Hi 'guys',
Well after a relaxing but frustrating days R/C sailing (no wind
) I managed to finally wrap this first stage up this evening.
I really ought to admit now that when I started I did not hold out too much hope that these cases would be successful due to those exhaust bosses but 'pleased to tell' I can say I'm well chuffed with the result - they are much better than anticipated and have set me up mentally for the rest of the build.
I realised as I was filing away that if I could have held the rotary table at a 4degree angle I could probably have milled around the case instead of those steps - something to think about in future.
Heres a couple of pics of said filing, and as previously mentioned, a tedious part of the process but by relaxing into it and not trying to 'force' it to see the end result it's surprising how soon the metal disappears......
Milling as much away as those mounting lugs would allow
Initial attack made with a dental burr to remove a bit more. This is a 'dangerous' op as it is easy to scar the surrounding area where it would take a lot of filing to remove the witness
Most of this was filed away using just two needle files - a square one with one face ground off as a safe edge and the other a barret reduced at the end for 25mm or so to 3mm wide. Still quite a bit here to go though
Nearly there but still a small witness to get rid of
And finally as finished tonight
They weigh 56/7 grams each without the top plate so by my reckoning thats 2192 gms of swarf made over the last fortnight
.
They'll get another final going over with Scotchbrite and Garryflex block before they get bead blasted but that won't get done until the backplates and front housings are finished.
Hope thats whetted your appetite for the rest of it to come - I shall sleep tight tonight but tomorrow will finally have to get to grips with cleaning all that swarf up before starting again
Regards - Ramon