Time Attack BRZ - Page 12

JDwhiteWRX · 12-27-2021, 03:57 AM

Hey guys, Merry Christmas to you all.

I recently had a visit from a motorsport journalist and he did an article on me and the car.

Please take a look here

https://www.racefix.com.au/blog/joel...K4GS4XvKKoEkfY

* Registered users of the site do not see these ads.

speedyHAM · 12-29-2021, 12:44 AM

Quote:

Originally Posted by JDwhiteWRX

Hey guys, Merry Christmas to you all.

I recently had a visit from a motorsport journalist and he did an article on me and the car.

Please take a look here

https://www.racefix.com.au/blog/joel...K4GS4XvKKoEkfY

Very cool.

Menjibros · 01-05-2022, 10:25 PM

this makes me wanna learn how to fab

Homemade WRX · 02-13-2022, 12:09 PM

Bump. Bring on the goodies. I know you've been working on it!

JDwhiteWRX · 02-16-2022, 04:55 AM

I've made the lower mounting brackets for the intercooler and radiator combo. There will be some upper supports eventually too and these will form part of the structure that supports front aero and holds the bumper in place.

You can see here how it fits with the bumper in place. There is a decent amount of space for ducting to bring the air out and over the motor as a hood exit.

JDwhiteWRX · 03-07-2022, 04:06 AM

A bit of an update on some of the smaller jobs I've been doing.

I have replaced all the rod end spacers in the suspension with a much better design that now fits perfectly between the mounting tabs and has a shoulder to take up any space between the rod end and the bolt. Old spacers are the gold ones (top left photo).

I have also started work on the intercooler charge pipes. This involved cutting up my expensive turbo to weld a 90 degree elbow onto the compressor cover. I then ran into some clearance issues with the pipe fouling on the lower control arm mount.

The main subframe was removed from the car today so I can trim down this control arm mount. I could have squeezed it in there but I don't want the pipe resting on the top surface of the undertray as an off track excursion could result in damage to the turbo, its better to leave a gap.

With the subframe out I can also shave off the old lower shock mounts that I am no longer going to use and also make a mount for the electric water pump on the subframe.

Speaking of the cooling system, lots of progress has been made. Here is the electric water pump with a small adaptor I fabricated that will allow me to attach a -8AN line and pull water through the header tank.

Fabrication of the header tank and swirl pot is now complete. The swirl pot was very challenging to make, especially welding the notched bends to the pot as the metal was super thin from the bending process.

The header tank wasn't too difficult but it always takes me a while to get back into welding when I haven't done it for a while.

I will explain in more detail how this race style cooling system works once I have it all in the car and have run all the lines to everything.

This week I will be working on the subframe, mounting it back in the car and then finishing off the charge pipe from the turbo to the intercooler. I have actually sold my Kpower intake manifold and ordered something new which will probably take a few weeks to arrive so the charge pipes on the throttle body side will have to wait until then.

KillerBMotorsport · 03-07-2022, 06:08 AM

Nice swirl pot. Always good to see someone doing it right!

Homemade WRX · 03-08-2022, 09:52 AM

This is so much fun for me to see someone doing it right in the grassroots side of things.

JDwhiteWRX · 05-01-2022, 06:17 AM

Some small updates for you guys. I've been working on the oil and fuel tanks and getting them mounted in the car.

The dry sump oil tank is just an off the shelf item I imported from the UK. I did have some plans to make my own but I got this one cheap enough that it wasn't really worth the effort.

The fuel cell on the other hand is something I haven't really seen anyone do before but I thought it was a good idea and I think its going to work well.

The starting point for the fuel tank is a 5 gallon portable air tank which should give me a rough capacity of 17 liters. These tanks are incredibly strong as they are rated to hold up to 125psi.

My basic idea is to construct an oversized surge tank, tall and round to prevent fuel starvation. Since the car is being used for time attack it only really needs to do an out lap, hot lap and cool down lap in each session, anything more is extra weight. I have estimated I will need up to 5.6litres of E85 per lap at Sydney Motorsport park if the engine is making 800hp for example.

I have purchased a billet triple fuel pump hanger from Proflow which will require a little bit of modification to make it work with the air cylinder because the cylinder is taller than most fuel cells.

You can see below I have welded the mounting ring to the end of the air cylinder and capped off the original air hose connection. I have also shaved off the stand but I might leave the handle as it is super handy for carrying the tank.

The reason I have gone for the triple hanger version is it leaves me with the required amount of ports in the billet plate to make this system work. I will be running 2 staged Walbro 450LPH pumps (F90000274) and I will be using the port for the third pump to house my rollover vent.

I will post more photos once the mounts are made for both tanks in the car, I'm still waiting on some parts to arrive to finish all this but below is a photo of where the tanks will be sitting in the chassis, basically as close to dead center as possible with the oil tank closer to the engine.

Homemade WRX · 05-02-2022, 09:34 AM

Do the foam! Especially if it won't at least have internal baffles.

JDwhiteWRX · 05-07-2022, 05:32 AM

I got some more work done on the fuel cell today, the remaining issue was the height of the cell and my billet triple pump hanger being too short to reach the bottom.

To fix this I got some aluminium tube of a similar size to the original threaded rod that screws into the billet plate. I then worked out how much longer it needed to be, cut it in half and welded the new tube in the center to make it longer to reach the bottom.

I have only purchased one fuel pump for now as I don't require 800hp straight away, adding the second pump at a later date is easy enough.

I plan to get the tank anodised including the pump hanger carrier that I modified to prevent the corrosion you can get with E85.

I have also purchased some matching brackets to hold the tanks in place in the chassis.

These brackets are actually designed to hold welding gas cylinders against a wall. I looked at the brackets available for dry sumps but they attract the usual "dry sump tax" which basically means they are way overpriced for what they are. I also looked at just buying some large T-bolt clamps and fabricating some brackets but it was still less expensive to just buy the gas cylinder wall mounts.
I did modify them slightly so they use a nylock locking nut instead of a basic wingnut and I welded the slot the bolt goes through so it could not come out from the side.

All I need now is a couple of mounting points in the chassis which will not be very difficult and I will probably do those at the same time as I am replacing the firewall in the car. Speaking of firewalls, I will need to build one around both tanks.

JDwhiteWRX · 05-07-2022, 05:33 AM

Quote:

Originally Posted by Homemade WRX

Do the foam! Especially if it won't at least have internal baffles.

Yes I will, foam is required under the rules anyway.

JDwhiteWRX · 05-26-2022, 04:41 AM

My new intake manifold finally arrived today, this thing is a work of art!

check out the video below.

https://www.instagram.com/reel/CeA0Q...on_share_sheet

I'm going to be doing lots of work on the car now that this has arrived like replacing the firewall and finishing off all the intercooler charge pipes on the cold side.

JDwhiteWRX · 05-27-2022, 05:41 AM

Test fitting today, this intake manifold is so beautiful.

chanomatik · 05-27-2022, 10:34 AM

That's gorgeous.

BlueSTI4Me · 05-27-2022, 05:15 PM

Straight parts PRON.

JDwhiteWRX · 05-30-2022, 01:55 AM

Yesterday I made this adaptor to mount my Bosch DBW throttle body to the new intake manifold.

It turned out pretty neat and now I can finish making the cold side tube to connect it to the intercooler.

JDwhiteWRX · 06-09-2022, 02:46 AM

I have finished all the intercooler and turbo plumbing now.

Part of the reason I changed to a center feed intake manifold is that it moves the throttle body away from the front of the engine and as you can see in the photo below I now have unrestricted space behind the radiator for a fully ducted hood exit.

Next thing I'm doing is to replace the firewall in the engine bay. I've bought some big sheets of cardboard for making templates, then I will have to remove the engine and weld in the sheet metal based off those cardboard templates.

This video is a pretty good overview of where the car is at now
https://www.instagram.com/tv/CedWQES..._web_copy_link

.

06-09-2022, 02:46 AM	#293
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	I have finished all the intercooler and turbo plumbing now. Part of the reason I changed to a center feed intake manifold is that it moves the throttle body away from the front of the engine and as you can see in the photo below I now have unrestricted space behind the radiator for a fully ducted hood exit. Next thing I'm doing is to replace the firewall in the engine bay. I've bought some big sheets of cardboard for making templates, then I will have to remove the engine and weld in the sheet metal based off those cardboard templates. This video is a pretty good overview of where the car is at now https://www.instagram.com/tv/CedWQES..._web_copy_link . Last edited by JDwhiteWRX; 06-09-2022 at 05:41 AM.

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12-27-2021, 03:57 AM	#276
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	Hey guys, Merry Christmas to you all. I recently had a visit from a motorsport journalist and he did an article on me and the car. Please take a look here https://www.racefix.com.au/blog/joel...K4GS4XvKKoEkfY * Registered users of the site do not see these ads.

01-05-2022, 10:25 PM	#278
Menjibros Scooby Newbie Member#: 528210 Join Date: Jan 2022 Chapter/Region: W. Canada Location: Calgary Alberta Vehicle: 2003 Jdm Impreza WRX WRB	this makes me wanna learn how to fab

02-13-2022, 12:09 PM	#279
Homemade WRX Scooby Guru Member#: 33782 Join Date: Mar 2003 Chapter/Region: MAIC Location: Milton Keynes, UK Vehicle: 96 3MI Racing search FIRST, then PM!!!	Bump. Bring on the goodies. I know you've been working on it!

02-16-2022, 04:55 AM	#280
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	I've made the lower mounting brackets for the intercooler and radiator combo. There will be some upper supports eventually too and these will form part of the structure that supports front aero and holds the bumper in place. You can see here how it fits with the bumper in place. There is a decent amount of space for ducting to bring the air out and over the motor as a hood exit.

03-07-2022, 04:06 AM	#281
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	A bit of an update on some of the smaller jobs I've been doing. I have replaced all the rod end spacers in the suspension with a much better design that now fits perfectly between the mounting tabs and has a shoulder to take up any space between the rod end and the bolt. Old spacers are the gold ones (top left photo). I have also started work on the intercooler charge pipes. This involved cutting up my expensive turbo to weld a 90 degree elbow onto the compressor cover. I then ran into some clearance issues with the pipe fouling on the lower control arm mount. The main subframe was removed from the car today so I can trim down this control arm mount. I could have squeezed it in there but I don't want the pipe resting on the top surface of the undertray as an off track excursion could result in damage to the turbo, its better to leave a gap. With the subframe out I can also shave off the old lower shock mounts that I am no longer going to use and also make a mount for the electric water pump on the subframe. Speaking of the cooling system, lots of progress has been made. Here is the electric water pump with a small adaptor I fabricated that will allow me to attach a -8AN line and pull water through the header tank. Fabrication of the header tank and swirl pot is now complete. The swirl pot was very challenging to make, especially welding the notched bends to the pot as the metal was super thin from the bending process. The header tank wasn't too difficult but it always takes me a while to get back into welding when I haven't done it for a while. I will explain in more detail how this race style cooling system works once I have it all in the car and have run all the lines to everything. This week I will be working on the subframe, mounting it back in the car and then finishing off the charge pipe from the turbo to the intercooler. I have actually sold my Kpower intake manifold and ordered something new which will probably take a few weeks to arrive so the charge pipes on the throttle body side will have to wait until then.

03-07-2022, 06:08 AM	#282
KillerBMotorsport NASIOC Vendor Member#: 198281 Join Date: Dec 2008 Chapter/Region: MAIC Location: Virginia Vehicle: 2005 WRX/STi WRB of course	Nice swirl pot. Always good to see someone doing it right!

03-08-2022, 09:52 AM	#283
Homemade WRX Scooby Guru Member#: 33782 Join Date: Mar 2003 Chapter/Region: MAIC Location: Milton Keynes, UK Vehicle: 96 3MI Racing search FIRST, then PM!!!	This is so much fun for me to see someone doing it right in the grassroots side of things.

05-01-2022, 06:17 AM	#284
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	Some small updates for you guys. I've been working on the oil and fuel tanks and getting them mounted in the car. The dry sump oil tank is just an off the shelf item I imported from the UK. I did have some plans to make my own but I got this one cheap enough that it wasn't really worth the effort. The fuel cell on the other hand is something I haven't really seen anyone do before but I thought it was a good idea and I think its going to work well. The starting point for the fuel tank is a 5 gallon portable air tank which should give me a rough capacity of 17 liters. These tanks are incredibly strong as they are rated to hold up to 125psi. My basic idea is to construct an oversized surge tank, tall and round to prevent fuel starvation. Since the car is being used for time attack it only really needs to do an out lap, hot lap and cool down lap in each session, anything more is extra weight. I have estimated I will need up to 5.6litres of E85 per lap at Sydney Motorsport park if the engine is making 800hp for example. I have purchased a billet triple fuel pump hanger from Proflow which will require a little bit of modification to make it work with the air cylinder because the cylinder is taller than most fuel cells. You can see below I have welded the mounting ring to the end of the air cylinder and capped off the original air hose connection. I have also shaved off the stand but I might leave the handle as it is super handy for carrying the tank. The reason I have gone for the triple hanger version is it leaves me with the required amount of ports in the billet plate to make this system work. I will be running 2 staged Walbro 450LPH pumps (F90000274) and I will be using the port for the third pump to house my rollover vent. I will post more photos once the mounts are made for both tanks in the car, I'm still waiting on some parts to arrive to finish all this but below is a photo of where the tanks will be sitting in the chassis, basically as close to dead center as possible with the oil tank closer to the engine.

05-02-2022, 09:34 AM	#285
Homemade WRX Scooby Guru Member#: 33782 Join Date: Mar 2003 Chapter/Region: MAIC Location: Milton Keynes, UK Vehicle: 96 3MI Racing search FIRST, then PM!!!	Do the foam! Especially if it won't at least have internal baffles.

05-07-2022, 05:32 AM	#286
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	I got some more work done on the fuel cell today, the remaining issue was the height of the cell and my billet triple pump hanger being too short to reach the bottom. To fix this I got some aluminium tube of a similar size to the original threaded rod that screws into the billet plate. I then worked out how much longer it needed to be, cut it in half and welded the new tube in the center to make it longer to reach the bottom. I have only purchased one fuel pump for now as I don't require 800hp straight away, adding the second pump at a later date is easy enough. I plan to get the tank anodised including the pump hanger carrier that I modified to prevent the corrosion you can get with E85. I have also purchased some matching brackets to hold the tanks in place in the chassis. These brackets are actually designed to hold welding gas cylinders against a wall. I looked at the brackets available for dry sumps but they attract the usual "dry sump tax" which basically means they are way overpriced for what they are. I also looked at just buying some large T-bolt clamps and fabricating some brackets but it was still less expensive to just buy the gas cylinder wall mounts. I did modify them slightly so they use a nylock locking nut instead of a basic wingnut and I welded the slot the bolt goes through so it could not come out from the side. All I need now is a couple of mounting points in the chassis which will not be very difficult and I will probably do those at the same time as I am replacing the firewall in the car. Speaking of firewalls, I will need to build one around both tanks.

05-26-2022, 04:41 AM	#288
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	My new intake manifold finally arrived today, this thing is a work of art! check out the video below. https://www.instagram.com/reel/CeA0Q...on_share_sheet I'm going to be doing lots of work on the car now that this has arrived like replacing the firewall and finishing off all the intercooler charge pipes on the cold side.

05-27-2022, 05:41 AM	#289
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	Test fitting today, this intake manifold is so beautiful.

05-27-2022, 10:34 AM	#290
chanomatik Scooby Guru Member#: 159474 Join Date: Sep 2007 Chapter/Region: NESIC Location: Northbridge, MA Vehicle: 2017 Impreza Sport Lithium Red - OLDKID	That's gorgeous.

05-27-2022, 05:15 PM	#291
BlueSTI4Me Scooby Specialist Member#: 34361 Join Date: Mar 2003 Chapter/Region: MWSOC Location: MI Vehicle: 04.7 STI WRB IG @got2boostit2	Straight parts PRON.

05-30-2022, 01:55 AM	#292
JDwhiteWRX Scooby Specialist Member#: 190502 Join Date: Sep 2008 Chapter/Region: International Location: Sydney, Australia	Yesterday I made this adaptor to mount my Bosch DBW throttle body to the new intake manifold. It turned out pretty neat and now I can finish making the cold side tube to connect it to the intercooler.