Kappa Performance Forum

Kappa Specific => Racing => Topic started by: DrJones on April 22, 2013, 09:03:01 AM

Title: F-Prepared GXP Build
Post by: DrJones on April 22, 2013, 09:03:01 AM
Instead of cluttering up someone else's thread I'll start a new one.
And instead of typing a bunch of stuff out I'm going to link to the other forum (GASP!) for stuff I've previously done up to now.

How it started with my ASP build about 5 years ago (http://www.solsticeforum.com/forum/f48/asp-gxp-build-44722/)

Weighed the car Saturday morning and it came in at 2340 lbs with an almost empty tank and no passenger seat.
If we switched to 10" wide wheels we would have a minimum weight of 2,400 lbs and if we keep the 11" wheels the minimum weight is 2,500 lbs.
We still haven't done much weight reduction to the front end of the car so it looks like we should be able to get a weight balance to the rear of the vehicle.


It was also the first event yesterday. The car ran great even though we need to work on the suspension since it wasn't touched from the ASP set up.
Pretty sure I had FTD yesterday too.
Here's Chris taking his son for a ride on it's maiden run in F-Prepared:
(http://i37.tinypic.com/keal8o.jpg)

Oh yeah, it needs a bit of body work on the hood, which was NOT made by Norm and it shows. All the panels made by Norm have amazing fit! Mad props to him!
Title: Re: F-Prepared GXP Build
Post by: Critterman on April 22, 2013, 10:13:03 AM
When will you know if you got FTD?  What kind of competition are you running against?  Here FP are mostly kit cars, Cobras, Daytonas, and Lotus
Title: Re: F-Prepared GXP Build
Post by: DrJones on April 22, 2013, 12:39:05 PM
When will you know if you got FTD?  What kind of competition are you running against?  Here FP are mostly kit cars, Cobras, Daytonas, and Lotus

I'll know in a couple days, the results are going to take a while due to some technical difficulties. They are usually posted the night of the event.

I should have FTD just based on being in FP. There were two cars that should have been faster (a shifter kart and an FSAE car) but they're somewhat new to it and the FSAE car was having issues (go figure!). So the competition for FTD wasn't too tough. Top PAX will be quite a bit closer as a friend in a SMF Civic was cooking pretty good and my 37.3 run needs to be 1.19 seconds faster than his run.

The kit cars you speak of should be running in E-Mod or D-mod. They aren't actually eligible for F-Prepared. But for local stuff the club can class them however they would like.
Title: Re: F-Prepared GXP Build
Post by: DrJones on April 23, 2013, 08:56:59 AM
Video from the event
https://vimeo.com/64634516 (https://vimeo.com/64634516)
Title: Re: F-Prepared GXP Build
Post by: elff on April 23, 2013, 09:02:32 AM
That is Mad Max insanity!!!!

Very very cool!!!
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on April 23, 2013, 10:28:27 AM
Dr Jones-
What kind if speeds are you hitting?  Looks like you hit 88 mph at one point and leaped in to the future.
Title: Re: F-Prepared GXP Build
Post by: DrJones on April 23, 2013, 11:11:02 AM
Dr Jones-
What kind if speeds are you hitting?  Looks like you hit 88 mph at one point and leaped in to the future.

Not sure as we didn't have the data-aqu system in the car. with the 3.23 rear gear we should be able to hit 72.5 mph in 2nd gear using 7200 rpm rev limiter.

If I were to guess on this course the fastest I went was probably around 70 right before I had to brake for the 1st left hand.
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on April 23, 2013, 12:00:50 PM
So not quite to time travel speeds then?
Title: Re: F-Prepared GXP Build
Post by: miller11386 on April 23, 2013, 12:24:37 PM
call me dumb, but is there really much of a gain from cutting the windshield off the car? I mean obviously its a weight reduction.. especially considering the weight of the glass. However I would think a poly carbonate windshield would be close to the same weight reduction without completely destroying the car... Or is there another reason to chop it?

I am only saying this because I would think chopping the windshield just made this car 100% unsellable.
Title: Re: F-Prepared GXP Build
Post by: Critterman on April 23, 2013, 12:52:07 PM
Nice run, but you seem to have a squeak in the car, every time you shift :)
Title: Re: F-Prepared GXP Build
Post by: DrJones on April 23, 2013, 01:00:28 PM
call me dumb, but is there really much of a gain from cutting the windshield off the car? I mean obviously its a weight reduction.. especially considering the weight of the glass. However I would think a poly carbonate windshield would be close to the same weight reduction without completely destroying the car... Or is there another reason to chop it?

I am only saying this because I would think chopping the windshield just made this car 100% unsellable.

It also makes it so I don't have to look around the A-Pillar. It actually blocks a lot.
Now visibility is amazing.
Title: Re: F-Prepared GXP Build
Post by: GXP_Matt on April 23, 2013, 01:19:04 PM
call me dumb, but is there really much of a gain from cutting the windshield off the car? I mean obviously its a weight reduction.. especially considering the weight of the glass. However I would think a poly carbonate windshield would be close to the same weight reduction without completely destroying the car... Or is there another reason to chop it?

I am only saying this because I would think chopping the windshield just made this car 100% unsellable.

It really is annoying to look around the A pillar when you are driving a course correctly, which means looking far ahead (you can see he is doing this by the helmet cam on the above video).  Also, the windshield isn't the only thing that is making it "unsellable."  All the interior is out, all the lights, a lot of wiring... it's already never going to be a street car again (without a ton of work), so why not chop the windshield.  This is about making a solstice as fast as possible around an autocross course, not resale value!
Title: Re: F-Prepared GXP Build
Post by: DrJones on April 23, 2013, 03:00:12 PM
It really is annoying to look around the A pillar when you are driving a course correctly, which means looking far ahead (you can see he is doing this by the helmet cam on the above video).  Also, the windshield isn't the only thing that is making it "unsellable."  All the interior is out, all the lights, a lot of wiring... it's already never going to be a street car again (without a ton of work), so why not chop the windshield.  This is about making a solstice as fast as possible around an autocross course, not resale value!

Ding Ding! When I decided to prep this car there was no thought of ever making it street legal again.
It would be sellable as a race car only.
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on April 30, 2013, 11:08:33 AM


I am only saying this because I would think chopping the windshield just made this car 100% unsellable.

You're dumb
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on April 30, 2013, 01:28:01 PM
You're dumb

Oh you smooth talker you.
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on May 01, 2013, 12:56:10 AM
His post opened with "call me dumb"

What else was I supposed to do?
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on May 01, 2013, 11:07:16 AM
His post opened with "call me dumb"

What else was I supposed to do?

Yeah I guess your hands were tied weren't they?

Miller your dumb.
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 01, 2013, 01:15:06 PM
Glad to see the internet is alive and functioning as usual! :P lol
Title: Re: F-Prepared GXP Build
Post by: elff on May 01, 2013, 01:20:18 PM
I have a new Signature
:D
Title: Re: F-Prepared GXP Build
Post by: TonyRedline on May 06, 2013, 10:07:20 AM
Nice job there Dr. That looks like a lot of fun!
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 06, 2013, 02:21:59 PM
Had another local event yesterday.
thought I had the win in Pro class but one guy (a very good driver with last years DSP national championship BMW) was not included in our class until afterwards.

Because it was Cinco De Mayo yesterday and I had a sombrero they changed my name to Alejandro.
http://nworscca.com/attachments/results/2013/2013_e2_index.htm (http://nworscca.com/attachments/results/2013/2013_e2_index.htm)

I'll take 3rd out of basically 160 competitors. I'll have to get some video loaded up later. Hopefully somebody got some pictures too.

Next Event: Spring Nationals in Lincoln Nebraska!
Title: Re: F-Prepared GXP Build
Post by: TomatoSoup on May 06, 2013, 02:31:00 PM
Wow!  Well done!
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on May 06, 2013, 02:39:34 PM
Dr Jones-

What do you do when it rains?
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on May 06, 2013, 03:37:56 PM
Dr Jones-

What do you do when it rains?

He borrows Millers car, duh.
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 06, 2013, 04:24:05 PM
He borrows Millers car, duh.

Rain-x the helmet visor and wear a rain coat (maybe) :)

Even when I had the convertible top in ASP did I run with it up in the rain. In between runs I would put it up, but during an actual run I'd leave it down.
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on May 06, 2013, 05:32:01 PM
Rain-x the helmet visor and wear a rain coat (maybe) :)

Even when I had the convertible top in ASP did I run with it up in the rain. In between runs I would put it up, but during an actual run I'd leave it down.

Your an animal
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 07, 2013, 07:07:14 AM
My 3rd dirty run from Sunday's event at Toledo.
I was the course designer and got bit by my own increasing slalom.
Went in too fast and got me behind so I ended up hitting the last cone :(

https://vimeo.com/65608134 (https://vimeo.com/65608134)
Title: Re: F-Prepared GXP Build
Post by: TonyRedline on May 07, 2013, 10:01:05 AM
OUCH!

Thats a dead link for me DrJones...
Title: Re: F-Prepared GXP Build
Post by: Critterman on May 07, 2013, 10:25:26 AM
Dead link Dr D
Title: Re: F-Prepared GXP Build
Post by: DaveOC on May 07, 2013, 11:06:36 AM
Dead link Dr D

Fixed it:

NWOR - 2013 - Event #2 - May 5th - AJones - 3rd Run on Vimeo (http://vimeo.com/65608134)
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 09, 2013, 08:39:53 AM
Thanks, Dave.
I think I also fixed the original link too.
Title: Re: F-Prepared GXP Build
Post by: DaveOC on May 09, 2013, 10:58:15 AM
Thanks, Dave.
I think I also fixed the original link too.

Yes, it's working great also.  The car is looking mean.  I hope you have a successful season. 
Title: Re: F-Prepared GXP Build
Post by: Vanguard on May 11, 2013, 04:35:27 PM
Been awhile since I've been on here... Glad to see someone's gone FP!  If I ever win the powerball, you'll have another competitor :)
Title: Re: F-Prepared GXP Build
Post by: DrJones on June 03, 2013, 10:33:12 AM
A picture from spring nationals memorial day weekend.
One day I'll get the vinyl wrap done...
(http://i44.tinypic.com/n21vnt.jpg)
Title: Re: F-Prepared GXP Build
Post by: Critterman on June 03, 2013, 10:39:30 AM
tucked in nice and tight!
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on June 03, 2013, 10:56:47 AM
Sweet!
Title: Re: F-Prepared GXP Build
Post by: LatinVenom on June 03, 2013, 10:14:38 PM
Looking good, hope you you did good at the event.
Title: Re: F-Prepared GXP Build
Post by: DrJones on September 09, 2013, 10:22:26 AM
Update:
Just got back from the 41st SCCA Solo Nationals and the SCCA Pro Finale

At the national championships I ended up taking 2nd in F-Prepared and my codriver took 4th (just missed 3rd by .041!).

At the Pro Finale, after leading until the very end, I took 3rd (.042 out of 2nd) and took 4th for the overall season in the R2 class.
Still trying to unwind after a week away from home and work.

a BIG shout out to Norm's Fiberglass and Wester's Garage! Norm for helping us lose a lot of weight and Lydon as always for his great support for getting us the power we need!

Next year we might be looking at some custom cams and E85!

(http://www.gotcone.com/photos/plog-content/images/2013-scca-tirerack-solo-national-championships/fp/img_3165.jpg)
Title: Re: F-Prepared GXP Build
Post by: elff on September 09, 2013, 10:39:01 AM
Whats the difference between FP and FP R2?
How do you get more than Full Prepared?
that sounds like a Space Balls Ludacris speed
:D

Congrats on kicking ass.  That's very impressive.
if you go E85, make sure you add the Ethanol compliant seals to your Fuel injectors.
Unfortunately you have to buy a $35 kit but all you need are the black seals from the link below
http://www.crateenginedepot.com/LNF-Fuel-Injector-Seal-Kit-217-3425-12633374-P18283.aspx (http://www.crateenginedepot.com/LNF-Fuel-Injector-Seal-Kit-217-3425-12633374-P18283.aspx)
Title: Re: F-Prepared GXP Build
Post by: DrJones on September 09, 2013, 10:46:44 AM
R2 is for the SCCA Pro Solo Series. It's a little different format.
The R2 class is a combination of all the prepared classes with appropriate handycaps to even the classes (eg. a prepared Honda CRX can run against a monster Lotus Exige)

Thanks for the heads up on the seals (sea lions? :P ). I'm sure there are a bunch of little things we need to research before anything is purchased.
Title: Re: F-Prepared GXP Build
Post by: elff on September 09, 2013, 11:14:07 AM
That is the only part our cars have that is different from the Flex Fuel compliant HHR.

I spoke in depth with Tom at CED about this.  The rest of the fuel system is identical to the HHR.
Title: Re: F-Prepared GXP Build
Post by: ihawk95 on September 09, 2013, 11:27:27 AM
Nice Job!

I saw a Miata and an RX8 on their way home on Saturday!  Both had Michigan plates on the trailers.
Title: Re: F-Prepared GXP Build
Post by: Kelu on September 09, 2013, 05:19:31 PM
Congrats Doc.
Title: Re: F-Prepared GXP Build
Post by: LatinVenom on September 09, 2013, 06:20:05 PM
Congratulations to you both.
Title: Re: F-Prepared GXP Build
Post by: Critterman on September 09, 2013, 07:25:25 PM
Congrats, good job
Title: Re: F-Prepared GXP Build
Post by: DrJones on September 19, 2013, 08:47:38 AM
Neat picture of some of the cars racing on Avon Tyres.
(http://atlantamx3.com/avon/AVON2small.jpg)
Title: Re: F-Prepared GXP Build
Post by: elff on September 19, 2013, 09:25:37 AM
My wifes first mini had Avon Tyres and I personally thought they were awesome.
Excellent dry grip and super stable in both the rain and snow.

Unfortunately, it seems like they dropped out of the US domestic market for street tires.
Title: Re: F-Prepared GXP Build
Post by: ophidia31 on September 19, 2013, 03:24:09 PM
Neat picture of some of the cars racing on Avon Tyres.
http://atlantamx3.com/avon/AVON2small.jpg (http://atlantamx3.com/avon/AVON2small.jpg)

Yellow caterham car..... Super Stalker or actual caterham? Its hard to make out the grill.
Title: Re: F-Prepared GXP Build
Post by: GXP_Matt on September 19, 2013, 04:52:39 PM
Congrats on 2nd in FP, quite an accomplishment for your first year!  Definitely showed how successful the GXP can be in that class.  I got an interesting shot of Chris spinning at Wilmington I thought I'd share:

(http://farm3.staticflickr.com/2889/9443957934_e14ef86a76_b.jpg)
Title: Re: F-Prepared GXP Build
Post by: DrJones on September 30, 2013, 01:00:54 PM
Congrats on 2nd in FP, quite an accomplishment for your first year!  Definitely showed how successful the GXP can be in that class.  I got an interesting shot of Chris spinning at Wilmington I thought I'd share:

(http://farm3.staticflickr.com/2889/9443957934_e14ef86a76_b.jpg)

Hmm, that's right about when the timing chain tensioner collapsed and we lost timing. Thanks for the shot. I'll forward that on to him and ask if he knows what's going on.
Title: Re: F-Prepared GXP Build
Post by: DrJones on September 30, 2013, 01:04:55 PM
Here's a sweet picture from Nationals by AutoxPix.com (http://www.autoxpix.com)!
(http://i40.tinypic.com/16hsux0.jpg)
Title: Re: F-Prepared GXP Build
Post by: SolNut on September 30, 2013, 05:13:06 PM
 :agree: Yes Sir!  :thumbs: :drive:
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on September 30, 2013, 05:14:52 PM
So cool!  Love that car.
Title: Re: F-Prepared GXP Build
Post by: elff on September 30, 2013, 07:06:33 PM
And then the geek in me realizes how cool the flat black helmet looks in contrast to the white car.
It really helps make the pic.
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 19, 2014, 11:45:25 AM
We were having trouble with the motor mounts.
I tore the drivers side into two pieces at some point and the replacement one didn't seem like it was doing a good job. Under full acceleration from a stop the gear shift would rise up about 2"! not to mention the replacement one was a little taller than the OE one for some reason which caused an offset of the gear shift to the right a tiny bit.

So, we made our own. And surprisingly the NVH isn't that bad... relative to what it was before the new mounts ;)
And the gear shift is centered again.

(http://i62.tinypic.com/2upg5tl.jpg)

(http://i62.tinypic.com/jsobde.jpg)

Material costs: <$50
Time: ~6 to 8 hours

Tools: Bandsaw, lathe, Drill press, welder, grinder.
Title: Re: F-Prepared GXP Build
Post by: normsf on May 19, 2014, 08:46:02 PM
Hello and great job, car looks cool. Thanks from Norm
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on May 19, 2014, 09:17:20 PM
Dr Jones is one if my favorite people. I've never met him, hardly ever see him post anymore. BUT-
He cut the top off his car
He drives like the stig
He crashes and tells
And he is smart enough to make his own solution to a problem.

Dr Jones- please clone yourself several times and send yourself out to conquer the world.


Sent from my iPhone using Tapatalk
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on May 20, 2014, 11:05:47 AM
You might want to get a room. :poke:
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 20, 2014, 11:59:58 AM
Dr Jones is one if my favorite people. I've never met him, hardly ever see him post anymore. BUT-
He cut the top off his car
He drives like the stig
He crashes and tells
And he is smart enough to make his own solution to a problem.

Dr Jones- please clone yourself several times and send yourself out to conquer the world.


Sent from my iPhone using Tapatalk

Awe thanks, You're making me blush.

You might want to get a room. :poke:

And sorry, as much as I like a Jack and ginger ale. I don't think I like this Gentleman Jack like that :P
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 20, 2014, 12:04:06 PM
Hello and great job, car looks cool. Thanks from Norm

Thanks, Norm!
All of your fiberglass is working great!

Any plans on a stock fiberglass hood? this off brand one I got (the only fiberglass piece that isn't from Norm) will have to go at some point. It's heavy even though we removed a lot of the under structure and it still doesn't fit well even though we chopped and sectioned it a bit to help it a bit.

Eventually I think a front clip will be used on the car. Either the hood and front bumper combined or Hood/bumper/quarters. But that would require some trick front quarters.
Title: Re: F-Prepared GXP Build
Post by: normsf on May 20, 2014, 11:19:26 PM
Hello, Ive always wanted to build a one piece tilt front end. It would eliminate a lot of the front tubing and complexity not to mention weight. Similar to what we build for the Fiero now. What rules can you run, can you have a upper vent to allow the hot air from the radiator go up and over the car rather than underneath, can the front tires be fully covered from the front view. Id like to incorporate the SD290 bumper into this with the top vent. The only reason I havnt done this is the roofs for the sky and Solstice have basically killed me in time and money.  Thanks Norm

(http://i167.photobucket.com/albums/u143/normsf/Dells_Run_2012497.jpg) (http://s167.photobucket.com/user/normsf/media/Dells_Run_2012497.jpg.html)

This Fiero went 155mph in the Texas Mile run, oh and guess what its all electric!
(http://i167.photobucket.com/albums/u143/normsf/DCPlasmaFierotilt.jpg) (http://s167.photobucket.com/user/normsf/media/DCPlasmaFierotilt.jpg.html)
 
(http://i167.photobucket.com/albums/u143/normsf/bobleggertsFierotiltclip.jpg) (http://s167.photobucket.com/user/normsf/media/bobleggertsFierotiltclip.jpg.html)

another race car, with the C6 headlights
(http://i167.photobucket.com/albums/u143/normsf/scottbradyracingtiltfrontfiero2.jpg) (http://s167.photobucket.com/user/normsf/media/scottbradyracingtiltfrontfiero2.jpg.html)
(http://i167.photobucket.com/albums/u143/normsf/scottbradyracingfronttiltfiero1.jpg) (http://s167.photobucket.com/user/normsf/media/scottbradyracingfronttiltfiero1.jpg.html)
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 11, 2016, 08:12:28 AM
A sneak peak of the next modification...

(http://uploads.tapatalk-cdn.com/20160511/f4a9a3bdd988ede8b0706dc783e9f208.jpg)

Sent from my SM-G920V using Tapatalk

Title: Re: F-Prepared GXP Build
Post by: 2kwk4u on May 11, 2016, 09:05:57 PM
That's a bit excessive for a differential cooler, DrJones!
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 15, 2016, 08:46:29 AM
(http://uploads.tapatalk-cdn.com/20160515/34f5209e16a1fd40f1096c9ed931bcaf.jpg)
(http://uploads.tapatalk-cdn.com/20160515/9aec278d984f5e90c353661bd4991663.jpg)
Title: Re: F-Prepared GXP Build
Post by: normsf on May 15, 2016, 11:24:59 AM
WOW!
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 16, 2016, 11:26:26 AM
Utilizing the stock radiator mounts (upper and lower)
(http://uploads.tapatalk-cdn.com/20160516/1fdfc7e73be433a6496fc1d9c14276f1.jpg)
Planning on placing the reservoir in the back.
Still debating hose/pipe running but it's looking like we'll run one line through each frame rail.
Hopefully there is enough space outboard the frame in the rear near the bumper to relocate the electric water pump
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on May 16, 2016, 11:45:23 AM
How do you plan on air exiting the trunk?
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 16, 2016, 12:16:34 PM
Cutting out the license plate opening right behind the fan.
I'll put some sort of grate/grill over the opening.
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 24, 2016, 08:58:41 AM
Ran one of the coolant lines to the rear last night.
(http://uploads.tapatalk-cdn.com/20160524/d8664f23fe03ac51fb2e947ba1272f62.jpg)
(http://uploads.tapatalk-cdn.com/20160524/02aa075006a3c3c5eac71d7704bc297b.jpg)
Title: Re: F-Prepared GXP Build
Post by: DrJones on May 26, 2016, 10:50:30 AM
Roughed in the coolant reservoir.
(http://uploads.tapatalk-cdn.com/20160526/71c4d93544fa26f879478ad8ea800f79.jpg)
Title: Re: F-Prepared GXP Build
Post by: Kelu on May 27, 2016, 01:58:33 AM
Ran one of the coolant lines to the rear last night.
Interesting real plumbing :) I didn't know our frame is so empty with no restriction that we can run a hose from front to back.
With so much more plumbing I suppose the water pump need to be upgraded, more flow & more pressure, right?
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 01, 2016, 10:57:49 AM
Interesting real plumbing :) I didn't know our frame is so empty with no restriction that we can run a hose from front to back.
With so much more plumbing I suppose the water pump need to be upgraded, more flow & more pressure, right?

Still using the Davies Craig electric waterpump.
Temps are about the same as before but the drivers seat is much cooler now that we don't have as much heat under the hood.

Next project we are working on is relocating the intercooler. Should end up with shorter piping and less weight up behind the bumper.
The big push for this is the number of cracks we had been getting in the current intercooler.

We first developed cracks in the begining of 2015. Fixed them for Nationals, ended up getting a crack at Nationals and fixing it on site.
Then about a month ago I noticed the power was down and I could actually hear the boost leaking. Pulled the intercooler to find 4 long cracks along welds.
Needless to say we are going with an intercooler with cast end tanks instead of the welded plate aluminum.

(http://i63.tinypic.com/2poqgle.jpg)
(http://i64.tinypic.com/25tuq2a.jpg)
(http://i64.tinypic.com/30vneoo.jpg)
(http://i65.tinypic.com/30hr2nl.jpg)
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on August 01, 2016, 11:02:09 AM
Holy cow. Looks like that IC fell from an airplane.
How did you fix in the spot? Duct tape and bubble gum?
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on August 01, 2016, 11:10:07 AM
What kind of intercooler is that?  You should never have a weld crack like that.
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 01, 2016, 12:19:16 PM
I'll leave the name of the company out as I had used this intercooler since 2008 without any issue. So it certainly held up great to being hit with 20 some psi over and over and over (remind you, Aluminum does not have an infinite fatigue life).

We fixed it on site with a generator and tig welder borrowed from a fellow competitor. Competitors at National autox events are the best. They want to try to beat you when you are at your best (not your worst).
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on August 01, 2016, 01:14:43 PM
For a weld to fail that way it is either a bad weld or an issue with the alloy of the filler rod.  A good weld should be stronger than the base metal so if the aluminum was fatigued the base metal should have failed first.
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 01, 2016, 01:59:52 PM
Ah, yes. I was on a different page than you.
The welds that were fixed before Nationals in the garage were cleaned very well and and back purged.
The welds that were fixed AT Nationals were wire brushed a bit a soaked in Acetone. Not the best prep work but it got us through the event (and 2nd and 3rd place).
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 01, 2016, 02:50:06 PM
A picture from this weekend's Pro-Solo in Wilmington Ohio from www.autoxpix.com (http://www.autoxpix.com)
(https://photos.smugmug.com/AUTOXPIX/2016-Wilmington-ProSolo-2/2016-Wilmington-ProSolo-2-1/i-7Fjhths/0/L/PB3_0847-1-L.jpg)
Title: Re: F-Prepared GXP Build
Post by: Critterman on August 01, 2016, 03:38:37 PM
That is a great picture.
Title: Re: F-Prepared GXP Build
Post by: Kelu on August 02, 2016, 01:33:40 AM
I like the picture ;)
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 02, 2016, 10:23:20 AM
Also found quite a bit of axial play in the turbo last night.
Swapping that one out for the one on the shelf (both stock units).
Big thanks for Solo Performance helping out with replacement down pipe gaskets!
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on August 02, 2016, 02:03:47 PM
Still running stock turbo?  Is that a class requirement?
Title: Re: F-Prepared GXP Build
Post by: elff on August 02, 2016, 09:19:51 PM
Interesting question for F-Prepared.  You are allowed to do almost anything else.  I'd have to check the rules.   The stock turbo might be in their best interest to run due to how responsive it is at lower rpms compared to larger turbos.  Top end HP isn't as important in AutoCross as it is in Track or road racing, but low end acceleration is uber important.

Super Cool Pic.

You need a James Bond Type Line

Jones,
Dr.  Jones

 :thumbs:
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 03, 2016, 07:38:51 AM
Stock turbo isn't required.
We've been looking at the Borg EFR turbos and will probably bite the bullet on one at some point.
Title: Re: F-Prepared GXP Build
Post by: Kelu on August 03, 2016, 09:18:47 AM
Initially EFR smallest model was announced with twin scroll exhaust but it was never produced, that would be a very good replacement for our stocker.
The higher ones I'm not sure they are very juicy for our slow revving engine in AutoX ...

PS: Everytime I read your nickname I hear this song in my head:
https://www.youtube.com/watch?v=I-NjWR4ZmAI
Title: Re: F-Prepared GXP Build
Post by: kwtoxman on August 04, 2016, 09:35:07 PM
Initially EFR smallest model was announced with twin scroll exhaust but it was never produced, that would be a very good replacement for our stocker.

Incorrect. Twinscroll small EFR turbos have been available for over a year, including the 6258 and 6758.

Title: Re: F-Prepared GXP Build
Post by: elff on August 05, 2016, 10:11:34 AM
I think the 6258 would be a better choice for Autocross than the 6758.
On some of the slower tighter turns, I think you would be in an RPM range where you would be waiting on a 6758 but the 6258 would be boosting.  I also think the 6258 would allow you to stay in second gear in situations where you would need to downshift with a 6758.

Title: Re: F-Prepared GXP Build
Post by: Kelu on August 08, 2016, 04:58:06 AM
Incorrect. Twinscroll small EFR turbos have been available for over a year, including the 6258 and 6758.


You sure? Because back in the days the twin scroll 6258 seem to be sold everywhere but nobody had it on stock, more investigation revealed that Borg Warner never produced that model. That sounds interesting, any back to back tests between single scroll and twin scroll of same turbo?
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 14, 2017, 02:56:13 PM
Haven't posted an update recently at all.
Lots of changes, i'll have to make a big post later.

But first...
Sunday morning at the Toledo Champ Tour, Chris came back from his first run and said the car was making a weird noise.
It really sounded like some valve train noise (up high, and near the front). I figured it was the cam phasers and associated solenoids.
After being sick the following week, I finally was able to tear it apart to replace the phasers and solenoids.
Why on earth I didn't drain the oil and check the filter immediately, I don't know. Pulled the filter cartridge to find it full of sparkly bits.
My guess is a rod bearing at this point.
Good news is that we didn't see much sparkle or debris else where in the motor. Just the filter.

Eitherway, we're in scramble mode. New short block arriving today with a bunch of other little bits and a brand new head that chris found a couple years ago on ebay for $90 or so.

ZZPerformance has lots of good bits for the ecotec line and has been really good about working with us.

[cross fingers] if everything goes ok, we should have it back together before the TnT at TEA next Saturday [/cross fingers]
Title: Re: F-Prepared GXP Build
Post by: Sol Asylum on August 14, 2017, 03:34:53 PM
You might want to just pull the valve cover and have a look, others have had the lifter mechanisms fail and make noise like you say.
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 15, 2017, 10:16:46 AM
You might want to just pull the valve cover and have a look, others have had the lifter mechanisms fail and make noise like you say.

When we did the cam gears/phasers we inspected to top end.
Eitherway, we're throwing the new head on the new shortblock.
Title: Re: F-Prepared GXP Build
Post by: Gentleman Jack on August 15, 2017, 10:40:04 AM
Capture the whole thing on video!
Speed rebuild! 
Title: Re: F-Prepared GXP Build
Post by: elff on August 15, 2017, 07:10:23 PM
is that a first gen engine?
Title: Re: F-Prepared GXP Build
Post by: DrJones on August 16, 2017, 10:57:46 AM
is that a first gen engine?
The block we pulled from the car is a 1st Gen.
The new one is a 3rd gen.