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new gas pipes under construction


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#1 Jim Allen

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Posted 29 January 2017 - 03:56 AM

The posted photos are of two new gas pipes for 27 cc & 35 cc engines under construction. Some sections are rolled from .018" sheet steel & some are machined from steel tubes. Tapered sections are generated from a computer program, spot welded & then silver soldered. All sections are silver solder in the final assembly making disassembly for modifications possible. 

 

Jim Allen



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#2 john bass

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Posted 29 January 2017 - 07:16 AM

Mr Allen...I am not having good luck in my quest to fabricate the new pipe.....I will call you later and see if i can get one of yours for my new 35cc zenoah....I hope that you can part with one for me....cost is not a factor...thanks





#3 Jim Allen

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Posted 30 January 2017 - 11:53 AM

John,

 

I sent you an email because the phone is not working. The slip roller we talked about is still available, but the price is much higher for the exact same model I purchased several years ago.

 

Precision Slip Roller

  WEB%20PR12W3.jpg

The Precision Roller, a long time favorite of the Accucutter® product line, has been significantly upgraded. The rollers are now manufactured from precision ground and polished tool steel, and the gears have been strengthened and fully enclosed for safety. Wire grooves have been added, and convenience items have been incorporated like easy to use knurled knob adjustment screws and a handle to assist in lifting the movable top roller. Stainless steel rollers are available as an option.

 

The Precision Roller is used to form metal into an infinite variety of  rolled shapes. By adjusting its three rollers, different shapes may be made and different thickness materials may be used. The Precision Rollerhas many applications in making custom awards and trophies as well as other industries.

 

Accucutter® also offers a dedicated Column Maker. Before extruded column blanks, trophy makers formed the columns for their trophies. Many used Accucutter®'s Column Maker. It is an inexpensive, easy to use device that enables you to accurately and repetitively form columns. Five formers are available to make round columns. The material opening is 12" wide. Now the Column Maker is used primarily for special projects, repair of older trophies, and scroll making. The base and formers are purchased separately.

 

Operator's Manual
     An Operator’s Manual is included with the PR12W. A copy of Accucutter®'s "Guide to Basic Trophy Forms" is included with the Column Maker.

 

PR12W Capacity: 
 
    Maximum material thickness is .040". Recommended capacities are: Aluminum - .040"; Half Hard Brass - .030"; and Mild Steel - .020". The wire grooves are for the following wire sizes: .063", .125", and .156"

 

Column Maker Capacity: 
 
    Maximum material thickness is .040". Recommended capacities are: Aluminum - .025"; Half Hard Brass - .020"; and Brass Plated Steel - .015".

 

Size & Weight:
     · Size: 23"L x 6"W x 7"H
     · Roller Size: PR12W - 1" Diameter
     · Weight: PR12W - 18 lbs.; Column Maker - 10 lbs.  

 

Availability & Ordering
     Please check for current availability and delivery. At the time of ordering the Column Maker it is necessary to specify which former or formers you prefer.

 

Model PR12W, $435.00
Column Maker & Formers, Call



#4 john bass

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Posted 30 January 2017 - 01:50 PM

thanks Jim...I have been looking online for this company...do you have a phone contact for Accucutter???



#5 john bass

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Posted 30 January 2017 - 01:55 PM

I have also seen one made in China for less than 200.00 but I am sure the quality is not as good as a 500.00 tool...but do you think that the less expensive tool will work for what i am trying to do??



#6 john bass

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Posted 30 January 2017 - 02:05 PM

found the company and ordered the tool 3 week wait though ....thanks for all your help



#7 Terry Keeley

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Posted 30 January 2017 - 03:54 PM

Incredible work as always Jim!  :)



#8 Jim Allen

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Posted 25 February 2017 - 07:49 PM

Some more photos of what is done to make a tuned pipe. Tapered sections come from computer generated pieces that are printed out to size. They are then glued to heavy paper, cut & then transferred to the .018" thick cold rolled sheet steel. A slip roller is used to roll the tapered sections. I use a shear to cut straight lines & metal snips to cut curved lines. 050" extra material is added where any straight line joint or curved section is to be spot welded with a Miller resistance welder before silver soldering.

JA

Attached Files

  • Attached File  001.JPG   77.41KB   40 downloads
  • Attached File  002.JPG   75.6KB   35 downloads
  • Attached File  003.JPG   64.18KB   36 downloads
  • Attached File  004.JPG   79.9KB   36 downloads
  • Attached File  005.JPG   63.64KB   35 downloads


#9 Wally Duarte

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Posted 26 February 2017 - 09:07 PM

Looking great Jim !

#10 Jim Allen

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Posted 10 March 2017 - 09:55 AM

Both tuned pipes in the photo would measure the same length from the side of the piston to the end of the flat section. However their tuned lengths are not the same because the tuned length is measured from the piston face to half of the entire length of the baffle cone. They also have very different total volumes which will determine the maximum length & inside diameter of the stinger section. Stinger length & inside diameter will effect the engines operating temperature. Different baffle cone angles not only effect the total volume of a chamber, but they effect the width & amount of power boost obtainable. Notice that the unpainted chamber does not have a flat flex section in its diffuser, but is tapered from its connection point at the engines header pipe.

 

Jim Allen

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#11 Mike Whitney

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Posted 11 March 2017 - 06:18 PM

Next level stuff as always. Good job, anxious to see real world results.

#12 Tom Foley

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Posted 12 March 2017 - 10:39 AM

Some more photos of what is done to make a tuned pipe. Tapered sections come from computer generated pieces that are printed out to size. They are then glued to heavy paper, cut & then transferred to the .018" thick cold rolled sheet steel. A slip roller is used to roll the tapered sections. I use a shear to cut straight lines & metal snips to cut curved lines. 050" extra material is added where any straight line joint or curved section is to be spot welded with a Miller resistance welder before silver soldering.[/size]

JA[/size]
Old world craftsmanship from cradle to grave on the part !Keep up the good work !

#13 Jim Allen

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Posted 12 March 2017 - 11:40 AM

This is what one of the finished chambers looks like. It will be used in a mono hull with a 35 cc engine by Performance Unlimited. The photo does not show the tuned pipe at its running tuned length! This chamber has two sections in the diffuser compared to three in the latest chambers shown.

 

JA

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Edited by Jim Allen, 12 March 2017 - 11:43 AM.


#14 Jim Allen

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Posted 09 April 2017 - 09:46 AM

The type of simple fixture shown allows not only straight section ID's but also tapered section ID's to be easily machined to the exact length needed. It is held in a collet & repeats within .0005". Tapered sections are then mounted on a tapered mandrel for OD machining.  Stinger & head pipe sections are typically .040" thick while other sections in the pipe are .018" to .020" thick. Thick walled, A 513 - type 5 steel tubing DOM (drawn over mandrel), can be purchased in 12" lengths from OnlineMetals.com. The carbon steel tubes have a uniform grain structure which is a seamless consistent structure. They also come in various OD & ID combinations & make it easy to machine any tapered section if the beginning ID & the ending OD are known. A 513 DOM steel tubing welds & silver solders extremely well.

 

JA

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#15 Jim Allen

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Posted 20 April 2017 - 09:57 AM

Tuned pipe construction continues with the use of the fixture shown in post #5. The completed pipe shown mounted between centers was silver soldered with Aufhauser Silver Alloy #45 & Nokrode Black soldering flux. Mounting the pipe sections between centers, with interlocking sections, gives a chamber that is straight & true. This flux works with all metals, except aluminum, at both low & high temperatures, (1000* F to 1700* F) without glazing. The paste should be brushed on all areas adjacent to the soldering joint as well as the joint area. After soldering, any flux residue left can be washed off in hot water with a steel wire brush. I clean the inside of the pipe by sand blasting & washing with hot water. In the photo, the center section is made of A 315 Type 5 DOM steel & both ends are # 303 stainless steel. Notice how smooth the silver solder has flowed over both pieces. White silver soldering fluxes will not give this result!

Jim Allen



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Edited by Jim Allen, 21 April 2017 - 05:08 AM.