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Old 09-03-2009, 03:24 AM   #326
jhargis
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Quote:
Originally Posted by brain juice View Post
jhargis is a great guy and was very patient answering my questions.

A true asset to the Subaru community!!
Thanks! Glad I could be of help!

Quote:
Originally Posted by dumdum View Post
What is the price going to be for the new one? I all about this as well!
I don't have the final price together just yet, but it will be a good deal cheaper than the old plate along with a diff brace (It replaces both). I will have this info up on my website probably this weekend though once I figure in the labor and materials costs when all is said and done.
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Old 09-03-2009, 03:31 AM   #327
jhargis
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Well, here's the prototype. Anybody notice how much cleaner the cuts are on these? Better tooling is a good thing! The only real differences between this and the production version is that the production plates will have a solid piece of square bar welded to the plate just above the big hole that the axle goes through... The plate is kind of thin there, so I wanted to reinforce it a bit. It stretches from the bell-housing back to the center diff section.

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Old 09-05-2009, 09:49 AM   #328
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Are the torque specs different on your better bolts?
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Old 09-05-2009, 05:16 PM   #329
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when is the prototype going to be ready for sale?
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Old 09-05-2009, 07:36 PM   #330
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tlooks real good!!

I It would be nice to hear from ppl using these braces... like some 300+whp guy tracking or abusing the car...

Regards
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Old 09-07-2009, 10:50 AM   #331
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Subscribed. Nice work beefing things up. Every little bit helps.
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Old 09-07-2009, 08:35 PM   #332
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with this new design, you will still have to take the transmission out, to install it?
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Old 09-09-2009, 09:37 AM   #333
RallyIt07
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getting new gearing, when is this going to be ready??
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Old 09-14-2009, 12:10 PM   #334
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hey i tried to pm you but ur inbox is full. Pm me when u get a chance
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Old 09-22-2009, 06:54 PM   #335
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ive got an 04 5mt case. anyone need this for more research? pm me
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Old 09-23-2009, 11:21 AM   #336
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+1 Im ready to purchase asap
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Old 10-05-2009, 03:49 PM   #337
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Updates?
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Old 11-02-2009, 02:25 PM   #338
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Have my 03 wrx PPG helical gearbox coming in this week.
Would be nice to have these case reinforcements...

Are they for sale on here or online somewhere?
Seen it on http://www.nighthawkautomotive.com/ but don't see a Buy it now option, just a price. Should I just call you guys up and order over the phone?
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Old 11-02-2009, 04:56 PM   #339
hybrid gti 2
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Ahh finally getting there.

Same question as above. Trans removal?
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Old 11-03-2009, 04:06 PM   #340
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+1234 ^^^ Hope these are released soon...
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Old 11-04-2009, 06:21 PM   #341
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Pretty surprised no update yet. I guess this is a no go.......
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Old 11-05-2009, 11:51 AM   #342
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I would also like one of these to go with my upcoming ppg gear install. Any updates?
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Old 11-23-2009, 12:13 PM   #343
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Any news?
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Old 12-20-2009, 07:36 PM   #344
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So anything?
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Old 12-23-2009, 02:38 AM   #345
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Quote:
Originally Posted by Dave_RalliSpec View Post
In 2003 we developed a test rig for measuring case distortion and worked with some Drexel engineering students doing their senior design project. The transmission was attached to an engine block in normal fashion and the input shaft fixed to the crankshaft. The whole assembly was solidly bolted into the test rig and the output shafts were fixed to the rig so they could not rotate. Also the center diff was replaced with a spool that directly connected the output shaft to the front pinion. Input torque was via a torque wrench and a special socket which allowed the torque wrench to apply force directly to the crankshaft.

The case was strain gauged at several critical locations and the the torque applied in fixed steps while case distortion was measured. The limit of the torque wrench was 450 ft-lbs. Even at the maximum torque the case distortion at the areas we measured was minimal (<.0005"). We did not measure the areas of the case forward of the front support bearing (i.e. the bellhousing) because it didn't seem to be relevant.

After this we drilled a hole in the side of the case and built a fixture to allow a dial indicator to be placed on the main shaft at a point approximately centered between the support bearings. The test was repeated. At 250 ft-lbs the shaft had deflected sufficiently to put the 3rd gear separation outside the recommended range by most gear manufacturers for this type and size of gear. At 450 ft-lbs the deflection was more than 4 times the recommended gear separation.

Granted these deflections were under a static condition and under dynamic conditions are most likely a good bit lower. But with sufficient traction and high enough shockloading the deflections probably peak fairly close to these levels.
...
On some of the higher power level cars where we've torn down the transmission we have found evidence of fretting at the bearing supports which seems to indicate that the bearing races are moving relative to the case.

...
Did you ever do the same tests with straight cut gears? wouldn't straight cut gears put a lot more force pushing the case halves apart as opposed to helical cut?
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Old 12-23-2009, 09:56 PM   #346
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Sorry guys, I've been pretty far out of the loop for a while...

For now, the project is a no-go... The primary job has me working 12-14 hour days with no shortage of travel pretty much non-stop and it's been that way for a few months.

I'll keep the website up though. The support section will continue to be up on the site as well, just in case anybody who has one of the 2 types of plates on their car needs install instructions.

That's not to say that Nighthawk is down for the count though. The design is pretty much set, most of the tooling I need to make these is already done so it won't take much to get the biz back up and running.

If I could ever get any free time aside from work and sleep, I'm planning on looking into having the plates themselves cut by one of a few local machine shops I talked to last month (water jet looks promising), so all I'd have to do is weld on the tab for the bellhousing bolt and paint them.

I'll definitely post something up both here and on my website as soon as I get things back up and running... Just not sure exactly when that is going to happen. Again, I really apologize to you guys that are interested.
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Old 12-23-2009, 09:58 PM   #347
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Quote:
Originally Posted by prometheum View Post
Did you ever do the same tests with straight cut gears? wouldn't straight cut gears put a lot more force pushing the case halves apart as opposed to helical cut?
Nope. I measured case distortion of a bone stock 5mt. I'd imagine that there could be some difference in a trans with different ratios & gear tooth profiles and straight or helical layout.
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Old 12-24-2009, 12:36 AM   #348
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please star making these again !!! :-)
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Old 12-31-2009, 01:02 PM   #349
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Is there a waiting list availible one could add one's name too? If so I would definately like to be on it.
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Old 12-31-2009, 02:01 PM   #350
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Quote:
Originally Posted by jhargis View Post
Sorry guys, I've been pretty far out of the loop for a while...

For now, the project is a no-go... The primary job has me working 12-14 hour days with no shortage of travel pretty much non-stop and it's been that way for a few months.

I'll keep the website up though. The support section will continue to be up on the site as well, just in case anybody who has one of the 2 types of plates on their car needs install instructions.

That's not to say that Nighthawk is down for the count though. The design is pretty much set, most of the tooling I need to make these is already done so it won't take much to get the biz back up and running.

If I could ever get any free time aside from work and sleep, I'm planning on looking into having the plates themselves cut by one of a few local machine shops I talked to last month (water jet looks promising), so all I'd have to do is weld on the tab for the bellhousing bolt and paint them.

I'll definitely post something up both here and on my website as soon as I get things back up and running... Just not sure exactly when that is going to happen. Again, I really apologize to you guys that are interested.
I would even suggest an all-out licensing agreement with a very reputable manufacturer or two.
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