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The transformer has to be large enough to drive the secondary load, volts times amps. The transformer neither knows nor cares that the secondary is connected in a buck or boost configuration.

If...

A very great deal depends on if you want to make just one cylinder head for yourself, or go into mass production.

If mass production, then you need to go the proper segmented master pattern, and...

I have never really thought about that.

The all up cost (I hope) should not be that horrendous, because I am using mostly secondhand and scrounged parts, or parts that I already have. It is a...

Yes this project is definitely over engineered, but I want to build something that will be powerful, reliable, and trouble free at the first attempt. So I would rather proceed slowly, than have to...

Thanks for the help Frank. I have been experimenting, and agree that very fine cuts with a sharply pointed (non radius) tool seems to give the best results.

Cheers, Tony.

Still not out of the woods with the cooling system yet, but at least the end this part of the project is now in sight.

http://i144.photobucket.com/albums/r166/Warpspeed_photos/100_0117.jpg

I...

Great pictures Andrew !! To get the full effect, he should really be welding in bare feet.

I have just e-mailed those pictures to two really good friends, each is an electrical engineer that owns...

Wow Rambo, that motor controller project sounds like a real beast. Alas, they are not copper bolts but merely ordinary cheapy 6mm mild steel bolts that just happened to have that "gold" passivated...

Oh, this is all so very true.

My knowledge area is in electronics design, but I agree that an apprentice fitter and turner probably knows far more about fits and tolerances than many a graduate...

Bruno,
What you are doing is completely outside my area of experience and knowledge, sorry.

Andrew,
That transformer winding experience of yours, certainly strikes a chord with me !! Some of...

Ha-ha, yes indeed !!!

Funnily enough a recent e-mail from a friend has had me thinking about all this before I saw your last post.

As a poor but enthusiastic engineering student I used to rush...

I cannot disagree with any of that.

As a now retired electronics design engineer myself, I can certainly identify with your strong feelings and great respect for margins, tolerances, and attention...

Well, All I can say is that the engineering team that designed the bearing in the first place probably know a lot more about all this than I do.

Quite obviously an overloaded, dirty misaligned...

I suggest you pop the bearings out of your motor and read the actual bearing number. Then look up the speed rating for that particular bearing from the bearing manufacturer. Their speed ratings are...

Once my choke was wound, testing showed that I had at least one shorted turn, and some significant electrical leakage resistance down to the ferrite. Not very good. Although extreme care was taken...

I am about to start fabricating some oil cooled electronic heatsinks for an induction heating furnace project (featured in another thread here).

These will be assembled out of various pieces of...

Ha-ha, yes, it was rather an ordeal Andrew. More mental than physical. I did consider buying a guillotine especially for this, but thought it might be rater difficult passing the foil past the hinge...

Further update on the induction heater project.

I now have the ferrite cores for the buck regulator choke, so the next task is to cut my roll of bulk .005" copper foil into 35mm strips so that it...

Yes Andrew I agree. An ordinary propane air burner will only just exceeds iron melting temperature by a very small margin, and to do it, it needs really good flame control and excellent furnace...

Propane works very well for melting aluminium, and with a well designed burner and furnace, copper and bronze too. But melting iron or steel is just not going to happen with a basic propane fired...

Rectifiers and filter capacitors have been fitted to the top deck plate, easy and there is not much really to show. The common mode choke for the three phase rectifier, is also now complete and...

O/k guys, further update on progress.

I now have all the heavy low tech and not very interesting "life support system" components mounted into the main frame, and on wheels.
...

If you want to get a good finish on your foam, run the wire only just hot enough to do the job, and go very slowly. As Brian T says, there is really no mechanical load on the motor at all if the...

How was your air velocity meter connected? and what units were you actually reading in?

An air velocity meter cannot be just taped over an air intake to directly read in flow!

Unless your round...

Chris, one liter equals 61.02 cubic inches.

Engine airflow can be estimated in two ways. The first is engine capacity, multiplied by rpm, multiplied by volumetric efficiency. As an engine is just...

Excellent advice, I was not aware that these could be bought off the shelf in smaller sizes.



You must be joking! The normal accepted figure is 1.5 CFM per horsepower for most internal...

I agree with you Chris, vacuum cleaner motors are noisy, hot running, inefficient, fast wearing machines, with a short life. Totally unsuitable for cooling anything.

The vacuum cleaner motor may...

Shawn, progress has been slowed by having to repair some major car engine problems, and various other annoying little distractions. But I am now firmly back on track.

Before I could really begin...

Have you ever checked out how a Dyson vacuum cleaner works? They use a patented multi stage cyclonic dust extraction system instead of the usual canvas "bag" type filter used in most other domestic...

If filter clogging is that bad, I would put a centrifugal "cyclone" type dust extractor ahead of any filter medium. Large diesel trucks almost all use these, very efficient drum type dust extractors,...