Originally posted by knot4u
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So one of the crates was brought down to the Compton hangar F8 (the first hangar Lyle had) and was used by Cliff Putnam to build the first somewhat crude but effective 2 into 1 exhaust set on the Bearcat. Over the years that exhaust that Cliff had built was maintained on ocassion as it would break often out of those parts that were in the crates of exhaust.
One of the things that Dave Cornell brought to the table was his history in motorcycle racing. Dave as he became more involved in the Bearcat decided that a complete revamping of the exhaust system was going to be necessary. Cliff's original system while designed to be two cylinders down to one exhaust pipe which was good didn't take into account pairing of the cylinders by firing order in order to maximize the scavenging effect of the cylinders paired to achieve two to one exhaust pipes. Dave went back to AC&T who still had crates of exhaust pipes for the Turbo Compound engines picked up more pipes and started over. He was having Rich Donahue take the pipes from the crates and by cutting and fitting the Dave and Rich fitted the pipes in the pairing of cylinders to provide the optimum effect of scavenging.
The next and most secret part was to optimize the back pressure to exhaust outlet velocity by machining rings that were shaped and sized in a manner that would make the best use of the pressure cowl design that Dave and Bill Prewitt were installing based on the DC-7 cowling. Bill was an excellent sheet metal fabricator and was able to bring to reality the design Dave envisioned.
The spinner off a Bristol Beverley was adapted to the four blade propeller and we were able to close down the gap between the spinner outside diameter and the cowlings inside diameter to a ridiculously small looking dimension. Without proper exhaust augmentation the engine simply would not have had enough air going through the cowling to cool the engine. A metal plate system was developed to increase the venturi effect between the higher velocity exhaust gasses and the slower cooling air. Ultimately flight tests showed that at speed the "flat plate" area between the gap of the cowling and spinner was negated to near net zero. The spinner afterbody that was fabricated by Prewitt under Cornell's direction shaped the airflow to get the maximum use of the air going through the cowling. To finish the package the baffles were installed using silicone sealer to control the airflow better. High temperature rubber pieces were installed to manage the airflow at the cylinder base gaps.
Torque meter readings showed that the augmented improved exhaust system was good for close to 300 horsepower, the engine cylinder head temperature was reduced and flight test numbers showed a significant speed increase due to the reduced drag.
So a really good system started by Cliff Putnam was perfected and included in a package of air/engine management thought up by Dave Cornell brought to life by the metal shaping magic of Bill Prewitt. Rich Donahue gets credit for training the exhaust pipes to fit as needed. Lief was correct, working on the exhaust was a Bearcat kinda deal.
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