection molds made for some plastic parts to start with.
Reproduce a lot of the plastic parts like AC vents, stereo surrounds, and the plastic part of the scoops on TurboII's. You could make pretty good money just doing those. The nice thing about that is that it is not rocket science and you are not having to test. Just make the molds and take them to a local plastic injection shop.
Sell them on Ebay, the net, etc. even here.
Because almost every RX out there has some bad plastic.
I thought about messing with that since there is a big market but I just don't get jazzed up about the money side of a project as much as the challenge.

If your uncle was willing to help you out you are a really lucky guy. You could make pretty good money with his services.
If you are interested in any ideas just PM me or throw out a new thread titled "RX7 tool and die project suggestions".

 

RB does re-surfacing to the housings.. check there site.. looks good.. hope that helps a bit...

 

Well, the renesis engine is making 240hp NA or so with the side ports. They are supposed to have better fuel economy, and due to the greater combined area, they can flow enough to run 10k rpm. Oh, and some of us DO care about emissions. I'm no tree hugger, though.
Don.

 

Well I am still waiting for my housings from the shop. Since they are doing this as a "test" they are not in a big hurry

 

I'm not a tree hugger either but anyone that does not have any problem with pollution should only drink water from their local lakes, creeks, and reservoirs for about a week and then come back and tell us their results.
Most area water that is not treated is not consumable and anyone that thinks that air cannot be contaminated to the point where it is not breathable needs to hang out with my brother in law. One pull of his finger and you will be hugging a tree!

 

I live very close to several Ford and Chevy plants. Less than 5 minutes by city streets.

Some days you could pour a gallon of gasoline out on the ground and not notice the fumes over the other crap in the air.

I'm not going to cry over a drop in the bucket...

 

Since I won't be buying a Renesis engine I want to at least get an intake gasket to see what they look like.

 

I'm more interested in the exhaust ports, myself.
Don.

 

Please accept some thoughts from someone who hasn't spent near the time you've invested in your project. As for coatings, I know general aviation engine rebuilders have a tremendous amount of research invested. Aircraft piston engines have mandated overhaul intervals, so engines are torn down every few thousand hours (or less, every one is different). Anyways, you're basic piston aviation engine is a boxer with individual cast iron cylinders (jugs) bolted to the split crankcase. It's been years since I have bothered to look but you can find many engine builders who are doing things like hard chrome plating and ceramic coating to the insides of the cast iron cylinder jugs; it's common.

Just thought that at least you could find some people who were truly informed in the first hand application of the coatings. Needless to say aviation has very stringent controls.

 

That is good info!

 

and the wiper switches as well.

 

Or any other electrical defects that their cars are prone to!

 

this is all mostly over my head at this point, I just have a rough understanding whats going on....

but, are you planning on fabricating a complete engine? Sounds like your working on the housings, but what about the rotor? Is that the "easy" part?

And if you are planning out an engine, what kinda displacement and compression are you looking at.

Very interesting idea, I'd love to try it if I had the money!

 

It would cost a ton to build all the parts from scratch. A rotor would not be easy to make at all a,d the rest is pretty tough as well.
I am still waiting to get my rotor housings back from the plasma spray shop. They still have not touched them.

 

Like I said this thread is way over my head... I'm obviously not as well informed, as you can tell by my ignorance!

 

Well, too bad that progress is so slow... but, after thinking for a little while (and I hope I am not restating something I already said a while back), a micro porous chrome surface will be ABSOLUTELY essential as far as I understand it. I beleive they went to the porous coating becasue then when oil is injected, it finds its way into these pores and more or less stays there, so it can lube any apex seal that passes over top of it. I believe they began using this microporous chrome coating at the same time they completely ditched carbon apex seals, because carbon seals would be self lubricating I'd think.

 

Scalliwag,
Ever heard of Nibron? There's an article on it in this month's Machine Design magazine.
"Nibron, a metallic coating of nickel, thallium, and boron, outperforms other aerospace coatings such as hard chrome and nickel-phosphorus when it comes to hardness and reducing wear...it extends the life of aerospace components, as well as improving their reliability and durability.."
"..usually applied using electroless plating.."
"Nibron coatings are well suited to complex shapes, including those with intricate profiles, corners, grooves, and holes.."
"Several military jets, including the F-22 Raptor, have engine components coated with Nibron to reduce wear."

Contact:
Marshall Menachem
VP of Engineering
Purecoat International LLC
West Palm Beach, FL

Sorry, I don't have a phone #.

 

Purecoat Int.
617-484-8870
561-844-0100

http://www.purecoat.com/contact.htm

 

Just got off the phone with George Bognar, President: Purecoat. For the housings we need to remove the hardchrome first, But for the Sideplates the Nibron appears to be a viable alternative to Nitriding after lapping.

 

Hey guys. I just picked up a housing from the plasma spray shop. The surface is really rough "gritty" as I expected. I will take pictures when I get home this evening and post them.
I will also stop at different points in the process and take pictures too. So be sure to tune back in.

 

Okay, here is a link to the picture after I prepped it
http://webpages.charter.net/mikeroberts/milled.jpg
This is the picture straight from the plasma spray shop.
http://webpages.charter.net/mikeroberts/coated01.jpg

I am going to start the polish process and more pics are to come.

 

wow... that's not smooth

I can't wait to see the final pics!

 

I don't know a lot about ceramic coatings but do know there are many different types. All of various hardness. Depending on the type you choose, will determine how long your diamond cutters will last.
A friend of mine works for a company that makes ballistic armor for the military and many other projects that are supposedly hush hush. He has showed me some pressure formed ceramics that I have no idea how they machine. I would be curious as to what type you chose for your coating process if you wish to share the information. I am also curios as to how long you think it will take for the seals to seat or if you even think that will be an issue.
Great project - I hope you succeed