WAR Corsair Update 5/26/2026

Added: 2026-05-30

[00:00:01]Hello everyone, Don Don back with my next progress report on my war cors air.

[00:00:05]As you can see, today is a little overcast, but it was pretty much sunny all day. And oh, it was probably pushing almost 80 and it was one of the first days in weeks that we really didn't have any massive winds. Winds had just been knocking everything down, trees, power.

[00:00:21]All right, so um last video I was waiting on materials. I had to plug in my power cord for this thing. thing and said I had 17 minutes left. I was like, "Dang it." Um, I was waiting on materials for finishing up my intake manifold.

[00:00:38]So, I finally got the 4-in tube today. I had welded on the four tubes yesterday, two per side onto the manifolds that I had made. And then today, I just finished up the intake just before I got went out and got this camera. But, I wanted to throw the calling on to show you something real quick. Let me get a quick down and dirty of what's going on here. There's the the carburetor.

[00:01:03]Problem is this in this uh round filter I had on the uh TBI throttle body injector from Rotek not going to clear the caling. It's hitting right in here.

[00:01:14]So So I can't use that. Um my I did put my piece back on here. Um but what I did find is my original air filter from the fuel injection setup. It was hanging clear down here with a baffle on it. But if I was to take this thing and stuff it in the cowling, so it's like this. And I can just make a an oval box that's big enough to clear this and just cut across to this. So it's a 3-in hole there. So it be only be like a 4 in oval shaped something like this.

[00:01:53]4 in um 2 in radius 4 in in diameter, air filter on one side and carburetor on the other. So, three screws. And then this will have to be made up around the top for the choke mechanism and possibly the uh the fuel enrichment plus a a standoff to hook the outer cable to. But it wouldn't have to be very long. It's only 5 and 1/4 in. 5 6 7 8. So, less than um 5 6 7 8 9 less than 10 inches across is kind of what I'm thinking now.

[00:02:22]So the air will be sucked in around the inside of the cowling and that's probably in itself just going to give you some carb heat effect right there.

[00:02:31]So throw this thing out of the way. Let me go ahead and see if I can set this down and I'm going to pull this caling back off real quick.

[00:02:42]I only put in uh three screws, one per side. If you don't put these side ones in, it droops in the front.

[00:02:52]Just little quarter 28 screws, aircraft bolts. That is one over here.

[00:03:18]All nice and dirty today.

[00:03:22]White t-shirts. All right.

[00:03:27]Let's get this out of the way.

[00:03:31]And that's what we got.

[00:03:36]You can see the throttle linkage is going to sneak around here. I got a tie wrap just kind of supporting it here. I can probably get away with putting a Adell clamp on to grab it. Here I need to uh this is in full retract mode. So I need to make a bracket that I weld onto here. Aluminum piece probably just piece of 90° aluminum angle that I can put a notch in to attach this to cuz this has to be stationary cuz that's what pulls back and forth.

[00:04:05]And then the uh when she's working, see if I can do this. you know, it pulls pulls like a so and pushes back in. The extension comes out here. So, as you see, but that's the uh throttle arm I got.

[00:04:21]So, once this is anchored in, be good to go. Um, I need to trim the fuel line.

[00:04:29]It'll it'll route up through here, around through here, maybe up through here. So, I can uh I can drill I can tap this hole if it isn't already. I don't think it is, but I can tap that and put a an Adel clamp there for the fuel line.

[00:04:45]And then shorten it up. It's longer than I need. And then this this is all going to be changed up a little bit. I don't know if I'll be using this regulator or not. It's a cheapo thing, but I'm only running like 3 PSI. So So that's that's where I'm at. I had to break the uh coolant connection here in order to make this cuz this has got to come out to get the intake off. I'm sorry.

[00:05:10]I have the cooling connection here. I had to disconnect in order to put the intake together because you can't take it off without removing this hose. So, I'll probably just put a hose clamp on this one. So, if something happened, I needed to pull this off. One hose and two bolts, four bolts per side. Fuel line, disconnect throttle linkage, and the intake, whole intake system is off. So, so that's where we're at.

[00:05:40]See if I can get this up high enough so you can see it. So, it's pretty cool looking. And I took and weighed the old one. This one, remember the original fuel injection manifold with everything on it weighed 12 lb. And then when I made this whole new system, it was 6 lb.

[00:05:57]Well, just this with all the couplings, hose clamps, and the likes weighed 4 lb.

[00:06:05]I just weighed this whole intake without the carburetor and it was only 3 lb. So, it's a whole pound lighter. They're not much. It's pretty light. So, let's see.

[00:06:21]These welds didn't turn out too bad.

[00:06:23]This is the easier stuff to weld. You know, trying to get around these things is a a royal pain. When you get into these 90° corners, uh it takes a lot of heat. I welded, you know, I welded these tubes into place yesterday. I went straight on them instead of angling this one because the carb was going to hang out so far out here. I thought it would want to with the tube being clear back into here to match that side, it was going to uh possibly be a little heavy out here on the nose.

[00:06:53]So, I decided to uh I needed to get the carb out past past my bell housing for a good fit. and then it's going to be in the way of the intake. Even if it was back, it would had to set higher and then then it may not fit under the cowling at all. So, so that's where it's at. Actually looks pretty snazzy.

[00:07:16]So, uh, tomorrow I should be able to I don't have the gaskets under here. I just bolted her down just to hurry up and get it together. I'm pretty much done for the night. It's already coming up on probably 7:00, but uh it's solid.

[00:07:34]Shake the whole plane. Wings are out there shaking.

[00:07:41]So, tomorrow I'll uh I'm not going to cut this right away, but I can hook this up.

[00:07:47]Uh put the tank back on. I took the tank out to empty it so I could work on that uh leak still. find some uh aircraft supplies sells a a sealant for wet wings when they take a whole aluminum wing of the airplane and seal it up with the sealant so you can just pour gas in it.

[00:08:07]There's no bladders and then the covers they use it on covers and everything.

[00:08:10]The only problem with that stuff is, I mean, it's like it's like adhesive um glue, you know, epoxy glue where it doesn't trying to take the panels off.

[00:08:19]It's tough. And those panels are, you know, got to be like an eighth inch thick just to keep from deforming them and get them off. But, you know, and then they got a ton of screws on them.

[00:08:27]So, plus the nuts and top are all captive sealed nuts where the bolts don't go all the way through it. But, I'm going to look up and see what that stuff is if uh Aircraft Spruce, I imagine, sells it. Um, or it could just be that the gas tank's over there somewhere. Um, it could just be the I used a thicker cork gasket on it. If I use a thinner one, it might uh might do a little better, but uh the RTV stuff, you know, doesn't really want to work.

[00:08:56]It wants to uh make it soft. So, I put some on this earlier today cuz it's the way this little heat temp sensing unit was, it um it wants to fray and break those leads out. It's epoxied into that little brass body. So, I packed that full this morning. Looks like it's set up nice. So, that's kind of where we're at.

[00:09:18]I should have this together and running tomorrow. There's the bull vent.

[00:09:24]Uh it's plenty. Um, this thing I did get that lever today also. That was the last thing to show up today. So, that's what she looks like. Choke. It mounts on that little hook tab goes inside there, but it's meant to go on like this. This is the pivot point. So, when you lift up on it, it picks that up. And then this big slot here is where the uh screw would probably be right about here coming into the plate. And then uh it only gives you, if I can get it to cooperate, it only gives you a little bit of uh lift there. Probably not even a/ an inch, but it only has to come up like quarter inch. And then the idea is to hook onto this arm with my choke cable, but it's getting kind of high.

[00:10:16]It's not a push cable, but I could set it up as a push cable. Then it could come around under here and push. But the handle would be pulled out. You'd have to push it in for fuel enrichment because it lets in air here and then fuel comes up through a metering tube and then it gives you a throttle and carb enrichment. It's not a choke, it's enrichment. And all right, there's my uh hi module I bought. It was in the house after all. I threw it in the box because I'm not going to be able to use it. It's not going to work. So, like I said, it was only u $10. That's why I only spend like $10 on this stuff. If it doesn't work, I'm not out a great a lot of money. All right. Well, I guess that's going to do her. I'll keep this one kind of short being maybe 15 minutes. So, I got to go get some more gas cuz I dumped the gas out and I threw it in the lawn mower so I could mow, but I didn't get to it today cuz this showed up just I just as I was starting to mow that fin it came at like noon. So, uh and then the other part didn't show up till after 2:00.

[00:11:20]That little lever. So, the only thing I got left coming now is the seal for the back of this. So, but I want to run it and see if it's going to drip with with that little adjustment I made with the uh boat damper disc. So, all right. And then this will need to be longer to reach up to here. So the computer will still work and control the timing with the MAP sensor and RPM tables. It's XY RPM across EX map pressure readings on the Y, which is basically engine vacuum from zero, which would be 30 in to 100, which would be zero in um zero pressure. All right, I think that's going to do her.

[00:12:07]Um, like I say, I'm going to run it on the system. might try and find me a little can that I can hook up so I don't have to hook up the fuel tank, put a little gas in it, but I got to go get some more gas so I can get it running.

[00:12:20]So, I think that's all there is. Uh, the next video you should see it up and running again with this and I'll have I'll get this finished up tomorrow, too.

[00:12:28]Get this mounted, get a bracket welded on there and lock that down. Right now, this is only on like one thread. So, okay. I guess that's finally going to do her. I don't think there's anything else that I can talk about. I was just waiting on materials and I got it and I I welded all this up today. I This was the last thing I welded was this cover.

[00:12:49]So, welded that one on. Went in did dinner and then weld this on. Did these earlier. I took my time welding those on. I'd tack them, put it on there, check it, bang on it, tweak it. I was using a a rubber uh dead blow hammer, plastic hammer to smack on the intake, kind of help it settle it, let it cool down, take it off, flip it over, tack the bottom, put it back on, bolter down, tack, hit it, let her set, cool down, then then weld some, and then come back.

[00:13:14]So, it was on off welding all day.

[00:13:17]Especially mostly to let her cool down, too, cuz this thing gets so dang hot with that TIG welder. All right, that's going to do her. As always, I appreciate everybody taking time to watch my videos. Don't uh feel free to leave any comments, questions, concerns and uh appreciate the comments people leaving now and I will get this thing up and running and so the next video and I don't know tomorrow, Thursday, I should have her running and you guys see what it sounds like and how it works. All right, that's going to do her and I will catch you guys on the next one. So for now this is down or down