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You don't have to be Jay Leno to own a jet powered motorcycle, and we will show you how to make your own jet enigne right here to power your wacky vehicles.
This is an ongoing project, and plenty of additional info will be available on our website soon. Building your own jet engine can be dangerous. We highly suggest that you take all appropriate safety precautions when dealing with machinery, and use extreme care while operating jet engines.
Serious injury or death can occur while operating a jet turbine engine in close proximity, due to explosive fuels and moving parts. Extreme amounts of potential and kinetic energy are stored in operating engines. Always use Build A Boat For Treasure Jet Tutorial Mac caution and good judgment while operating engines and machinery, and wear appropriate eye and hearing protection. Neither Bad Brothers Racing or Gary's Jet Journal accept any liability for your use or misuse of the information contained herein.
I started the build process of my engine with a design in Solid Works. I find it much easier to work this way, and creating parts using CNC machining processes turns out a much nicer end result.
The main thing I like about using the 3D process is the ability to see how the parts will fit together before fabrication, so that I can make changes before spending hours on a part. This step is really not neccesary, as anyone with decent drawing skills can sketch out the design on the back of an envelope rather quickly.
When trying to fit the entire engine into the final project, the jet bike, it will certainly help a lot. I would also suggest that to get the best answer to questions if you are attempting to build a jet engine or turbine based project, subcribing to a user group is the way to go.
Use care when selecting your turbocharger! You need a large turbo with a single non-divided turbine inlet. The bigger the turbo, the more thrust your finished engine will produce. I like the turbos off of large diesel engines and earth moving equipment. The use of one of these turbos will yield enough thrust output to move a vehicle of some sort pretty well. It is best to buy a rebuilt unit if possible. Ebay is the way to go here, as you can really save some money.
As a general rule, it is not so much the size of the whole turbo as it is the size of the inducer that matters. The inducer is the visible area of the compressor blades that can be seen when looking at the turbo's compressor with the covers housings on.
Looking at the turbo here will show that the air inlet is quite large at almost 5 inches in diamter, while the visible blades of the inducer are only 3 inches in diameter. This is plenty for creating enough thrust to drive a mini motorcycle, go kart, or other small vehicle. The turbo in the picture is a Cummins ST off of a big 18 wheeler truck. Here is a quick rundown of the process of how the jet works and how to figure the size of the combustion chamber you will be making for your jet engine.
The combustion chamber works by allowing compressed air coming from the turbo's compressor to be mixed with fuel and burned. The hot gasses then escape through the rear of the combustion chamber to move through the turbine stage of the turbo where the turbine extracts power from the moving gasses and converts them to rotational shaft energy.
This rotating shaft then powers the compressor attached to the other end to bring in more air to make the process continue. Any additional energy left in the hot gasses as they pass the turbine create thrust. Simple enough, but actually a bit complicated to build and get it right.
The combustion chamber is made from a large piece of tubular steel with caps on both ends. Inside of the combustion chamber is a flametube. This flametube is made of another smaller piece of tubing which runs the length of the combustion chamber and has many holes drilled in it.
The holes allow the compressed air to pass through in certain ratios which are beneficial for 3 steps. Step one is mixing the air and fuel. The combustion process also begins here. Step to is to provide air for the completion of combustion, and step three is to supply cooling air to lower the temperatures before the airstream comes into contact with the turbine blades. To calculate the flametube dimensions, you double the diameter of the inducer of your turbocharger, and this will give you the diameter of the flametube.
Multiply the diameter of the Build A Boat For Treasure Jet Plane Online inducer of the turbo x 6, and this will give you the length of the flametube. Again, the inducer of the turbo is the part of the compressor blades that can be seen from the front of the turbo with the covers or housings on. While a compressor wheel in a turbo may be 5 or 6 inches in diameter, the inducer will be considerably smaller.
The inducer of the turbos I like to use ST and VT models is 3 inches in diameter, so the flame tube dimensions would be 6 inches in diameter by 18 inches in length. This is of course a recomended starting point, and can be fudged a little. I wanted a slightly smaller combustion chamber so I decided to use a 5 inch diamter flametube with a 10 inch length.
I chose the 5 inch diameter flametube primarily because the tubing is easy to aquire as diesel truck exhaust pipe. The 10 inch length was figured because the engine will be going into the small motorcycle frame of the mini jet bike eventually.
With the size of the flame tube calculated, you can then find the size of the combustion chamber. Since the flametube will fit inside of the combustion chamber, the combustion chamber housing will have to be a larger diameter.
A recomended starting point is to have a minimum 1 inch space around the flametube, and the length should be the same as the flametube. I chose an 8 inch diameter combustion chamber housing, because it fits the need for the airspace and it is a commonly available size in steel tubing.
With the 5 inch diameter flametube, I will have a 1. Try to use steel tubing instead of pipe when possible. The difference between 8 inch tubing and 8 inch pipe would be that the tubing would be measured at 8 inches outside diameter and you then select the thickness of the "wall" you need.
Now that you have the rough dimensions you will be using for your jet engine, you can proceed to putting it together with the caps on the ends and the fuel injectors. All of these parts combine to form the complete combustion chamber. To make the combustion chamber result in a simple bolt together piece, I use a method of constructing rings that will not only provide a surface to which the end caps can be bolted, but they will also hold the flametube centered in the combustion chamber.
I find going this route much easier that trying to machine the parts. You can use a milling machine, water jet, or hand tools to make the rings. Any method which gives acceptable results will work. By welding nuts on the back of these holes, bolts can be threaded right in.
This is a requirement since the back side of the rings will be inaccesible for holding nuts with a wrench once mounted on the combustor. You could still replace a nut inside of the combustor if one were to strip out, making this a better method that tapping the holes in the rings for threads. Three tack welds placed on every other flat of the nuts should hold them tight enough to keep them in place.
With the end rings ready, they can be welded on to the combustor housing. The housing must first be cut to the proper length and have the ends squared up so that everything will align properly. Start by taking a large sheet of posterboard and wrapping it around the steel tube so that the ends are squared with each other and the posterboard is pulled tight. It should make a cylinder shape around the tube, and the ends of the posterboard will be nice and square.
Slide the posterboard to one end of the tube so that the edge of the tube and posterboard cylinder ends are almost touching, making sure there is enough room to make a mark around the tube so you can grind down the metal flush with the mark. This will square one end of the tube. Next measure from the squared up end towards the other for the length you want the combustion chamber and flame tube to be. Since my combustor will be 10 inches in length, my measurement will be taken at 9.
Mark the tube, and use the posterboard to create a nice mark all the way around the tubing as before. Make nice even strokes with Build A Boat For Treasure Jet Plane Pack the wheel, and rotate the tube as you go cutting a little deeper with each pass. Don't worry about making the cut perfect, in fact you should leave a little material and clean it up later. I like to use flap discs in the angle grinder for the final cleanup.
Once the cut is made and cleaned up, use the flap disc to bevel the outside edges of both ends of the tubing just a bit to get good weld penetration. The tube is then ready for welding. Using magnetic welding clamps, center the end rings on the ends of the tubing and make sure they are flush with the tube. Place tack welds on 4 sides of the rings, and allow to cool. Once the tacks are set, use stitch welds of about 1 inch length to close the weld bead all the way around the rings.
Make a stich weld, then alternate to the other side and do the same. Use a fashion similar to tightening the lug nuts on a car, also called the "star" pattern. Do not overheat the metal, so you can avoid warping the rings. When both rings are welded on, grind the welds smooth for a nice look. This is optional, but it just makes the whole combustor look much nicer. With the main combustor housing complete, you will need 2 end caps for the combustor assembly.
One end cap will be the fuel injector side, and the other will route the hot exhaust gasses to the turbine. Fabricate 2 plates with the same diameter of your combustion chamber, in our case it will be 8 inches.
Place 12 bolt holes around the perimeter to align with the bolt holes on the end rings so they can be attached later. The injector cap need only have 2 holes in it.
One will be for the fuel injector, and the other for a spark plug. You can add more holes for more injectors if you like, as this is a personal preference. I will be using 5 inejectors, with one in the center and 4 in a circular pattern around it.
The only requirement is that the injectors be placed so that they end up in the flametube when the parts are bolted together. For our design, this means that they must fit into the center of a 5 inch diamter circle in the middle of the end cap.
Offset from the center slightly, you will add the hole for your spark plug. The hole should be drilled and tapped for a 14mm x 1.
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