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 Post subject: rotor housing honing . shady tree
PostPosted: Fri Sep 29, 2017 12:01 am 
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nearly there maybe another 10 hrs./ from painting dummy garden ornament to 12a .

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sat Oct 07, 2017 11:17 pm 
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There's some commitment right there. I read a while back you were playing with this, good to see you stuck it out. Does it sort out deformation around the plug holes? Or more of a surface finish improvement?

Ps bit confused on the shady tree thing? Please explain :shock:


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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sun Oct 08, 2017 11:32 am 
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shady tree . backyard . honing takes back the surface so the gouges and chatters can be removed. here i literally picked up one of the housings i have been using as a painting dummy for blocks and gave it about 20 hrs on the jig and managed to get through most of all the scratches
it still isnt perfect but the housing is now at a state where it is not dissimilar to those that are reused, having copped a bit of styration from after market seals .
its useable. it wasnt before. but still not perfect . i will be using this jig to save a numbered set of 20b housings . so it is going to save someone a LOT of coins from the outset .
i can if i want //alter the jig slightly and take down the housing near the waist where early rotors will kiss late housings
i suspect that is what big cat and goopy can do to

in concert with hugo taking down 13b housings, and maybe even getting into rotor balancing . people in WA will soon have much better options than to lose out on double freight


i have another jig in the process. it will work even slower but use a stone and i expect will get a more uniform job

to note.
side by side with a 12a housing . the 20b has a substantially meatier chrome section/ tighter inside diameter

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sun Oct 15, 2017 9:57 pm 
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nice work


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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sun Nov 12, 2017 12:09 am 
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should have followed up a bit sooner but .-
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i find it a bit hard to find the time to get a run on this but the process has narrowed down and shortened a bit .
that last pic still needs a little finish time , and the grooves along the edge will be lost in the slim down to 12a process

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Last edited by bumpstart on Sun Nov 12, 2017 7:23 pm, edited 3 times in total.

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sun Nov 12, 2017 5:47 pm 
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How deep were the grooves in the housing initially?
I have a pair of early 13B housings which dropped an apex, I thought the one with the dropped seal would be no good, but the scratches don't seem to be through the chrome so they may be candidates for resurfacing?

Can I also ask what you are using to do the honing? as in sandpaper, stone or whatever, and what the jig consists of, I don;t intend on going to volume production and stealing ideas, just interested is all :)

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sun Nov 12, 2017 7:15 pm 
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repair depends on the damage/ how deep that is and where it is .
edge wear cannot be restored though if you see my other post . then can be thinned down and grooved ( or not ) to make 12a or 12C or 12D engines

this housing still has a little mark along each edge above exhaust port . most of that will disappear in the reduction to 12a process
not bad for my painting dummy ! test 2 housing is worse and will come good too
( i used to race on it last century and the exhaust port got so large to consumer scratches from other fails , i retired it because it had the witness from kiss with rx4 rotors )

the lathe is all mazda . 8)

tools required -
welder , grinder , dropsaw, belt sander ( lathe also required for a tricky bit , propriety knowledge )

i have added an electric motor, speed controller . a bit of angle iron , a bit of flat bar , engine stand . overhead spray gun bottle and some fittings . + mig jet

you will need . 1 front plate . . 4 dowels. 2 tension bolts , crank + front float shite , timing cover , old sump x 2 ., old FC fuel filter and hose, 2 x split air pipes , FC PS bracket and tensioner and pulleys and belt
12a s3 front mass. s5 - FD rotors
3 extra front keys . few old springs

stone

MacGyver

cider

dont say i dont give you nothing

post 11600 :thrust:

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sun Nov 12, 2017 7:48 pm 
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I understand, giving the game away there lol.

but somewhat along the lines of what I expected.

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Sun Nov 12, 2017 10:38 pm 
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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Tue Nov 14, 2017 11:43 am 
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bumpstart wrote:
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What apex seal brand did that damage!! wow....

I think if you can set the jig up so it ensures that the chrome is refinished flat and true (not just smooth and uniform) and you will be over run by customers wanting to true up some used housings.
Still cant believe no one on the mainland offers this service like in the US or NZ. Dressing them by hand using a diamond roll pin only gets them so close, but a repeatable CNC process would ensure they come out as close to OEM as possible.

Good work mate

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Wed Nov 15, 2017 12:45 am 
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test2 . if you can tell by the enormous exhaust port that grew each time i scratched the housing racing 20 years ago. has been alternating since then as garden ornament and as a painting dummy .

it was originally the housing with the big witness to show that yes rx4 rotors really can touch the FC housings at revs

it really wasnt damaged enough for a good test so it copped 8 hrs on 80 grit on a flap rotor . . steel science seals beat me there by 7.5 hours

it is more or less fixed. maybe another hr on a finer cut to get the last marks . but it proved its point . wasnt really trying to fully recover it unless i feel like making a mad PP one day . exhaust is very large

jig wise . it isnt CNC. i have a bigger, badder iteration planned that moves the housing around the stone/ diamond roller
. but this is proving itself . is considerably easier to build. is all mazda . it is very flat .
and i may not have to go there to the mad table just yet

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Thu Nov 16, 2017 11:57 pm 
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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Fri Nov 17, 2017 1:39 pm 
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I did catch the vid on facebook, neighbour would love hearing that in the back yard for 10hrs at a time.
Love your work as always mate

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Fri Nov 17, 2017 7:45 pm 
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Wow, you must have a lot of patience!!
It's good to know that there is hope to have damaged housings repaired tho
Just my thoughts tho, (and I'm not real smart so be prepared to laugh lots!!)
Could you somehow use the rotating assembly as a jig?? I mean it follows the right path around the housing, mill down a rotor to house some sort of stone and then rig up an electric motor to spin it all??
Krem

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 Post subject: Re: rotor housing honing . shady tree
PostPosted: Fri Nov 17, 2017 8:04 pm 
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Quote:
Could you somehow use the rotating assembly as a jig??


1st post . 2nd pic

all mazda jig right down to pulleys and tensioner, even using a PS belt and an FC fuel filter . self oiling . diesel.
electric motor added

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