Last x Days Posts  1 | 3 | 7 Days  Search  Topics  Tree View  Help
  Soarer Central * Track and Major Rebuild Car Projects * Ben's Time Attack Soarer * Archive through March 19, 2016 Previous Previous    Next Next  

Author Message
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3989
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Tuesday, December 15, 2015 - 12:39 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

It has been a busy few days. The passenger side skirt has been completed, including a little work on the underside to tie it into the factory floor.

Upload

Upload

Upload


The car was turned around in the garage and the drivers side started. This side was much quicker as I already had all the measurements and technique sorted. The carbon/Kevlar/epoxy composite is currently curing.

Upload

Upload

Upload

Upload
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 843
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, December 18, 2015 - 01:25 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Is there a cover that goes over the vent on the lower guard behind the front wheel, or are you leaving that open now?

Also, interested in the bits of sheet metal you cut away in those pics. Did it pull any weight out do you reckon?

Inspiring work as always Ben.
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 844
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, December 18, 2015 - 02:15 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

You and Aaron are both famous...

Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3990
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, December 18, 2015 - 02:57 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

There is a cover to join the guard to the skirt. I am reusing the same pieces from the previous set of skirts. I am waiting to make up some small carbon pieces to join them up, as the last set used blocks of MDF painted black at the top, and metal gutter mesh at the bottom.

The bits of metal I cut out were in the way of my skirt design. They weigh something, but not much. They al went in a tip run so I didn't get to weigh them. I can say the old skirts, inner guards, brackets, and metal and other junk I pulled out weighed in at 12kg(approx. 6kg per side). The new skirts weigh in at 3kg (1.4kg each) so the car is another 9kg lighter.

I was going to either cut out or swiss cheese the sill panels, but looking at the thickness of the steel it probably isn't worth it.

In that video, are you talking about the pan across the car at the start?
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 845
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, December 18, 2015 - 07:52 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Yeah the pan across the car, which also shows Aaron wandering around taking pics, but also about halfway through they are interviewing folks in the crowd, and your car blats through in the background on one of your runs, then later (about 2/3 through) they are highlighting the run from another car and in the background yours is moving up to the start line.

3 shots in one 25-minute video makes you famous.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3991
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, December 18, 2015 - 09:30 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I saw the first and third, but totally missed the one in the middle. Well spotted.

I want to go back next year with more power, more revs, and revised aero. I would love to see 250kph.

I am currently working on a new rear diffuser. I am building the mould out of MDF. The design exploits the rules as much as possible: beginning at the axle line and running just passed the factory bumper location. In order to run a 1200mm wide diffuser, I have had to neck it in at the front. I did this using a NACA duct design spreadsheet. I am also incorporating generous radii inside the diffuser walls, and have pre-planned fins or vanes in the design, so their mounting points will be recessed in the diffuser. This has the added benefit of increasing the cross section on the diffuser roof, increasing rigidity for no weight penalty.

Pics to follow when I recover the camera from the sawdust...
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3992
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Wednesday, December 23, 2015 - 09:59 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

After the side skirts were completed I turned my attention to the rear of the car. The original aluminium sheet metal diffuser has served me well, but it is well and truly time for an update. It was designed to fit between the old twin exhaust and as such was only half as large as it could have been. So it got ripped out.


Upload


Cardboard was used to sketch out the dimensions I had to work with.

Upload


Then MDF was used to start the mould.

Upload

Upload


The shape was roughed out using the MDF, and fine tuned using builders bog.

Upload

Upload

The whole thing was coated in polyurethane and polished and waxed.

Upload

Upload
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3994
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Wednesday, December 23, 2015 - 10:07 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

The diffuser came out of the mould today. I am in the process of making some fences (vanes?) to go inside the diffuser, as well as bonding mounts to it etc.


Upload


This pic look familiar, Andrew?

Upload



Upload

Upload
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 846
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Thursday, December 24, 2015 - 09:08 am, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Very nice work mate. Did the MDF mould survive? Would be happy to discuss doing same operation with my diffuser, which is also aluminium and not optimum design.

And yep, I recognise that photo. It's my old house, isn't it?
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3995
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Thursday, December 24, 2015 - 12:19 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

MDF moulds work perfectly. I did scratch the clear coat because I used screwdrivers to extract the part. It states very clearly in every text I own, NOT to use metal tools for this very reason. I used wooden wedges on the fin/vane mould and didn't damage it at all.

Overnight I straightened the old fences from behind the rear wheels with the gentle application of heat and clamping. These were reused to form the outer vanes in the diffuser.


Upload

The central vanes were formed from a simple 'U' channel mould made from MDF. The composite part was then cut on a diagonal to form two vanes or fins. These were then bonded to the diffuser in the recesses by use of sikaflex and wide flanged rivets with cup washers on the underside to try and prevent pull through of the rivets.


Upload

Upload

Upload


I am about to go back out to the garage and work out how I want to mount it and what I am doing with the 'diff guard' at the front of the diffuser. I am also keen to provide some sort of fence to keep the airflow going around the topside of the diffuser.
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 847
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Saturday, December 26, 2015 - 09:07 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Excellent work mate. I might need to come down and have a look at this setup.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3996
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Saturday, December 26, 2015 - 10:16 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Feel free to come down. I am home for the next two weeks. Got lots of work in the garage to do.

Essentially finished the body work today. The diffuser put up a tough fight. Mounting it was a challenge. The rear tow hook had to be removed, cut and welded and then remounted.


Upload

Upload


I decided to make up some fences for the topside of the diffuser.

Upload

Upload


I also had to modify my diff guard/shield to act as the mounting point for the leading edge of the diffuser.


Upload

Upload


Pretty happy over all though.


Upload

Upload

Upload


Still need to remount the side fences on the guards. I have made up some neat carbon right angle, and a wedge shaped 'U' channel mount for the top edge.

Upload
Ryan Owens
Newbie
Leinster
V8

Posts: 3
Reg: 05-2013

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Sunday, December 27, 2015 - 12:31 am, by:  Ryan Owens (Ryano085) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Love this build Ben

Did you go for a ECU change after you went manual?

}
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3997
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Sunday, December 27, 2015 - 06:49 am, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

G'day mate, glad you like it. The car is actually a factory manual, and this is the original box. It is a factory LSD too.

When I fitted the Munro Racing high flow CT12a turbos I also started running a Haltech PS2000, which saw the power jump to 254rwkw on pump with the factory injectors maxxed out. 1000cc injectors and a swich to e85 saw 303rwkw.
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 848
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Sunday, December 27, 2015 - 11:05 am, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Great result with the diffuser Ben, it looks awesome.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3999
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Wednesday, January 06, 2016 - 09:48 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Been another busy week so far. This week I removed the factory ignition loom, ignitor, and superspark coils. In went the 1NZ coils and loom made by Matt for me a few years ago.

Initially the car would not start, backfiring and carrying on. It was suggested it might be a firing order issue, but after checking the loom twice I was convinced I had it connected to the Haltech correctly.

I jumped feet first into the PS2000 setup page to have a look. The ignition page looked OK, but the main setup page had the firing order 1-2-3-4-5-6. Knowing the firing order is actually 1-5-3-6-2-4, I tentatively changed it in the Setup. With no small amount of trepidation I fired the car up. It started fine, but idled quite rough. By this stage I was out of ideas.

Facebook came to the rescue, with Jamie, a tuner from QLD, messaging me and helping me diagnose the issue. It seems when the Haltech was wired in the coils and injectors were wired in firing order, not cylinder order.

After pulling the loom plug apart and changing the pins to the firing order, and changing the firing order back to 1-2-3-4-5-6 in the setup menu the car started and ran fine. This was a great relief to me, but some annoyance to everyone else at 9:30pm last night.

The other thing that has kept me occupied the last few days is the installation of the new Munro Racing CT20 stage 4 highflow turbos and Kurt's custom CT20 to 1JZ manifold and piping kit. The turbos look great, and the piping kit came with everything needed to put it together apart from time.


Upload

I decide to port match the Compressor housing to Kurt's hot pipes before putting them in.

Upload

I was unable to find anyone to ceramic coat the pipes for me, so I did it myself. Not sure how good the stuff from a can will be, but it is better than nothing.

Upload

I also made up a new front pipe as my old one was just not quite perfectly lined up. I figured I had a bunch of 3 inch exhaust tubing taking up space in the corner anyway.

Upload


It is all in and running, but I have two small leaks with the oil feed lines I am using, and the OEM rubber oil return hose will not seal. Toyota are getting me a new oil return hose for $35. I am trying to sort the oil feed leaks at the moment. I cant send it to the tuners until I find a solution to that little problem.


Upload

Upload

Upload

Upload
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 4002
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, January 08, 2016 - 09:00 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

All the oil leaks are fixed. New hose fixed the front oil drain leak, and reusing the old OEM oil feeds fixed the other leaks. Not sure why the AN style fittings on the ebay oil feeds leaked so badly - might just have to put that down to poorly/cheaply made. The OEM feeds needed a fair bit of manipulation to get to line up with the oil ports on the side of the block, but they managed.

It is all back together and has been fired up and warmed up. It sounds very tough when you give it a rev. I am very keen to dyno this thing and then get in and drive it.

Made up a heat shield for the intake filters but first making a paper template, then making it in 0.5mm ally before finally cutting the shape out of 1.6mm aluminium scrap.


Upload

Upload

Upload

Upload


I still need to make a lid to turn this shield into an air box of sorts. Due to the nature of the location, the intercooler pipe, and the position of the intakes being offset the lid will be a complex three dimensional shape. I am thinking I might tape a bit of cardboard or rubber over the top of everything and then do a wet layup of glass or carbon to create a lid for the box that seals perfectly.
Kurt Atzmuller
DieHard
Victoria
TT`s

Posts: 789
Reg: 05-2011

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, January 08, 2016 - 09:46 pm, by:  Kurt Atzmuller (Kurt) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Your the man Ben! Not real easy making a box to fit those twin pods but looking good!
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 4013
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Monday, March 14, 2016 - 09:06 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I had been thinking about the front splitter failure at the Snowy Mountains 1000. I don't know if it was caused by the splitter drooping and dragging on the track and subsequently failing, or if it failed and then hit the runway.

It failed at 230kph. It is possible I will hit speeds of 250kph at Phillip Island. Whilst I did a pretty good job at wrapping the leftovers in carbon and Kevlar into one single piece again, I decided maybe it was time to add some supports.

I also decided to make some front canards (dive planes in some circles) for a little bit of additional front downforce. I haven't run the car with the new skirts and massive rear diffuser so I am shooting in the dark at what the balance will be like.


Upload

Upload

Upload

Upload


The canards were made by first shaping a curved section from aluminium sheet, and then taping this to the front bar in position. Fibreglass was laid over the back of the aluminium to make it stiff enough to mould from. Carbon was laid over the aluminium and allowed to go off. The aluminium was removed and the canard trimmed to shape. It was then bonded and riveted to the front bar.
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 857
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, March 18, 2016 - 06:19 am, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Why do you have those little gates at the back end of the front splitter, down below the canards?
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 4014
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, March 18, 2016 - 06:27 am, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

They effectively extend the air dam out to the side of the car, and combined with the side fences increase front downforce for a small increase in frontal area (hence drag).

They work by the vertical rear fence impeding air flow down the side of the splitter. The side fence stops air 'spilling' off the side of the splitter a bit like end plates on a wing. This causes an increase in air pressure, which combined with the lower air pressure beneath the splitter creates a pressure differential creating downforce.
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 858
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, March 18, 2016 - 10:25 am, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Kind of what I figured.

Would they not be better with a "ramp" up the front face of the vertical rear fence, similar in profile to the canard, which should reduce drag by tipping the airflow up and over the fence?

Or

Is it acting like a Gurney flap, in which case should it not be as high as you have it?
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 859
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, March 18, 2016 - 10:39 am, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

The 2015/16 Mustang has air ducts running from outside the lower fog lights and out through the guards to spill air around the outside of the car in the same way I think you are trying to achieve. Might be something for you to consider too.



Upload



Upload
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 4015
Reg: 04-2006

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Friday, March 18, 2016 - 06:03 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Andrew McKellar wrote on Friday, March 18, 2016 - 10:25 am:

Would they not be better with a "ramp" up the front face of the vertical rear fence, similar in profile to the canard, which should reduce drag by tipping the airflow up and over the fence?




That is another way of doing it- make winglets. Then you could add a guerney flap to the winglet to make it more efficient.

Regardless of its shape frontal area is still frontal area and punches the same size hole in the air.

What I am doing is using the principle of an air dam and splitter, combined with end fences. I have some doctrine on it somewhere in either a Joseph Katz or Simon McBeath book somewhere.
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 860
Reg: 06-2008

Top of pagePrevious messageNext messageBottom of page Link to this message

Rating: N/A
Votes: 0 (Vote!)

Saturday, March 19, 2016 - 01:13 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Upload


Upload


Upload

  Administration Administration      Log Out Log Out Previous Previous      Next Next