240rs New Spec and Update

[driftstyre]

Winter has been somewhat slow here at DSG, along with the progress on the 240. The front end is still in the works, mainly held up by which bodywork I will use. The head was sent out to Chris Beran at Head Dynamics in Illinois and is awesome. The exhaust manifold is in the middle of fabrication for a twin scroll 3076, HKS GT 60mm wastegate and 3" to 3.5" exhaust. The pistons are being removed as the #2 cylinder wall suffered some kind of light FOD and the cylinders will be honed as well as recieving new ringsets. Everything in the engine looks great otherwise. The factory waterpump will finally be removed and the Craig Davies EWP will be used by itself. Tim at TIP Motorsports is working with the revalving and spring specs for the suspension as well as the sway bar rates. At the end of last season I installed the electric power steering setup and am happy to say it works great.

I'll update some more as I anticipate more happening in the coming weeks.

Some pics.

MR2 power steering pump.
http://www.dentsport.com/gallery/d/9748-2/DCP_1209.JPG
http://www.dentsport.com/gallery/d/9753-2/DCP_1208.JPG

Head Ports
http://www.dentsport.com/gallery/d/9494-2/DSCF5199.jpg
http://www.dentsport.com/gallery/d/9485-2/DSCF5195.jpg
http://www.dentsport.com/gallery/d/9488-2/DSCF5196.jpg

Throttle Bodies ported to match
http://www.dentsport.com/gallery/d/9733-2/DCP_1215.JPG

Turbo being mocked up
http://www.dentsport.com/gallery/d/9698-2/DSCF5278.JPG
http://www.dentsport.com/gallery/d/9703-2/DSCF5276.JPG

HKS GT 60mm
http://www.dentsport.com/gallery/d/9708-2/DCP_1214.JPG

Engine Pulled
http://www.dentsport.com/gallery/d/9713-2/DCP_1207.JPG
http://www.dentsport.com/gallery/d/9728-2/DCP_1213.JPG
http://www.dentsport.com/gallery/d/9718-2/DCP_1211.JPG

Piston/Rods
http://www.dentsport.com/gallery/d/9723-2/DCP_1218.JPG

New Dash
http://www.dentsport.com/gallery/d/9743-2/DCP_1210.JPG

[brndck]

more info on the electric p/s pump plz!

[300hp owen]

wow cool stuff, the headwork looks amazing.
I love the way you guys @ DSG build stuff.
hmmm, now for my n00b questions...
what throttle bodies are those? (I'm a little confused / new here)
is that a non-SR tranny?
what kinda power will the new build put down?
whats your favorite part of the car?

[Antihero983]

how about a writeup on the the MR2 steering pump install?

[driftstyre]

wow cool stuff, the headwork looks amazing.
I love the way you guys @ DSG build stuff.
hmmm, now for my n00b questions...
what throttle bodies are those? (I'm a little confused / new here)
is that a non-SR tranny?
what kinda power will the new build put down?
whats your favorite part of the car?

Thanks owen.
The throttles are from a Sunny GTiR
Transmission is a G-Force T5 dogbox
The new power goals are 400whp at low boost, 500whp at high
I kinda like everything on the car, whenever I don't like it anymore I try and change it:)


The EPS is an MR2 pump with custom resivoir, -6 pressure lines, run with a 75amp relay, switched on or off.

[kuruptR]

close ups of the steering column pleeeeeeeeeeeeeease!

[DJButton]

Bill, looking great as always, what is the first event on the docket for the car this year? I was bummed we didn't get to see much of it down at GT Live, I would love to see it competing this year! A friend mine is always talking about the MR-2 electric PS pump set-up, good to see someone using it. (My friend use to run one in his team's K-car over in Japan-land)

[sillyvia13]

Good stuff...

[Wiisass]

This thing is going to be awesome this season. I can't wait to get that suspension figured out and on the car.

Tim

[JVD]

Awesomeness! What are the two connectors on the firewall for(passenger side metal panel)?

[Maximamike]

Awesomeness! What are the two connectors on the firewall for(passenger side metal panel)?

Wiring harness is on plugs for quick disconnects.

[JVD]

Wiring harness is on plugs for quick disconnects.
That's what I thought. Looks like an Amphenol socket. Heh heh. Just didn't want to look dumb by assuming. Neat idea.

[300hp owen]

most excellent, thats pretty cool using the ITBs and I bet the car runs really hard (well) with the dogbox.

best of luck on the reconstruction and improvements!

[Dousan_PG]

sweet!
that G-Force T5 dogbox
did u have to get a bellhousing made to fit the SR block or ??

is it H pattern still?

which gear set did you get?
i was looking at their site a few weeks back
dogmission is the shit!!

[tknbkthrsdy4anfg]

Aaron, it looks like he hacked up a SR bellhousing, welded a plate to the back and bolted the T5 to it.
Bill, have you thought about producing these? I would be very interested.
EDIT: From DSG's website
huge pic: http://www.dentsport.com/gallery/main.php?g2_view=core%3ADownloadItem&g2_itemId=6238
From here: http://www.dentsport.com/gallery/v/dsg/DEMO/bill240_001/drivetrain_001/DSCF3413.JPG.html

[Flybert]

Do you think the electric p/s setup will work as well as the stock pump? Do you think you'll get noticeably more response from the motor with it?

[SoSideways]

Here's a video that should help answer a lot of you guys' questions:

http://www.youtube.com/watch?v=_pSvOEY8pVw

[Xandy Boosts]

I loved the tighter feeling of my steering back when I had my IS300. It was much more firm, and my friends TSX has that same feeling. Does the MR2 pump do this for the 240? Or does it just help clean up the engine bay...

[SoSideways]

I loved the tighter feeling of my steering back when I had my IS300. It was much more firm, and my friends TSX has that same feeling. Does the MR2 pump do this for the 240? Or does it just help clean up the engine bay...

Bill had to use an electric PS pump on his motor because of his turbo set up. He basically didn't have room on the driver's side of the engine bay to mount the PS pump and all its accessories.

The tighter steering feeling is probably a combination of caster setting, steering rack ratio, and tie rods/suspension pieces all working together, not just from the PS pump.

[Xandy Boosts]

Bill had to use an electric PS pump on his motor because of his turbo set up. He basically didn't have room on the driver's side of the engine bay to mount the PS pump and all its accessories.

The tighter steering feeling is probably a combination of caster setting, steering rack ratio, and tie rods/suspension pieces all working together, not just from the PS pump.

Ah gotcha. Thanks for the informative post though, +REP

[driftstyre]

Aaron,
I used an automatic bellhousing (per SMRacing's recommendations as he ran a tremec TKO on his KA at one point) machined it down and then made up an adaptor plate. All of the other stuff required was a pain but it was worth it to have a dogbox with awesome ratios for under $2500. The gears are good for 600hp in a 3600 lb car with slicks so it should be fine for me. I got the "road race ratio set". 2.46, 1.54, 1.22, 1.0 and I got a S80 .80 5th. 60mph in first and 175 vmax, close ratios in between.

tknbkthrsdy4anfg,
Enjuku approached me about making a few adaptor sets for their cars but it was right before the X-Games and we were flat out getting ready for that. I gave them some measurements and they figured the rest out in time for their drift event in Portland. If there was enough demand, I would have some adaptor plates made. I think Enjuku used the 300zx T5 rear section to move the shifter further back than mine.



sweet!
that G-Force T5 dogbox
did u have to get a bellhousing made to fit the SR block or ??

is it H pattern still?

which gear set did you get?
i was looking at their site a few weeks back
dogmission is the shit!!

[Bobafreak]

i smell redrum on the track. very nice

[driftstyre]

I think the above vid is the one where my diff explodes, this one below is better:)

http://www.youtube.com/watch?v=id2f4DO2hyc
I don't know how I just triple posted...jesus

[whiterps13]

Awesome video +1

[SoSideways]

I think the above vid is the one where my diff explodes, this one below is better:)

http://www.youtube.com/v/id2f4DO2hyc&rel=1

Damnit!

That was the video I meant to link to hahahahahaha

Awesome sliding on the hill climb :)

[fromxtor]

Bill what material is that you guys are using on your dash?

[driftstyre]

The new dash is pre-preg carbon made by robot racing. The lower half is clear coated and the upper half is some kind of matte coating.

[RedtopTech]

that was some amazing driving buddy! There were a couple times where MY butthole tightened up!

[Dousan_PG]

holy shit thanks
overtime all next week
im there
i want a dogmission.
haha


one last q!

you still run a Sr clutch/flywheel/etc?

[ms!3]

damn that is nice. +1

[driftstyre]

Aaron,
I am running an OS twin plate but with quarter master plates, 1 5/32 x 26 spline as OS doesn't make them. I talked a bit with Sean from OS Giken at PRI and they might have some discs that will work. I am running a Howe hydraulic TOB as well.

[driftstyre]

Started a bit of the manifold yesterday. Hopefully will have it done within a week or so. This is so exciting!

http://www.dentsport.com/gallery/d/9778-2/DSC00460.JPG
http://www.dentsport.com/gallery/d/9783-2/DSC00459.JPG

[Jefferson]

That manifold is looking sweet so far, those welds are looking amazing.
This car never ceases to amaze me
Keep up the good work Bill

[driftstyre]

Thanks Jefferson!

Here is the manifold tacked up. I'll remove each runner individually, weld them w/ back purging and then re install them and weld the last two welds. I still need to do the wastegate runners but will do that once I can get the head back in the car. The material is 304. I would have liked to use 321 or 316 but it would have been over 3x the money. I'm going to send the manifold to zircotec in the UK once it is completed.
http://www.dentsport.com/gallery/d/9793-2/DCP_1220.JPG
http://www.dentsport.com/gallery/d/9788-2/DCP_1221.JPG
http://www.dentsport.com/gallery/d/9798-2/DCP_1222.JPG

[MavericStephenc]

Bill,

great job with the car, I cant wait to see more updates.

[axiomatik]

mmmm, beautiful

[PoorMans180SX]

amazing work.

I take it you're getting it coated?

[driftstyre]

I will be getting the manifold coated at zircotec in the UK. Some bracing will be made for the turbo once it is back in the car.

[opponheimer]

That is so nice. Love the bracing too... I guess you're going to cut a hole in the collector later for external gate? Or are you running internal?

[sideview_180sx]

so Bill will you be getting the colored coatings they offer, hehe. I'm curious once you get the manifold completed, will you leave the jig bracing just to help with weight management when the car is running or will you have another method of supporting the turbo/manifold. its nice to see the car making progress for the upcoming season. It would awesome to see you guys make a westward appearance. Miller or Laguna would be epic.

[driftstyre]

That is so nice. Love the bracing too... I guess you're going to cut a hole in the collector later for external gate? Or are you running internal?

There will be two runners for the WG, one for each collector.

sideview, I'll be getting the natural colored white coating:) I'd love to make it out west for a time attack sometime. We usually head out 3 or 4 times for rallying but can't afford it for our own stuff:(

[driftstyre]

I forgot about the superbowl. Whatever. The manifold is done and ready for some heat. The wastegate routing is less than ideal but space is at a premium. It will work fine regardless. I need to get a 80mm V-band for the HKS 60mm. Downpipe is next but the motor needs to be back in the car. I got a cosworth headgasket, new total seal rings and had the block honed. I found a nice precision IC core and will buy that whenever I can afford to. Construction on the front end will happen in the coming weeks but I first need to finalize the intercooler and bumper. Does anyone know of any fiberglass hoods? All I find are heavy carbon ones. Light carbon ones are way out of my price range:)

I also did some calculations. I should be at 4.2lbs/hp at my estimated low boost power level.:)

http://www.dentsport.com/gallery/d/9823-2/DCP_1229.JPG
http://www.dentsport.com/gallery/d/9808-2/DCP_1226.JPG
http://www.dentsport.com/gallery/d/9818-2/DCP_1228.JPG
http://www.dentsport.com/gallery/d/9828-2/DCP_1230.JPG
http://www.dentsport.com/gallery/d/9813-2/DCP_1227.JPG

[opponheimer]

Looks like a handful of worms having sex...

So hott!

[driftstyre]

Looks like a handful of worms having sex...

So hott!

hahaha, now that I think of it, it does!
Here is a shot in the engine bay.
http://www.dentsport.com/gallery/d/9843-2/DCP_1231.JPG

[Slidin240Wayz]

WORM SEX.....hahahaha.

Nice work.

Carlos

[Maximamike]

Hire me please.

[Johny5]

god.damn.

fucking artwork, NICE!

[snowmansent2hel]

im feelin that dash

[sideview_180sx]

bill hit these guys up http://www.deftracing.com/fiber_glass_hoods/fiber_glass_hood_mainlist.htm

[a_ahmed]

that reminded me of imature years in high school when it was cool to do gummie bear sex lol... nice work

[ThatGuy]

Amazing work as always Bill. :rawk:

I can't believe I've somehow overlooked this thread until now. :duh:

I can't wait to see the car back in action again!!!

[driftstyre]

Thanks dude, Nice osprey in your sig:bigok:

Amazing work as always Bill. :rawk:

I can't believe I've somehow overlooked this thread until now. :duh:

I can't wait to see the car back in action again!!!

[steve shadows]

Do you see any specific performance advantage following your philosophy of such an oversized wastgate? I would think a single 44 mm is already overkill.

My 38/40 is perfect for my 3076R setup.

[ThatGuy]

Thanks dude, Nice osprey in your sig:bigok:

I love my aircraft! :rawk:

[driftstyre]

I mainly don't want to worry about the backpressure on a twin scroll. Depending on gear, I am planning on running between 18 to 28 lbs. I definitely know its overkill but I bought it for the same price as a 44 tial. I like overkill:)

Thatguy,
Do you work on Ospreys? Those are bad ass. Its taken a while but they seem to be reliable now (for the most part):)

Do you see any specific performance advantage following your philosophy of such an oversized wastgate? I would think a single 44 mm is already overkill.

My 38/40 is perfect for my 3076R setup.

[GSXRJJordan]

Bill your work looks awesome! I love your car, and always reference it as one of the "truly hardcore" s-chassis race cars. Also, I think it's awesome that Tim is doing the suspension :) Keep it up, and keep us posted!

[ThatGuy]

Thatguy,
Do you work on Ospreys? Those are bad ass. Its taken a while but they seem to be reliable now (for the most part):)

I was part of the squadrons that got them opperational for the Marine Corps. Right now I'm an instructor, teaching young and transition Marines how to troubleshoot and repair the electronics on them. I've flown a couple of times and it is an unbelievable experience. I can't think of any other aircraft I'd rather be working on right now.

[unicoladron]

that's an awesome looking manifold. i have never seen one like it. I've also never seen a WG positioned like that either. i like how it's visible in the engine bay tho.

and worms can't have sex, you should have said it looks like worms "dry humping" lol.

(since internet currently lacks emotion, i was being sarcastic for those who did not detect it)

[steve shadows]

I like overkill:)

:)

I can tell, nothing to be ashamed of there.


unless it offsets your weight goals :p

[driftstyre]

Finished the short block yesterday. I made a waterpump block off plate with an old waterpump and put the primary coolant temp sender there. The autronic sender is where the factory one goes. I also installed a air bleed on the rear upper most portion of the head as I have changed the routing of the coolant outlet pipe. The head is assembled but I need to measure the shims/guides and replace accordingly. Once the motor is complete I can get going on some front end fabrication. I also need to finish collecting the suspension/chassis information for Tim @ TIP so i can then send out my dampers:)

Some pics.
Water Pump Block off @ HKS temp sensor
http://www.dentsport.com/gallery/d/9945-2/DSC00512.JPG
Three Bond, the best!
http://www.dentsport.com/gallery/d/9940-2/DSC00511.JPG
Short Block Assembled
http://www.dentsport.com/gallery/d/9950-2/DSC00513.JPG

And, the new cylinder head!
http://www.dentsport.com/gallery/d/9970-2/head3web_large.jpg








Just Kidding!

Cyl Head
http://www.dentsport.com/gallery/d/9955-2/DSC00517.JPG
The port job is awesome. If anyone is interested in headwork from Head Dynamics, let me know or email chris directly
@ [email protected] He said a similar port job would be about $700.
http://www.dentsport.com/gallery/d/9965-2/DSC00516.JPG
http://www.dentsport.com/gallery/d/9960-2/DSC00514.JPG

-Bill

[upSLIDEdown]

Just Kidding!


LOL, Nice. Water pump block off looks great! Always love seeing updates on this car, especially love checking it out at VIR!

[DJButton]

Looking great as always, Bill!

[punxva]

awesome looking bill, cant wait until you guys come back down to VIR, i had a blast

[Coolwhip]

looks great! Always excited to watch this car go under the knife

[alindeman1989]

Man that thing is awesome. It looks like a blast to drive.

[GSXRJJordan]

Lol you got me with the supercharger. Wow.

Port job looks incredible, but the dyno will tell :)

Everything looks great ~ definitely among the best S-chassis builds.

[JRas]

tell us more about the power-steering setup

also the trans :D

[irritatedmax]

Hi Bill. My name is Steve and I work for Webster. I was wondering if we could use a picture of the 240RS to show the true definition of the word "amazing" in the upcoming edition of our dictionary.

[hstylez]

Damn that car is hot. I would totally love to see that thing in person. And plans of racing at mid ohio? So much work into this car...

[driftstyre]

-Punxva
I only got about 15 laps in this past year so I want to make it down again for sure. Its expensive to tow long hauls for me but I love the tracks down south and out west. I've been to most well known courses in the US but not to drive myself, just to wrench:( When I win the lotto (I guess I would have to play to win) I'm gonna get a sick Scania rig and travel the world with the Maxi:)

hahaha, thanks steve, you can use the pictures for anything

I'd like to make it to Mid Ohio with my car. I've been there a few times when I worked in World Challenge and love the course.

[driftstyre]

Lol you got me with the supercharger. Wow.

Port job looks incredible, but the dyno will tell :)

Everything looks great ~ definitely among the best S-chassis builds.
I wasn't sure what you are talking about but I assume it is that Nissan head.
Its a reverse timing chain head from a 99-00 spec BTCC Primera. Intake on the front and exhaust on the rear...crazy. Chain on the rear of the block and tranny on the front.

Just out the door to the 100 Acre Wood rally in Missouri but I thought I'd post some pics of the motor back together.
What a relief
http://www.dentsport.com/gallery/d/9973-2/DCP_1238.JPG
Cossie headgasket
http://www.dentsport.com/gallery/d/9983-2/DCP_1240.JPG
Vacuum Accumulator
http://www.dentsport.com/gallery/d/9978-2/DCP_1239.JPG

[irritatedmax]

i love tigged aluminum. there is nothing hotter. how did you learn to weld -self taught or class? i believe i read in a post a long time ago that you said you had some random degree not car related.

[driftstyre]

Started and finished the new oil pan today. The flange is 1/2" T6 that I cut on the bridgeport with the rotary wheel to do the contours. Jesus that was lame. I'm still in the stone ages here. The baffles aren't yet welded in, drain plug as well.

http://www.dentsport.com/gallery/d/9998-2/DCP_1245.JPG
http://www.dentsport.com/gallery/d/10003-2/DCP_1242.JPG
http://www.dentsport.com/gallery/d/9993-2/DCP_1243.JPG

[driftstyre]

i love tigged aluminum. there is nothing hotter. how did you learn to weld -self taught or class? i believe i read in a post a long time ago that you said you had some random degree not car related.

Max, I read a lot of information about TIG welding before I started. I bought a scratch start DC inverter for a $500 and just practiced. It forces you to be very steady and precise, good when you are just learning. I also had a master NASA certified welder critique some stuff when I started and he gave me some good advice. I have a degree in multimedia but work doing what I love the most. It doesn't really pay too well but its all I really want to do.

[ms!3]

im speechless, very nice work man, cant wait to see more progress on this thing.

[S14DB]

You use the upper chain guide?
Is the pan angled with the lay of the motor?

[driftstyre]

You use the upper chain guide?
Is the pan angled with the lay of the motor?

You mean the stopper thing on top of the gears? I use all of the factory chain system. It doesn't look to angled in the photos but is is the same height / angle as stock.

[veilside180sx]

Nice gasket choice Bill, happens to be the same one I chose as well=)

Cosworth Headgasket
http://www.sr20forum.com/gallery/data/500/medium/CIMG1781.JPG

[S14DB]

You mean the stopper thing on top of the gears? I use all of the factory chain system.
There is a TSB to remove that guide cause it breaks. 97+ motors don't have it.

[johngriff]

Or throws metal shavings around once it wears down that black coating.

Bill, what does your oil pump system look like? Thinking about going dry sump?

[driftstyre]

Or throws metal shavings around once it wears down that black coating.

Bill, what does your oil pump system look like? Thinking about going dry sump?



John,

The upper guide has a good amount of plastic left and I used a new one less than 1000 miles ago. Hopefully everything is alright:boink:

The oil pump is stock w/ a 1.5mm shim, runs 6 bar cold and 4 bar hot on 15/50 with external HP1 filter and mocal cooler. The new cooler is twice the size and a tube/fin fluidyne unit. The oil cooler and new 18x11x4.5 precision intercooler will be one unit, ducted in and out.
One of the planned goals for next winter is a drysump setup. The ARE pans are under $500 ( I also have a contact in the UK with a few magnesium BTCC pans but am trying to find out if they are compatible with a factory rwd block. They used modified GTiR blocks but I think the pan mounting is the same.

[opponheimer]

That oil pan is worthless, very poor quality and pathetic craftsmanship..

Thats why you should give it to me!!

Good work!

[driftstyre]

I finished the heatshield for the coolant outlet and CAS. The piece is 035 Ti alloy, 3 layers of carbon aerospace heatshielding blanket material and wrapped in 010 stainless waffle covering. Next is a larger one for the master cylinders and the last will be to jacket the 2nd half of the exhaust with this combination of materials, otherwise my feet will melt (even more so than before) Its supposedly good for 2600F so my toasty feed might feel a little better now. Hopefully the manifold coating and shielding will keep vital components cool:)

http://www.dentsport.com/gallery/d/10123-2/DCP_1247.JPG
http://www.dentsport.com/gallery/d/10128-2/DCP_1248.JPG
http://www.dentsport.com/gallery/d/10133-2/DCP_1249.JPG
http://www.dentsport.com/gallery/d/10164-2/DSCF5288.JPG
http://www.dentsport.com/gallery/d/10180-2/DSCF5291.JPG
http://www.dentsport.com/gallery/d/10170-2/DSCF5290.JPG
http://www.dentsport.com/gallery/d/10175-2/DSCF5289.JPG

[driftstyre]

Started the front end over the past few nights. The supports shown are the 2 of four mounting points for the front end. The intercooler/oil cooler will be semi supported by them but their primary function will be supporting the front undertray through a series of triangulations. It will make more sense once more is fabricated but hopefully extremely indepth description gave some insight:) I also finished my brake cylinder/line heatshield. It is the same as the CAS/coolant neck heatshield except it features inconel outer shell.

http://www.dentsport.com/gallery/d/10202-2/DSCF5297.JPG
http://www.dentsport.com/gallery/d/10197-2/DSCF5302.JPG

http://www.dentsport.com/gallery/d/10220-2/DSCF5295.JPG
http://www.dentsport.com/gallery/d/10225-2/DSCF5296.JPG
http://www.dentsport.com/gallery/d/10235-2/DSCF5299.JPG
http://www.dentsport.com/gallery/d/10230-2/DSCF5298.JPG

[Coolwhip]

looks awesome man!

[GSXRJJordan]

Wow I got a stiffy over those joints... damn that's clean. I'm definitely interested to see what type of undertray you make/test, because I'll probably be making another one (for my S14) out of .020" aluminum flashing again - they just get beat up so much on the street :/

Keep the updates comin!

[driftstyre]

Jordan is that a 70-200L in that photo?

[629RWHPstang]

nice work man

[GSXRJJordan]

Jordan is that a 70-200L in that photo?

EDIT: I just figured out you're talking about my avatar... yeah it is! Lol I was looking at my bike and S13, like, "WTF?" It's a great lens, but you'd be surprised how close 200mm is when you have a full-size CCD (on the 5D and the 1D Mk3)... makes you really want the 300mm or 400mm fixed lens :)

Note: That's Brian Harte's S14 behind me too! I'm famous!

[hstylez]

Keep us updated with the photos. Super nice build. Will there be a schedule on the website for where you are taking the car this season? If you guys come to Mid Ohio I'll be there.

[driftstyre]

I'll have a schedule on the site once the site is finished being updated. I definitely want to go to mid-ohio, just depends on finances.

[driftstyre]

Just a few updates. Been working on the front end, and am confident about the way it is working out now. Its far from completion but will hold the intercooler, oil cooler and most importantly, house the four mounting points for the splitter bird cage.

http://www.dentsport.com/gallery/d/10301-2/DSCF5355.JPG
http://www.dentsport.com/gallery/d/10306-2/DSCF5361.JPG
http://www.dentsport.com/gallery/d/10311-2/DSCF5356.JPG
http://www.dentsport.com/gallery/d/10296-2/DSCF5354.JPG
http://www.dentsport.com/gallery/d/10316-2/DSCF5357.JPG

[SR20d2fourT]

freaaakkkiiiinnn awesome build!

Can't wait to see the final product.

[PoorMans180SX]

Wow, if I ever smash my front end, I'll just hire you to tube it up for me. Sheesh.

Still amazing.

[driftstyre]

Just a few other pics of the front, new blades for the sway bars and the new Precision intercooler core.
http://www.dentsport.com/gallery/d/10331-2/DSCF5369.JPG
http://www.dentsport.com/gallery/d/10362-2/DSCF5371.JPG
http://www.dentsport.com/gallery/d/10357-2/DSCF5372.JPG

[300hp owen]

whats with the yellow light sabre??!?!?!?

man, thats some amazing cage work there, the detachable front section with the alignment bosses on the bolt-on points is wicked cool. looks great, cant wait to see more pics and hear how lightweight this car is at the end of all of this.

[driftstyre]

hahaha, it does look like a lightsabre. Its one of the blades for the new sway bar setup.

[Ian]

so i just moved into a new apartment recently


and my neighbor is like "dude, you HAVE to see this 240 in this sport compact car mag that i have"


and he's talking about how it's so awesome as he looks for hte magazine


and then he pulls it out and it's the maxi


and then i laughed

[naed240sx]

Just a question about the blade style swaybar setup....So instead of putting a bar in torsion, it simply bends the yellow section of that blade, almost like a leafspring? The advantage is for easier swaybar rate changes? Do you swap in different blades, or is it done by changing the angle at which the blades are held in? Will it be adjustable from the driver's seat while in motion? If you have any online references to the subject that would be awesome.

Edit: Found this picture that explains everything. Cockpit adjustable, blade pivots to adjust stiffness. Only one blade, other side is rigid. Cool stuff.

http://www.hrpworld.com/client_images/ecommerce/client_39/products/1432_1.jpg

[sillyvia13]

Max, I read a lot of information about TIG welding before I started. I bought a scratch start DC inverter for a $500 and just practiced. It forces you to be very steady and precise, good when you are just learning. I also had a master NASA certified welder critique some stuff when I started and he gave me some good advice. I have a degree in multimedia but work doing what I love the most. It doesn't really pay too well but its all I really want to do.



bill your car is amazing! still!

love the oil pan!
love the entire car! lol...

hey what kind of welder are you useing now?
a airco? heliweld? 300amp?
lmk!
Russ
JNR!

[allntrlundrgrnd]

That is one beautiful manifold. nice driving too :bigok: +1

[nisans13turbo]

Pea Sex! :wackit:

How do you guys do this, I dont get it!

Lost Soul! :confused:

[Wiisass]

Just a question about the blade style swaybar setup....So instead of putting a bar in torsion, it simply bends the yellow section of that blade, almost like a leafspring? The advantage is for easier swaybar rate changes? Do you swap in different blades, or is it done by changing the angle at which the blades are held in? Will it be adjustable from the driver's seat while in motion? If you have any online references to the subject that would be awesome.

Edit: Found this picture that explains everything. Cockpit adjustable, blade pivots to adjust stiffness. Only one blade, other side is rigid. Cool stuff.

http://www.hrpworld.com/client_images/ecommerce/client_39/products/1432_1.jpg

The way it's supposed to work is it acts like springs in series. When the wider, flat part of the blade is inline with the endlink force line it acts as a rigid moment arm. When the flat part of the blade is perpendicular to the end link force line, the moment arm is softer and this effectively softens the rate of the bar. This is just another method of adjusting the overall stiffness of the sway bar assembly. So depending on the angle of the blade, the stiffness of the sway bar assembly will be different with it being stiffest when the blade is inline with the endlink force line. The torsion tube is still in torsion, just some of the force is used to bend the moment arm depending on its alignment.

I don't think Bill is going to have a cockpit adjustable setup. I would love for him to, but adjusting them should be easy enough. I will be spec'ing out a couple different torsion tubes for easier tuning of the suspension. I also plan on testing the stiffness of the blades throughout its range of adjustment at some point.

Tim

[driftstyre]

Ian,
Hahaha, thats awesome. Where do you live? I better get my ass in gear if I want to do any events this year.

Naed204sx,
The bar is still in torsion, just not nearly as much as it would be if completely solid without a blade. You can change tube diameter and wall thickness to suit. That photo shows a bladed setup with a cable for in-cockpit adjustability. I don't have that:(..yet. It only takes about 30 seconds to adjust these by hand in the paddock. I have worked with bladed setups on a few circuit cars and two group A rally cars and just appriciate the adjustability (especially when you are setting the car up). The blades I have are from a company in Sweden who manufacture really sweet parts for rally/rallycross cars. They are a lot cheaper than the Genesis ones (or any other ones besides surplus race parts, but are expensive to ship).

Thanks for the compliments guys.

Thanks Russ!
Whats happening? Good to hear from a new englandite. This lame weather better make way for spring. It must be cold by the river up there. William was up here today hanging out for a bit. I think his brother is going to drop off his turbo 4AG for a rebuild.

Well, thats all for now. Better get to bed, the alarm is set for 6:15, my morning 2 hours of 240rs time!

[blu808]

I've said it before and I will say it again. Bill is the shit.

Nice work bro.

[sillyvia13]

Ian,
Hahaha, thats awesome. Where do you live? I better get my ass in gear if I want to do any events this year.

Naed204sx,
The bar is still in torsion, just not nearly as much as it would be if completely solid without a blade. You can change tube diameter and wall thickness to suit. That photo shows a bladed setup with a cable for in-cockpit adjustability. I don't have that:(..yet. It only takes about 30 seconds to adjust these by hand in the paddock. I have worked with bladed setups on a few circuit cars and two group A rally cars and just appriciate the adjustability (especially when you are setting the car up). The blades I have are from a company in Sweden who manufacture really sweet parts for rally/rallycross cars. They are a lot cheaper than the Genesis ones (or any other ones besides surplus race parts, but are expensive to ship).

Thanks for the compliments guys.

Thanks Russ!
Whats happening? Good to hear from a new englandite. This lame weather better make way for spring. It must be cold by the river up there. William was up here today hanging out for a bit. I think his brother is going to drop off his turbo 4AG for a rebuild.

Well, thats all for now. Better get to bed, the alarm is set for 6:15, my morning 2 hours of 240rs time!


William...in his new EVO!? so nice..

COLD by the river you have no idea! but no matter...I keep goin...
I have ALOT of work to do! to even keep up to your dust...lol...

[BobbyDigi]

I'll have a schedule on the site once the site is finished being updated. I definitely want to go to mid-ohio, just depends on finances.

i might be able to put you up for a couple of nights, i live in Cbus

[driftstyre]

Thanks Bobby. The main cost is towing out there, probably like $400 in diesel:( , then gas for the car will be $150-175. Ron will be coming out in when we finish his new tomei 2.2 EJ207 motor for the Subaru so we might camp out at the track:)

[Ian]

Ian,
Hahaha, thats awesome. Where do you live? I better get my ass in gear if I want to do any events this year.




I'm from DC but I live in Richmond for school right now. I drift at Summit Point and VIR...We've met before at a GT Live (maybe 2 GT Live's ago?)

[driftstyre]

I finished the endtanks for the intercooler and they might need a little tweaking but they are ok. I'd love to get some better metal fabricating tools...someday. I also got my dual wall 2.5" stainless bellows (from coast fab)for the wastegate return and the twin scroll housing for the GT30. Now I can fit the exhaust and then send the housing/manifold to swain for coating.


http://www.dentsport.com/gallery/d/10461-2/DSCF5433.JPG
http://www.dentsport.com/gallery/d/10456-2/DSCF5432.JPG
http://www.dentsport.com/gallery/d/10446-2/DSCF5431.JPG

[sr20powerd]

Those end tanks look amazing

[driftstyre]

I wish I had more updates than I do. Our 4th mechanic left so its been crazy hectic with customer's cars. We also were out in Washington for a rally last week servicing for two customer's rallycars. But, I did manage to almost finish the intercooler mounting, completed my extra cheap, 17lb, triple plate clutch setup and started on the bladed sway bar setup as well. Here are a few pics. I'll hopefully be completing a bunch of stuff in the next couple of weeks. I'm slackin over here:)

Its not done but its close. I need to spend an entire day and just go crazy on some of this stuff. Its tough doing it before work from 7-9 or after from 6-9. By the time you really get into it, its almost time to leave.
http://www.dentsport.com/gallery/d/10556-2/DSCF5616.JPG
http://www.dentsport.com/gallery/d/10551-2/DSCF5614.JPG

various 4130 Chromo tubes for torsion/bladed sway bar setup.
http://www.dentsport.com/gallery/d/10576-2/DSCF5613.JPG
http://www.dentsport.com/gallery/d/10362-2/DSCF5371.JPG

Fidanza Flywheel for Tilton/QM clutches, used from Mazworx and a 1-5/32" 26 spline QuarterMaster Optimum-V triple plate from a Nextel cup car (used in one race).
http://www.dentsport.com/gallery/d/10561-2/DSCF5610.JPG
http://www.dentsport.com/gallery/d/10566-2/DSCF5611.JPG

[GSXRJJordan]

Wow, that clutch'll get the job done :)

We'll be waiting for the 'serious' update!

[Landers]

Big things goin on at DSG. Very nice work i love seeing serious work being done to 240's in New England. Keep it up!

[iHeartTheTouge]

i hope i can see this bad boy in action at VIR in october

[Sil-Eighty SE-K]

Bill......ur a fackin MANIAC!

hows everything?

[blu808]

Good stuff Bill. It was nice chatting on the phone with you yesterday.

[driftstyre]

Good stuff Bill. It was nice chatting on the phone with you yesterday.

No doubt Luke. Hopefully we can meet up if we're out there for any events this year. The FC sounds like it will be absolutely insane.

I finished the intercooler mounting/undertray cage support. It weighs 7.5 lbs and uses the intercooler as a stressed member. The intercooler adds 20lbs and the oil cooler should add 9. I measured all dimensions to 1/8th inch, which I used to be very lax about on the last front end.
I'm going to work on the exhaust exit over the next week (which requires some plasma cutting of the drivers footwell) as well as the front/rear torsion bars. I need to work some late nights soon as time is really flying by.
http://www.dentsport.com/gallery/d/10606-2/DSCF5628.JPG
http://www.dentsport.com/gallery/d/10601-2/DSCF5627.JPG
http://www.dentsport.com/gallery/d/10596-2/DSCF5624.JPG

[GSXRJJordan]

Can't wait to see that front end covered by body work and ducted... keep the pics coming :)