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Author Topic: Milwaukee Midget  (Read 1651863 times)
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fordboy628
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« Reply #6840 on: February 24, 2018, 08:05:52 AM »


Mostly it's just trying to explain the new health insurance plans and health savings accounts, writing release forms, attending meetings, maintaining files, auditing I-9 forms, creating HIPAA compliance policies, auditing payroll and answering 401(k) questions.

It's funny - we operated for 59 years with a system of index cards and a recipe box.  Today, I've got enough files to organize a fairly substantial prison break from Stateville.


Uh-huh . . . . .

Yeah, the phrase that strikes terror into the "wallet" of every small businessman:

I'm from the "guvmint", and I'm here to help . . . . . .

Don't get me started . . . . . .

 Dead Horse  Dead Horse  Dead Horse  Dead Horse  Dead Horse
? W ? T ? F ? ? ? W ? T ? F ? ? ?   ! * ! @ * ! # * ! % * ! * !   $ $ $ $ $ ! ! !
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Milwaukee Midget
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« Reply #6841 on: February 25, 2018, 01:18:37 PM »

I will say this - with respect to employee retention and acquisition, our new insurance and 401(k) options make us a REALLY competitive employer.

As to payroll accounting, we've dismissed two people by FINALLY being able to put together a proper paper trail.  And while I miss her a great deal - we became good friends - one of the people skimming hours was our payroll person.

It was the toughest thing I've ever done in a work situation, and I wish her the best, but we really had no choice but to let her go.

Back to the Midget.

Finishing up the fuel tank today.  I've installed an aviation-style filler directly to the tank, and have an access door coming from Tanksinc.com.  I was always a bit nervous about running the fuel filler through the trunk, and this set-up keeps all fuel lines and the filler outside the body of the car, yet retains the stock tank.  When it's done, you'll flip open the access door, unscrew the filler, gas it up, have the boys at ERC seal it, lock town the access panel and go racing.

Much to do, but if I can find some time, I'll get some photos up.

I also picked up a tip from the HAMB boards on mocking up headers.  The suggestion was to use flexible conduit, put it all in place, fill it with "Great Stuff" insulation and coat it with fiberglass resin to hold the form.  It's worth a try - I picked up the BX style conduit today.  My concern is that the tightest you can go is about a 4 - 4 1/2" radius.
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Well, I guess we're making a LOT of progress . . .  rolleyes

We are NOT rebuilding . . . We are reloading.

GOD SAVE MG - The Queen can take care of herself!
Rex Schimmer
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« Reply #6842 on: February 25, 2018, 02:28:16 PM »

Chris,
There are several "metal doughnuts" available that can help with tight header radius requirements. Pegasus has some and also Pro Werks  http://www.pro-werks.com/partlist/979/.

You can also do a certain amount of "cheating" on a radius if it is not to much. The pic is a set of headers that I built for Steve Nelson's new 3 liter banger for his lakester. Several of the bend radii were reduced to make everything fit inside the car. Never tried the doughnuts though.


Rex


* Nelson headers R.jpg (188.41 KB, 1024x768 - viewed 157 times.)
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« Reply #6843 on: February 25, 2018, 02:53:37 PM »

I've just used six donuts, no make that eight to make the world's ugliest set of headers. We had so many donuts I was worried the cops were going to turn up.
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Milwaukee Midget
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« Reply #6844 on: February 25, 2018, 06:53:04 PM »

turret by

Doc, I'm sure your headers are fine - just wrap 'em, and nobody else will know.

Still some internal work to do - a bracket to hang the pump from, but I've certainly created uglier work . . .
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"Problems are almost always a sign of progress."  Harold Bettes
Well, I guess we're making a LOT of progress . . .  rolleyes

We are NOT rebuilding . . . We are reloading.

GOD SAVE MG - The Queen can take care of herself!
Milwaukee Midget
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« Reply #6845 on: February 25, 2018, 07:01:41 PM »


There are several "metal doughnuts" available that can help with tight header radius requirements. Pegasus has some and also Pro Werks  http://www.pro-werks.com/partlist/979/.


Rex, thanks for that, but this has been the rub from the git-go - we're looking at 1 1/4" tubing.

It's a good idea - I just need to see if there is a supplier of bike doughnuts - but bikes seldom need radii that tight.
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"Problems are almost always a sign of progress."  Harold Bettes
Well, I guess we're making a LOT of progress . . .  rolleyes

We are NOT rebuilding . . . We are reloading.

GOD SAVE MG - The Queen can take care of herself!
WhizzbangK.C.
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« Reply #6846 on: February 25, 2018, 07:37:53 PM »


There are several "metal doughnuts" available that can help with tight header radius requirements. Pegasus has some and also Pro Werks  http://www.pro-werks.com/partlist/979/.


Rex, thanks for that, but this has been the rub from the git-go - we're looking at 1 1/4" tubing.

It's a good idea - I just need to see if there is a supplier of bike doughnuts - but bikes seldom need radii that tight.

Search Summit Racing, exhaust pipes, individual bends, you can select pipe size, material, etc.
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fordboy628
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« Reply #6847 on: February 25, 2018, 07:55:19 PM »


Rex, thanks for that, but this has been the rub from the git-go - we're looking at 1 1/4" tubing.

It's a good idea - I just need to see if there is a supplier of bike doughnuts - but bikes seldom need radii that tight.


midget,

Stepped headers, not straight 1-1/4".        1-1/4" to 1-3/8"   OR    1-1/4" to 1-3/8" to 1-1/2"

Straight 1-1/4" are going to be too small for a 4V, 980cc with peak bhp @ 8500 to 9000 rpm, even with a "throttled" inlet tract.        Cosworth spec for an 1098, admittedly running 10,000 rpm, 1-7/8" O.D.

Think about that . . . . . .     As much as you don't want to make a custom header, you don't want to make 2 custom headers . . . . . . . .

Email Roman @ Burns Stainless for a recommendation for sizes and a merge collector.    Be sure to complete the form.

I'll crunch more numbers sometime this coming week.   Waaaayy too much effort into this to screw it up now . . . .

 cheers
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Peter Jack
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« Reply #6848 on: February 25, 2018, 09:27:13 PM »

Look at the collector in Rex's photo. That's what you want. They're very efficient and available from Burns among others. They make fabrication relatively easy with the slip fit so you can set the collector where you want and then simply ( grin grin grin) run the equal length pipes in between.

Pete
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Milwaukee Midget
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« Reply #6849 on: February 25, 2018, 10:37:46 PM »

I was about to place an order with Burns for the collector.

I thought we were at 1 1/4.

I guess we're in a holding pattern, which is okay - I've got to fit the engine, anyway.
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"Problems are almost always a sign of progress."  Harold Bettes
Well, I guess we're making a LOT of progress . . .  rolleyes

We are NOT rebuilding . . . We are reloading.

GOD SAVE MG - The Queen can take care of herself!
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« Reply #6850 on: February 26, 2018, 12:43:14 AM »

   Is ceramic coating a possibility  ??


* DSCN1923.JPG (121.98 KB, 640x480 - viewed 74 times.)

* DSCN1926.JPG (121.17 KB, 640x480 - viewed 61 times.)
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Milwaukee Midget
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« Reply #6851 on: February 26, 2018, 09:08:04 AM »

Cost considerations tell me no, but anybody out there know of someone who does this?  The Grenade used a ceramic coated header, and I'm a fan.
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"Problems are almost always a sign of progress."  Harold Bettes
Well, I guess we're making a LOT of progress . . .  rolleyes

We are NOT rebuilding . . . We are reloading.

GOD SAVE MG - The Queen can take care of herself!
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« Reply #6852 on: February 26, 2018, 10:07:23 AM »

Cost considerations tell me no, but anybody out there know of someone who does this?  The Grenade used a ceramic coated header, and I'm a fan.
This guy is a Bonneville racer, did my header, I liked it.
http://finishlinecoatings.com/
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Rex Schimmer
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« Reply #6853 on: February 26, 2018, 04:29:33 PM »

Chris,
Our little Kawa 4 banger that we turned 11,000+ has 1-1/2 ODx .065wall (for a 1-3/8 ID)  about 15 to 16 inches long. The motor last year was 900 ccs, this year a full 1000 but still 11-12,000 rpm. Really hope to be in the 175-180 hp range on methanol. Might think about a new set of headers, need to get my partner (Duke) thinking about them. The ports are really made for the 1-1/2 OD but we could easily make a step from 1-1/2 to 1-5/8 or even 1-3/4. Now you've got me thinking and will probably have to add "new headers" to the "to do" list! If we do go with new headers they will be stainless steel as Duke is an artiest with that stuff.

Rex
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« Reply #6854 on: February 26, 2018, 07:32:37 PM »

Calvin Elston (www.elstonheaders.com) did a header for a friend of mine, and boy does it work.  

1 3/8" od off the head to match the port area for 10" before stepping up 2 more times. Leaving the rest a secret Wink . Each cylinder displaces ~562cc and is pushing about 60hp through each. revving to 7200rpm. Picked up 10-12% power everywhere over the Stahl based 1 5/8 > 1 3/4" header. Within 2" overall length wise and the same exact Burns collector (2.25" outlet). Also was able to go down a main and an air corrector on a DCOE Weber since the jet signal was much stronger.

Not related to power, it has a bit more crackle than the older header. This is just a warm up run, cut short. Just getting heat into the drivetrain.


Paying attention to bend radii is paramount on a header like that. The function of a header is science, but getting large bend radii to fit in tight spaces is the art.

Calvin has a blog, which he hasn't updated in a while unfortunately (www.exhausting101.com. He also has lots of posts on Speedtalk and Yellowbullet with the username "exhausted". He was the guy who introduced tri-ys back to Cup, and has championships in NHRA, NASCAR, WoO, Le Mans, etc. has a header builder.

One thing he said to keep in mind with the Burns specs - the diameter they give you is what it needs to be at the end of that length. If your port is smaller than that value, you're going to step to get there even though they didn't specify it. The only way you can go with his sizes though is with large bend radii and attention to flow. How he fits what he does in some of the spaces I've seen is pretty extraordinary. Not using a header plate helps a lot (so each tube has it's own flange and the header apart looks like a bunch of single cylinder primaries).

He loves chatting about this stuff. Certaintly worth a call to him to just chat after you get your specs from Burns in hand.

Likely, with your displacement decrease, the exhaust ports are probably way too big to begin with, so best not exacerbate the problem. You’ll still need to step, however.
« Last Edit: February 26, 2018, 07:56:33 PM by hoffman900 » Logged
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