NC 20BPP Time Attack / Track Car - Build Thread

Postby **orx626** » Sat May 03, 2014 8:22 pm

April wasn't kind to progress on the race car for a number of different reasons. Hopefully May will be better.

However, April did see the fixed section of the airbox completed.

This is the air box outer shell.

The panel filter flange plate that attaches to the airbox shell was milled from a piece of 30mm think aluminium billet.

The inside profile is a negative of the panel filters urethane flange.

For the airbox to attach to the throttle body flange some minor modifications to the engine body were required....just a bit of die-grinding here and there.

With the inlet manifold removed it really highlights how low the engine is positioned in the chassis. It's just below the top flange of the chassis rails. :mrgreen:

Time to assemble the fixed section of airbox.

.....and ta-da!! The shell was glued (Sikaflex) and attached with drive pins.

It was also a good opportunity to drill and tap the throttle body flange plate for the air temperture and air pressure sensors.

....and back on the engine.

With and without the panel filter.

The crankcase breather was also remade to give more clearance to the underside of the airbox.

Other work that was completed was the installation of the ECU, PDM and ignition module assembly....

...and the design of the battery mounting bracket.

Hopefully the month of May is more productive.

Cheers,
Danny

toppertee · Postby **toppertee** » Sat May 03, 2014 10:21 pm

Top shelf! As always :BROADY:

Postby **orx626** » Sun May 11, 2014 6:59 pm

toppertee wrote:Top shelf! As always

Cheers mate! :mrgreen:

Well the beginning of May has seen quite a few items ticked off the list as we inch closer to firing the 20B up for the first time. :twisted:

The brake master cylinder is now plumbed to the front brake circuit and through to the in-cab bias adjuster.

The fuel pressure regulator has been relocated as it would've interfered with the intake air box if it had stayed where it was.

A fuel temperature sender was added to the fuel rail

The rear section of the exhaust system was painted with the appropriate hi-temp coating and refitted.

It has assumed the wiring position!

Other completed jobs are as follows:

Water pump and remote oil filter head mounted.

The water distribution manifold that delivers coolant directly to the spark plug area of the rotor housings was made and plumbed.

The ignition coil assembly has been mounted and the ignition leads measured and ordered (2 sets).

The accelerator cable bracket.

The brake booster vacuum line.

So this is where it's up to. The oil system is effectively completed with just a header tank for the coolant system left to complete the water system.

Cheers,
Danny

Postby **Okibi** » Sun May 11, 2014 8:05 pm

Dat exhaust

Postby **orx626** » Sun May 11, 2014 8:27 pm

Regie · Postby **Regie** » Sun May 11, 2014 9:08 pm

the size of that fuel line :shock:

Magpie · Postby **Magpie** » Mon May 12, 2014 8:23 am

I see a brake booster as well!

plohl · Postby **plohl** » Tue May 13, 2014 12:17 pm

Yo Danny,

Are you going to have TC set up through the Motec? Or is that against the rules?

Postby **orx626** » Tue May 13, 2014 6:38 pm

plohl wrote:Yo Danny,

Are you going to have TC set up through the Motec? Or is that against the rules?

Hi Shane,

Are you referring to traction control? If so I haven't given any thought to it at this stage and I don't believe that there are any restrictions in the rules.

Cheers,
Danny

plohl · Postby **plohl** » Tue May 13, 2014 11:08 pm

Yeah, I figure you'll still have the WSS and enough inputs for it. The SAE team recently got a yaw sensor and they're are using that for the traction map. Might be something to look into if you have some spare time

Postby **orx626** » Tue May 13, 2014 11:41 pm

plohl wrote:Yeah, I figure you'll still have the WSS and enough inputs for it. The SAE team recently got a yaw sensor and they're are using that for the traction map. Might be something to look into if you have some spare time

I've got a couple of other traction aids that will be assessed first...NA rotary torque curve and downforce.

It will be interesting to see how the theoretical model translates into reality.

Cheers,
Danny

plohl · Postby **plohl** » Thu May 15, 2014 11:45 pm

Yeah I bet! It'll be well interesting to see how it goes.... and sounds :mrgreen:

Postby **orx626** » Sat May 17, 2014 7:26 pm

I found a bit of spare time late this week to finalise a couple of things. However, I keep finding jobs other than my race car for my Auto Electrician to do.

The steering components that facilitate the use of the custom power steering rack are now designed and can be manufactured. These are the prototype items. The RH side is pretty much the same.

....and these are the production items.

Due to the rather large alternator I found that the dry sump front cover bracket wasn't as stiff as is necessary. So I added a bolt in stiffener between the front cover bracket and the engine front cover.

This is the battery I'm using. It weighs a huge 1.7kg

The lightweight battery bracket (190 grams) was also finished.

...and mounted.

Two sets of custom ignition leads have also been manufactured and one set installed.

...and the dip stick hole plugged.

Cheers,
Danny