NC 20BPP Time Attack / Track Car - Build Thread

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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby orx626 » Sun Oct 09, 2011 1:48 pm

Here's the long overdue update :?

It's pretty obvious that progress has been very limited over the past 2 years....however, other projects I've been working on during this period are having a positive influence on the build of this car. I just that I don't have a lot to show for my efforts at the moment. :D

Firstly, development of the RX-8 supercharger kit hit a bit of a stumbling block about this time last year when the product designer/manufacturer announced that he was unable to continue to support the product at the level that was necessary to ensure its longevity. Of course due to my own workload I was unable to proceed with the further road testing that was required. There were two main issues (one was electrical/electronic and the other mechanical/lubrication). On the positive note, initial performance results for the supercharger kit were very encouraging with torque increased by 40 to 55% in a fair spread of the engines rev range (2500-6750). Even at 7,750rpm there is just under 40% more torque available. Peak horsepower of 232rwhp was at 8,000rpm where the boost was a very mild 7 psi. Bear in mind that this is with standard headers and catalytic convertors. So things are looking very promising for the race car engine where I'll be running 14-15 psi, no cat convertors, and a Motec M800 ECU. I did take my RX-8 out to Queensland Raceway in early July last year but only completed 3 laps before an oil leak spectacularly presented itself....although, IIRC I did extract a low 62 sec lap time on the Clubman Circuit on cold tyres and the Dynamic Stability Control (DSC) left on (as I was too busy watching all the gauges for issues)! :mrgreen:

Fast forward 5 months to December 2010....the Xmas to New Year break to be exact....I dusted of the ol' girl with a view to getting the roll cage wrapped up. Here's a sequence of photos capturing the fabrication, Bear in mind that this is not a CAMS compliant cage as it has members that they don't have documented in Schedule J. But it does exceed FIA's performance requirements which is far more important. The structure significantly increases the standard chassis' beaming and torsional stiffness.

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.....then on New Years Eve at 3:15pm to be exact....this happened!!!! :shock: This is what happens when 8 piston Brembos and Enkei RPF1's crunch fingers! The project was on-hold once more! :cry:

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New Years 2011 was spent in the Holy Spirit Hospital...luckily an exceptional surgeon wasn't on leave and was able to reattach them. Best part is that they stuck! :mrgreen:

This is how the damage looked after 5 weeks....much better than both fingers being an inch shorter!!!

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This is how they look today almost 9 and a half months later after 6 months of intensive remedial therapy to get motion and strength back in them....We didn't think I'd have a nail regrow on my middle finger...so I'm very, very lucky...the dodgy part is slowly growing out. Should be gone by New Year's 2012! :lol: Beside's the dodgy finger nail...you really wouldn't know the extent of damage they experienced.

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Anyhow, enough blood and guts.....In mid-March this year we got stuck into finishing the roll cage fabrication and welding it out. I'm still to run the member behind the dash.

Now before anyone says anything about the weight of the cage and that it is overkill....simply, I don't care!!! I don't feel comfortable with anything less in an open top car! :P :P :P

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More to come......

Cheers,
Danny

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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby mx52nv » Sun Oct 09, 2011 2:01 pm

Simply awesome workmanship as usual Danny and sorry to be reminded of your injury - I can so relate. :mrgreen:

Cage looks like it is higher than the roofline in some pics so is the hardtop still able to be attached?

With the amount of rotary vehicles in your collection, I don't see why you put them all in a section of the warehouse and charge an admission fee - History of Mazda Rotary Vehicles? :lol: :lol: :lol:

Les

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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby Okibi » Sun Oct 09, 2011 2:37 pm

.. What Les said!

Given the speeds you'll be doing I don't think the cage is over kill (although a couple more bars and you'll keep the rain out). :P

Glad to see your fingers are mending, a mate did the exact same thing with his race car and almost lost a thumb.
If you had access to a car like this, would you take it back right away? Neither would I.

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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby Big G » Sun Oct 09, 2011 2:38 pm

Great to hear some more on the build DannyImage
Really sorry to hear about your injury, I can't begin to imagine how that must have felt, but you seem to be on the road to recovery, so all the best mate :beer:
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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby orx626 » Sun Oct 09, 2011 2:43 pm

mx52nv wrote:Simply awesome workmanship as usual Danny and sorry to be reminded of your injury - I can so relate. :mrgreen:


My injury was nothing on yours Les! :shock:


mx52nv wrote:Cage looks like it is higher than the roofline in some pics so is the hardtop still able to be attached?


The cage follows the internal profile of the factory hardtop so that all the factory attachment points are retained. This was one of my main requirements.


mx52nv wrote:With the amount of rotary vehicles in your collection, I don't see why you put them all in a section of the warehouse and charge an admission fee - History of Mazda Rotary Vehicles? :lol: :lol: :lol:

Les



I like the way your thinking Les!!! :mrgreen: The admission fee might be a bit rude though! :P

Cheers,
Danny

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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby orx626 » Sun Oct 09, 2011 2:45 pm

Okibi wrote:.. What Les said!

Given the speeds you'll be doing I don't think the cage is over kill (although a couple more bars and you'll keep the rain out). :P

Glad to see your fingers are mending, a mate did the exact same thing with his race car and almost lost a thumb.



Thanks Dave! Yes, these sorts of injuries are far too common...your well aware of what you're doing yet it only takes a fraction of a second and their gone...well almost!!! :lol:

Cheers,
Danny

ps. Dave are you able to remove the date reference in this thread title? :)
Last edited by orx626 on Sun Oct 09, 2011 2:48 pm, edited 1 time in total.

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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby orx626 » Sun Oct 09, 2011 2:46 pm

Big G wrote:Great to hear some more on the build DannyImage
Really sorry to hear about your injury, I can't begin to imagine how that must have felt, but you seem to be on the road to recovery, so all the best mate :beer:



Great to hear from you Geoff! Hope life's treating you well. :D

Regards,
Danny

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Re: Renesis NC Track Car - In the Build - Updated 17 April 2

Postby tbro » Sun Oct 09, 2011 3:22 pm

Seems that the period between Chrissy and NY is a nasty time !!!!

And now I know why you DIDN'T give me the finger last time we meet :lol: :lol: :lol:

Glad to see you on the mend.


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Re: Renesis NC Track Car - In the Build

Postby PaulF » Sun Oct 09, 2011 4:39 pm

Love the cage. Seriously beefy. :D

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Re: Renesis NC Track Car - In the Build

Postby Dave » Fri Oct 21, 2011 4:27 pm

Danny, I don't get on this forum much these days, however I have just gone through this build from the start this afternoon... all I can say is echoing all the preceding compliments - however... RESPECT! This is a huge undertaking and being approached very holistically. Superb workmanship and a great concept. Like the rest, I look forward to the finished product!

Cheers,
Dave
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Re: Renesis NC Track Car - In the Build

Postby orx626 » Sun Oct 23, 2011 11:58 am

Dave wrote:Danny, I don't get on this forum much these days, however I have just gone through this build from the start this afternoon... all I can say is echoing all the preceding compliments - however... RESPECT! This is a huge undertaking and being approached very holistically. Superb workmanship and a great concept. Like the rest, I look forward to the finished product!

Cheers,
Dave


Hi Dave, thanks for so many kind words about the project. I too look forward to the finished product. My biggest disappointment is that it is now near the end of 2011, some 5 years on and it's still not finished. That being said, unless I'd won the lotto, the project wouldn't have played out any different to how it has. :beer:

Regards,
Danny

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Re: Renesis NC Track Car - In the Build

Postby orx626 » Mon Oct 24, 2011 1:19 am

Okibi wrote:Danny is at Time Attack welding carbon 35 skylines back together.


As Okibi previously eluded to, I had another distraction of the automotive type this year. In March I was approached by GT Auto Garage to assist them with the engineering aspects of the build of a Pro-class entry for this years World Time Attack 2011 (Superlap) event at Eastern Creek (4-6 August). Although the vehicle was not a Mazda, there was no way in the world I was going to knock back such an opportunity. Especially when no other R35 in the world had been modified to this level before. 8)

The only problem was that the chassis wasn't available yet and wouldn't be until the first week of May....which meant that we only had some 13 weeks to build and test the car before the event! :shock:

This is the build specification for the car:

Engine
* HKS GT 800 Turbine kit
* Hi Octane Performance Coating dump pipe and turbo housings
* Side exit exhaust
* HKS Pistons
* HKS Rods
* HKS Head gasket system
* HKS Camshafts
* HKS F-Con V-Pro
* HKS Valcon Controller
* HKS EVC Boost controller
* HKS GT2 Wastegate x2
* Custom Fuel Cell
* PWR Light weight Intercooler(WRC & BTCC)
* PWR Light weight Radiator(Nascar Spec)
* PWR Light weight Oil cooler(F1 Spec)
* PWR transmission cooler(F1 Spec)
* PWR Diff cooler(F1 Spec)
* 2000cc Injectors(E85)
* 2000hp Magna Fuel Pump

Interior
* Motec Sports Dashlogger
* Roll-over Protection Structure (Meets FIA performance requirements)
* Custom Carbon Dash
* Works Bell Paddle shifter RaptorII and Boss Kit
* Bride Racing Seat
* Willans Racing 5 point Harness

Exterior
* Dry Carbon
* Aerodynamics by Andrew Brilliant (FXMD Aerodynamics)
* Front Bonnet Fenders Bumper Headlight one piece Dry carbon
* Rear Bumper Guards Boot one piece Dry Carbon
* Dry Carbon Doors
* Dry Carbon Roof
* Dry Carbon Front lower splitter
* Dual Rear Diffuser Dry Carbon
* Dual Element Rear wing Dry Carbon(GT AUTO SPEC)

Transmission/diff etc.
* PPG 6speed upgrade transmission
* Willall Racing Kevlar clutch packs
* Upgraded Front and Rear LSD's

Suspension/Handling
* HKS Hypermax 3 suspension with custom Valving/Spring rates
* Hi Octane Front Camber Arms
* Sunline Adjustable Rear Camber Arms
* Sunline Adjustable Castor Arms
* Sunline Adjustable Toe Arms

Wheels & Tyres
* Volk Racing TE37 Super Lap Edition 18 x 11 +18
* Hankook 295/30/18 Z221 tyres

Brakes
* Project Mu SCR-Pro Rotors
* Project Mu H16 Racing Pads

What the above list doesn't cover was as the custom design and fabrication work that was necessary to pull all these items together.


Some of you may have already put 2 and 2 together and worked out that the vehicle was the full carbon bodied R35 GTR. This is how it was delivered to me on the 13th May....yes, we did butcher a AUD150,000 Nissan R35 GTR. :twisted:

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It was put on a bit of a diet....throughout the build we monitored the weight as these beasts of a car aren't particularly light at almost 1,800kg in road trim. Any reduction in weight was always going to be beneficial to the cause. My first contribution was to design and manufacture the roll-over protection structure in no more than 1 week. This was so that the chassis could be sent to Sydney to get the carbon body work could get underway. Whilst this part of the build was happening the engine and transmission upgrades were being addressed.

Due to the weight saving process necessary with building a Pro-Class entry for Superlap (World Time Attack), our approach to designing the roll cage for GT Auto’s R35 GTR was somewhat less than traditional (CAMS compliant). Besides ensuring that the critical safety aspects of the roll cage were met, considerable effort was put into enhancing the beaming strength and torsional rigidity of the chassis. This was achieved through the addition of unconventional structural members (in on-road roll cages) between key node points for superior structure triangulation, and through the selection of structurally competent footplate attachment points on the GTR chassis. The weight penalty that goes hand in hand with the installation of a roll cage was minimised with the use of appropriately sized cold drawn seamless chrome-moly tubing. Here's some piccies of the roll cage fabrication....

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On its way south......

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Here's a couple of photos of the moulds being made for the carbon body...

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It was some 7 weeks before we got the chassis back from Sydney and we could proceed with tidying up the roll cage structure and start to workout how all the gear forward of the front axle and rearward of the rear axle would need to be arranged. The next series of photos tell the story. :D


July 2011 - only 5 weeks to go!!!

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It's amazing what a coat of paint can do.... 8)

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Got tyre!!! :lol:

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With less than 3 weeks to go we finally received the first piece of the carbon body...

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Cooling package sorted...

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Fuel system sorted...

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Exhaust system coming together...

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...and finally on the dyno for a tune and to get some run-in kilometres under our belts...

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Man this engine makes easy torque and hp. The engine was run at 17psi and 22psi power levels. On 17psi it made 490kw ATW and just over 800nm engine torque (uncorrected). At 22psi it made just under 600kw ATW and 1100Nm engine torque (uncorrected). The engine has been built to operate at 30 psi so it has more up its sleeve. It's quite a beast!!!

1 week left to go and we still didn't have the rest of the carbon body! :evil: After numerous phone calls and weighty discussions and agreement was reached and the parts became available...we just had to live with the lessor quality and poor execution of some aspects. The final 6 days leading up to when the R35 had to be loaded into a transporter was and still is a blur. The team worked from 7am to midnight each of those 6 days to meet the deadline. Here's a few photos from the final stages. As you would have realised by now...we never got to a race track for any testing...guess we're gonna have to do it at WTAC! :roll:

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I think the front splitter is up to the task!

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My favourite detail...the rear wing mount...designed to withstand 800kg of downforce at 280km/h.

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The side exhaust...

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The cockpit...

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...and loaded! Time for rest before the big event.

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Here's some piccies of the R35 in all its glory at WTAC 2011....

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Mr Steve Glenney of Mazda Motorsport fame did the steering for us.

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Out on the track and in the pits...

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We had a little BBQ late on the Friday as result of a leaky fuel pressure regulator which caused a fuel fire that fried one of the main chassis looms. At 2am on Saturday morning she roared back to life and we were ready to hit the track once again.

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Mr Adrian Zaini working his magic...

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The team...

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Here's a couple of vids...the first is from the front splitter.




The second is from the roof. You'll see we got baulked pretty badly which prevented Steve from going even faster....but hey we don't want to give away too much in its first ever event! :wink:




Well what can I say about the event....an absolute blast and one of my all time highlights....we ending up getting 9th outright with a 1 minute 32.4 second lap of Eastern Creek. Some 1.5 seconds of last years winning lap time and only 3.5 seconds of this years winning lap time. Not bad considering that we're up against seasoned some race teams and cars that have had millions of dollars of money invested. I believe that the Sierra Sierra Evo's engine development budget was over USD1.5 million! Mind you this was a Cosworth development. There is so much room for improvement in the aero department on the R35 as the design wasn't executed by the carbon guy particulary well. We were only able to use half of the rear downforce that is available, yet the car still achieved a maximum lateral 'g' of over 1.8!!!

The result exceeded our wildest dreams...considering the compressed time frame and zero track time prior to the event. I've learnt so much from this build that I'd be insane not to apply it on the NC. :mrgreen:

Cheers,
Danny

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Re: Renesis NC Track Car - In the Build

Postby PaulF » Mon Oct 24, 2011 2:22 am

Great write-up Danny. So did you end up just running 22psi of boost for the event, or did you "crank it up", so to speak?

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Re: Renesis NC Track Car - In the Build

Postby lightyear » Mon Oct 24, 2011 7:17 am

Nice work, it is great to be involved in such a project. It is similiar concept to my car, only much bigger budget. And i enjoyed your write up and pics of the build. Do you have any weights on the c.f parts such as the doors or the front clip. My doors are just over 2 kg's bare, and the whole front clip is <8 kg's. Mine is not dry carbon, but vac infused.
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Re: Renesis NC Track Car - In the Build

Postby orx626 » Mon Oct 24, 2011 10:35 am

PaulF wrote:Great write-up Danny. So did you end up just running 22psi of boost for the event, or did you "crank it up", so to speak?


Hi Paul, yes, as we and Steve got comfortable with the car the higher boost was level was used. The datalog info from the event found that maximum boost level achieved at the event was 20 psi.


lightyear wrote:Nice work, it is great to be involved in such a project. It is similiar concept to my car, only much bigger budget. And i enjoyed your write up and pics of the build. Do you have any weights on the c.f parts such as the doors or the front clip. My doors are just over 2 kg's bare, and the whole front clip is <8 kg's. Mine is not dry carbon, but vac infused.


Hi Lightyear, off the top of my head I think that the rear "clam" was around 12kg. I don't know what the other components weighed. All up, the car weighed 1,467kg with 60 litres of E85. I'm lookng forward to seeing how your car comes together. Keep up the excellent work.


vortex wrote:Thanks for that writeup Danny!
I was in the line up for WTAC scrutineering on Friday with Glenn and Brad's FD's directly behind the car - it sure is one imposing beast of a car! We had a good chat to Dave from GT's about the car, it's an amazing work of art! Has it got brake lights now? :oops: :P


Thanks Vortex. I'll have to make sure we catch up at next years event. Yes, it had a brake light (LED high level)...it just doesn't have a redundant one as yet :lol: ...but it definitely will before scrutineering for WTAC 2012 :wink: .

Cheers,
Danny


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