AFGMOTO1978 Build Thread
01-11-13, 09:27 PM
#151
6/15/09
Well, I sprung a few leaks this last weekend. The Mazmart pump seal is going away and is dribbling coolant. Already in the process of getting a new one. Also was leaking at the turbo coolant outlet line. It was just too short to maintain a seal so I made a longer loop, just need to shorten it a little. Also it was leaking at the filler cap of all places, so I replaced it.
I also finally got my 12Kg springs that was on back order from Tein. Put them on the front, as well as put my .120 front bar in, man what a difference should have done this awhile ago. I moved the 10kg springs to the back, but the rear wants to step out sooner, may revert back to the 8 Kg springs. I also put on my new rear swaybar end links finally.
Also need to replace my leaking oil injector lines with some custom SS braided units I will be making.
Well, I sprung a few leaks this last weekend. The Mazmart pump seal is going away and is dribbling coolant. Already in the process of getting a new one. Also was leaking at the turbo coolant outlet line. It was just too short to maintain a seal so I made a longer loop, just need to shorten it a little. Also it was leaking at the filler cap of all places, so I replaced it.
I also finally got my 12Kg springs that was on back order from Tein. Put them on the front, as well as put my .120 front bar in, man what a difference should have done this awhile ago. I moved the 10kg springs to the back, but the rear wants to step out sooner, may revert back to the 8 Kg springs. I also put on my new rear swaybar end links finally.
Also need to replace my leaking oil injector lines with some custom SS braided units I will be making.
01-11-13, 09:40 PM
#152
7/14/09
Update
Removed the 99 spec bumper and will be fitting up and installing the GTC bumper this week.
Sprung a leak on the driver side oil cooler, no visible signs of damage so will have to pressure test it to see where the leak is. Kinda of unusual, anyways I will see if it's repairable. In the mean time I line looped the system so I'm running with only one gigantic oil cooler.
Also, just recently installed the fast reacting Triumph AIT sensor, will see if they're is any noticeable change in the tune with the more accurate air temp readings. This will help great with sudden changes in air temps when I eventually put an AI system in the car.
This same week I will be removing the sound deadening off my R1 chassis to get it prepped for the new front clip. By the end of next week I should have a rolling chassis.
The clay modeler has completed one side of my front diffuser and is currently work on a mirror copy this month. If all goes to plan I should have my custom front splitter/diffuser done by mid August. Then the rear diffuser and the adapter piece that will allow my front splitter to be used on a 99 spec/stock front bumper.
Also bought a JDM tranny from Japan2LA, this unit has the 0.806 fifth gear ratio. Now I need the 4.3 or 4.44(FE) rear diff gear and I will be set.
JDM tranny
First Gear: 3.483
Second Gear: 2.015
Third Gear: 1.391
Fourth Gear: 1.000
Fifth Gear: 0.806
OEM Tranny
1st: 3.483
2nd: 2.015
3rd: 1.391
4th: 1.00
5th: 0.719
7/21/09
Alright started mocking up the GTC bumper and everything doesn't quite fit. Will need to do some tweaking before sanding and paint. This week is going to suck....
Update
Removed the 99 spec bumper and will be fitting up and installing the GTC bumper this week.
Sprung a leak on the driver side oil cooler, no visible signs of damage so will have to pressure test it to see where the leak is. Kinda of unusual, anyways I will see if it's repairable. In the mean time I line looped the system so I'm running with only one gigantic oil cooler.
Also, just recently installed the fast reacting Triumph AIT sensor, will see if they're is any noticeable change in the tune with the more accurate air temp readings. This will help great with sudden changes in air temps when I eventually put an AI system in the car.
This same week I will be removing the sound deadening off my R1 chassis to get it prepped for the new front clip. By the end of next week I should have a rolling chassis.
The clay modeler has completed one side of my front diffuser and is currently work on a mirror copy this month. If all goes to plan I should have my custom front splitter/diffuser done by mid August. Then the rear diffuser and the adapter piece that will allow my front splitter to be used on a 99 spec/stock front bumper.
Also bought a JDM tranny from Japan2LA, this unit has the 0.806 fifth gear ratio. Now I need the 4.3 or 4.44(FE) rear diff gear and I will be set.
JDM tranny
First Gear: 3.483
Second Gear: 2.015
Third Gear: 1.391
Fourth Gear: 1.000
Fifth Gear: 0.806
OEM Tranny
1st: 3.483
2nd: 2.015
3rd: 1.391
4th: 1.00
5th: 0.719
7/21/09
Alright started mocking up the GTC bumper and everything doesn't quite fit. Will need to do some tweaking before sanding and paint. This week is going to suck....
01-11-13, 09:49 PM
#153
Jeese and I finished stripping both the front clip and most of the chassis Wednesday night. Spoke with Phil the chassis repair guy and we will be most like putting the chassis on the rack next Wednesday. Come the end of this month I should have a rolling chassis. Peace.
Oh, the GTC bumper is going to take a lot of work to be at the level of fit and finish I want, yeah.
7/27/09
I will do a full inspection next week to see if a line to the WG has a leak.
I wish I was running with AI, I had put a deposit for the new HFS-6 unit, but haven't gotten it yet.
As far as the knock going ballistic before the boost spike? Everything else looks to be in order on the data log.
Well on a side note I finally fixed that leaking oil cooler. There was a hairline crack in the weld mid way up the side passage.
Oh, the GTC bumper is going to take a lot of work to be at the level of fit and finish I want, yeah.
7/27/09
I will do a full inspection next week to see if a line to the WG has a leak.
I wish I was running with AI, I had put a deposit for the new HFS-6 unit, but haven't gotten it yet.
As far as the knock going ballistic before the boost spike? Everything else looks to be in order on the data log.
Well on a side note I finally fixed that leaking oil cooler. There was a hairline crack in the weld mid way up the side passage.
01-11-13, 10:15 PM
#154
7/30/09
Barry Bordes pointed it out and I noticed it too, it may have been an injector dropping on me(will have to get them flow checked), but it looks more like a fuel pump pressure drop. The power was smooth up to that point and the base map is fat enough in that region. I've been driving this fuel map for a month without issue. Seems rather odd for two major items to go haywire.
9/8/09
Update,
Was working on the front bumper, found a few more holes in the bumper and had to add a few layers to the upper edge to compensate for all the material I've removed. Currently at a stoping point on the bumper until I have made the front splitter/diffuser. So close.
Also still waiting for my new FD chassis to be repaired...
Anyways, here's some pic's.
10/2/09
Alright, plaster molds are being made off of the clay models, so in a few weeks will be making fiberglass molds and start working on making the diffuser/splitter. Already have Jared on-board and asked Memphisraines if he wanted in on the build. Should have finished parts middle of November if all goes as planned.
Barry Bordes pointed it out and I noticed it too, it may have been an injector dropping on me(will have to get them flow checked), but it looks more like a fuel pump pressure drop. The power was smooth up to that point and the base map is fat enough in that region. I've been driving this fuel map for a month without issue. Seems rather odd for two major items to go haywire.
9/8/09
Update,
Was working on the front bumper, found a few more holes in the bumper and had to add a few layers to the upper edge to compensate for all the material I've removed. Currently at a stoping point on the bumper until I have made the front splitter/diffuser. So close.
Also still waiting for my new FD chassis to be repaired...
Anyways, here's some pic's.
10/2/09
Alright, plaster molds are being made off of the clay models, so in a few weeks will be making fiberglass molds and start working on making the diffuser/splitter. Already have Jared on-board and asked Memphisraines if he wanted in on the build. Should have finished parts middle of November if all goes as planned.
01-11-13, 10:23 PM
#155
11/29/09
Picked up the chassis and it looks legit. Now I just need to put in a cage, stitch weld and strategically gusset the F out of the chassis. Yeah!
12/13/09
Currently taking care of some started and unfinished projects. Dan and I just finished welding in the custom front shock towers on Dan's cage. Now he has the option to go to 6.5 and 8.5 degrees of caster instead of the stock 4.5 degrees. Will be finishing it this weekend once I get tubing for Dan's car, my FD and a E36 BMW six point.
Picked up the chassis and it looks legit. Now I just need to put in a cage, stitch weld and strategically gusset the F out of the chassis. Yeah!
12/13/09
Currently taking care of some started and unfinished projects. Dan and I just finished welding in the custom front shock towers on Dan's cage. Now he has the option to go to 6.5 and 8.5 degrees of caster instead of the stock 4.5 degrees. Will be finishing it this weekend once I get tubing for Dan's car, my FD and a E36 BMW six point.
01-11-13, 10:24 PM
#156
1/5/10
I have four points bend up and tacked in place, currently working on the rear shock tower plates and the door bars. Within the next two weeks I hope to be done with the cage and stitch welding the chassis.
Still have the Tungsten car, it's just sitting in my garage waiting for me the have the funds to buy a new Odyssey battery and do a few things to it. Will be putting an AEM EMS unit into it towards the end of the month assuming the motor is broken in.
This chassis I'm working on will be my race car, and it will be tungsten metallic silver as well to make it more confusing. Doing the build on a tight budget. Would love to paint it Roso Corsa, but I don't have the extra funds for it. The dash bar is off the front clip that was put on the chassis, it was sitting out in the elements for sometime. Will be sand blasting it and painting it black once I'm done modifying it to fit the rest of the cage.
Due to the RTA rules change where the required minimum ride height is 3.5" I won't be making a rear diffuser. The ride height negates the usability of a diffuser. Still doing the front splitter though.
I would be cool to see at a few track days.
1/11/10
I have four points bend up and tacked in place, currently working on the rear shock tower plates and the door bars. Within the next two weeks I hope to be done with the cage and stitch welding the chassis.
Still have the Tungsten car, it's just sitting in my garage waiting for me the have the funds to buy a new Odyssey battery and do a few things to it. Will be putting an AEM EMS unit into it towards the end of the month assuming the motor is broken in.
This chassis I'm working on will be my race car, and it will be tungsten metallic silver as well to make it more confusing. Doing the build on a tight budget. Would love to paint it Roso Corsa, but I don't have the extra funds for it. The dash bar is off the front clip that was put on the chassis, it was sitting out in the elements for sometime. Will be sand blasting it and painting it black once I'm done modifying it to fit the rest of the cage.
Due to the RTA rules change where the required minimum ride height is 3.5" I won't be making a rear diffuser. The ride height negates the usability of a diffuser. Still doing the front splitter though.
I would be cool to see at a few track days.
1/11/10
01-11-13, 10:32 PM
#157
1/14/10
So while doing the engine tear down I found where my omp oil leak was coming from. Good thing I was premixing, even though I poped the motor anyway.
Here's the fix, custom steel braid lines and fittings.
Making progress, made a support plate for the seat, used some cool specialty bolts so my back doesn't feel anything. Also finish welding up the back end, just need to add gussets. Then the door bars and under chassis cross bracing.
1/18/10
Just got back from LA, did a AEM Series 2 EMS debrief and initial tuning setup seminar. This will be the EMS to have once it becomes available, I'm pushing to get an early unit late summer. Lots of really cool and usable features.
2/1/10
Rethinking my game plan with the race car. May put it on hold while I save up to buy a house. I would be stupid not to buy one right now with housing prices. Ugh.....
Also, thinking of ditching my plans to run street class in RTA and just build it to ITE and Mod RTA spec's once I start on it again. Which means I'm going to change the cage a little to be legal in SCCA competition. I was going to do it eventually.
3/2/10
GTC bumper painted and on the car. Just need to cut and buff it, let the clear out gas and then 3M clear bra it.
Will be starting on the diffuser section of the front splitter I designed, tomorrow. The plaster molds look good. Will be putting a gel coat on them and then make molds off them. Should be interesting how it turns out once done. jkstill will be the beta tester once one unit is made.
AEM install sooooooon
So while doing the engine tear down I found where my omp oil leak was coming from. Good thing I was premixing, even though I poped the motor anyway.
Here's the fix, custom steel braid lines and fittings.
Making progress, made a support plate for the seat, used some cool specialty bolts so my back doesn't feel anything. Also finish welding up the back end, just need to add gussets. Then the door bars and under chassis cross bracing.
1/18/10
Just got back from LA, did a AEM Series 2 EMS debrief and initial tuning setup seminar. This will be the EMS to have once it becomes available, I'm pushing to get an early unit late summer. Lots of really cool and usable features.
2/1/10
Rethinking my game plan with the race car. May put it on hold while I save up to buy a house. I would be stupid not to buy one right now with housing prices. Ugh.....
Also, thinking of ditching my plans to run street class in RTA and just build it to ITE and Mod RTA spec's once I start on it again. Which means I'm going to change the cage a little to be legal in SCCA competition. I was going to do it eventually.
3/2/10
GTC bumper painted and on the car. Just need to cut and buff it, let the clear out gas and then 3M clear bra it.
Will be starting on the diffuser section of the front splitter I designed, tomorrow. The plaster molds look good. Will be putting a gel coat on them and then make molds off them. Should be interesting how it turns out once done. jkstill will be the beta tester once one unit is made.
AEM install sooooooon
01-11-13, 10:39 PM
#158
3/10/10
Front diffuser molds seperated, they turned out nice. Just need to do some clean up, sanding and polishing of the gel coat and the molds will be ready to make some parts. Will be getting flat stock in a few days to start working on the splitter laminates. Will be doing a thee piece laminate so the top and bottom surface will be smooth and once bonded together should be super stiff, even when made out of fiber glass.
4/18/10
Prototype splitter/diffuser part made, turned out pretty good. The part turned out really light and really stiff.
Making some changes, ordered a different resin that not as viscous and also ordered some stretchable vacuum bagging material. Also got a killer deal on some 3K twill weave carbon fiber. The plan is to test the front splitter on the 8th of May at ORP PCA track day.
4/20/10
Alright! Got the new resin and stretchalon 800 vacuum bagging material today so I will be making the other prototype diffuser part tonight. And planning on making the splitter this weekend.
4/24/10
Alright! Second part turned out really good except for the tight corners. Looks like I will have to create a epoxy or gel coat layer to get a smooth surface. Used a lighter weight fiber glass as the first layers to get a better surface without the air bubbles like the first one, it worked, but still need to tweak the process.
Anyways did a mock up of the diffuser pieces on the car, looks good. May have went to wide considering the sway bar is directly aft of the diffuser, but will do some flow studies to see how it interacts. Will be making fences for it to help keep attached airflow.
Will start on making the splitter piece Monday.
Getting the car prepped for the ORP track day on the 15th. Looks like I can drop the oil coolers, originally set them up high to clear the diffuser piece, but it looks like I went a little overkill. Will fix than down the road.
Front diffuser molds seperated, they turned out nice. Just need to do some clean up, sanding and polishing of the gel coat and the molds will be ready to make some parts. Will be getting flat stock in a few days to start working on the splitter laminates. Will be doing a thee piece laminate so the top and bottom surface will be smooth and once bonded together should be super stiff, even when made out of fiber glass.
4/18/10
Prototype splitter/diffuser part made, turned out pretty good. The part turned out really light and really stiff.
Making some changes, ordered a different resin that not as viscous and also ordered some stretchable vacuum bagging material. Also got a killer deal on some 3K twill weave carbon fiber. The plan is to test the front splitter on the 8th of May at ORP PCA track day.
4/20/10
Alright! Got the new resin and stretchalon 800 vacuum bagging material today so I will be making the other prototype diffuser part tonight. And planning on making the splitter this weekend.
4/24/10
Alright! Second part turned out really good except for the tight corners. Looks like I will have to create a epoxy or gel coat layer to get a smooth surface. Used a lighter weight fiber glass as the first layers to get a better surface without the air bubbles like the first one, it worked, but still need to tweak the process.
Anyways did a mock up of the diffuser pieces on the car, looks good. May have went to wide considering the sway bar is directly aft of the diffuser, but will do some flow studies to see how it interacts. Will be making fences for it to help keep attached airflow.
Will start on making the splitter piece Monday.
Getting the car prepped for the ORP track day on the 15th. Looks like I can drop the oil coolers, originally set them up high to clear the diffuser piece, but it looks like I went a little overkill. Will fix than down the road.
01-11-13, 10:47 PM
#159
4/28/10
First part of the proto splitter lay up is tonight.
Also having SRC Fabrication laser cut some wing mounts plates for me. Untitled Document
Also here are some wing mock-up photos. Photos show you the spacing in reference to the edge of hatch where the mounts will be.
First part of the proto splitter lay up is tonight.
Also having SRC Fabrication laser cut some wing mounts plates for me. Untitled Document
Also here are some wing mock-up photos. Photos show you the spacing in reference to the edge of hatch where the mounts will be.
01-11-13, 10:50 PM
#160
5/3/10
Made some more modifications to the alumacore splitter to clear the sway bar mounts and shorten it to be at the center-line of the front axles. Overall it looks good. Also in the process of making the aluminum frame mounting. I will be making chassis brackets that will be using the OEM tow hook bolt points.
5/4/10
Wing mount closed end nut inserts are in place and epoxied to prevent spinage. Did a mockup of the wing to the new mounts. Need to trim and weld in a base pad on the upper aluminum plates. So far so good.
Doing the second part of the front splitter lay up tonight. Wish me luck on getting a good part out of it.
Made some more modifications to the alumacore splitter to clear the sway bar mounts and shorten it to be at the center-line of the front axles. Overall it looks good. Also in the process of making the aluminum frame mounting. I will be making chassis brackets that will be using the OEM tow hook bolt points.
5/4/10
Wing mount closed end nut inserts are in place and epoxied to prevent spinage. Did a mockup of the wing to the new mounts. Need to trim and weld in a base pad on the upper aluminum plates. So far so good.
Doing the second part of the front splitter lay up tonight. Wish me luck on getting a good part out of it.
01-11-13, 10:56 PM
#161
5/5/10
Here are some photos of the alumacore with the surface prep for laminating and a shot of the new wing end plate profile.
5/6/10
Well, added this to the memory banks of what not to do. Didn't quit get desired finish on the top surface of the splitter. Should have either laid a board on top or made another laminate piece. Needless to say it won't win any appearance contest, but it will get the job done. I did get the desired surface on the bottom though, which is the more important surface.
Also here are the wing end plates. I might be able to salvage the CF finish and clear coat them. They are super light and stiff at least.
Here are some photos of the alumacore with the surface prep for laminating and a shot of the new wing end plate profile.
5/6/10
Well, added this to the memory banks of what not to do. Didn't quit get desired finish on the top surface of the splitter. Should have either laid a board on top or made another laminate piece. Needless to say it won't win any appearance contest, but it will get the job done. I did get the desired surface on the bottom though, which is the more important surface.
Also here are the wing end plates. I might be able to salvage the CF finish and clear coat them. They are super light and stiff at least.
01-11-13, 11:01 PM
#162
5/9/10
Rear wing mount done and it turned out pretty good. Just need to put clear on new end plates and mount the other rear hatch. I will paint it later.
-1 Degree to 12 Degrees at the center. The angle at the outer elements are 5 degrees more attack angle than the center.
I need to test t see at what angle I get stall, there really isn't that much aero info on the RE-A wing. I'm going to start of with 6 degrees and go from there at this Saturday's ORP track day.
Rear wing mount done and it turned out pretty good. Just need to put clear on new end plates and mount the other rear hatch. I will paint it later.
-1 Degree to 12 Degrees at the center. The angle at the outer elements are 5 degrees more attack angle than the center.
I need to test t see at what angle I get stall, there really isn't that much aero info on the RE-A wing. I'm going to start of with 6 degrees and go from there at this Saturday's ORP track day.
01-11-13, 11:04 PM
#163
5/11/10
Well, was able to get the front splitter mounted, but still need to do a few things to it. I will also have to eventually redo the chassis mounting plates, in my hast and sleep deprivation I screwed up the design and placement of the mounting plates while welding it. Had to drill/grind holes offset to the originals.
Well, was able to get the front splitter mounted, but still need to do a few things to it. I will also have to eventually redo the chassis mounting plates, in my hast and sleep deprivation I screwed up the design and placement of the mounting plates while welding it. Had to drill/grind holes offset to the originals.
01-11-13, 11:10 PM
#165
5/17/10
Holy Sh@t B@lls this thing corners now! ORP counter clockwise is a roller coaster of a track, just about everyone I knew was getting car sick after driving for about 20-25 minutes.
In order to get the car balanced front/rear I ended up going to 10 degrees wing angle to match the down force generated by the front splitter.
I need to create a surge tank now since I was getting fuel surge at 3/5 of a tank. My neck is sore. The combination of G's and off camber corners caused my properly filled diff to overflow, lol.
Also need to Roll the fenders or put on my over fenders.
Video of ORP. Didn't get a lot, sorry.
Oregon Raceway Park Counter Clockwise on Vimeo
Fast frward to 6:35 on video -
Holy Sh@t B@lls this thing corners now! ORP counter clockwise is a roller coaster of a track, just about everyone I knew was getting car sick after driving for about 20-25 minutes.
In order to get the car balanced front/rear I ended up going to 10 degrees wing angle to match the down force generated by the front splitter.
I need to create a surge tank now since I was getting fuel surge at 3/5 of a tank. My neck is sore. The combination of G's and off camber corners caused my properly filled diff to overflow, lol.
Also need to Roll the fenders or put on my over fenders.
Video of ORP. Didn't get a lot, sorry.
Oregon Raceway Park Counter Clockwise on Vimeo
Fast frward to 6:35 on video -
01-12-13, 11:38 AM
#169
8/2/10
Also did an Adrenaline Racing track day this last Thursday with my FD and had a great time. 7 different passengers, a record for me and a lot of track time, 25 gallons of fuel worth. The tires, brakes and some SPA gauge sensors are spent. The car was running great except for an over boost issue (1.3-1.4 bar) in the morning caused by my aggressive settings. Dropped the boost down to 0.96 bar and went conservative on the cycle duty setting to keep it safe for the day. Also made sure I kept the fuel tank topped off before every session.
8/4/10
Got my AEM stuff today.
Also did an Adrenaline Racing track day this last Thursday with my FD and had a great time. 7 different passengers, a record for me and a lot of track time, 25 gallons of fuel worth. The tires, brakes and some SPA gauge sensors are spent. The car was running great except for an over boost issue (1.3-1.4 bar) in the morning caused by my aggressive settings. Dropped the boost down to 0.96 bar and went conservative on the cycle duty setting to keep it safe for the day. Also made sure I kept the fuel tank topped off before every session.
8/4/10
Got my AEM stuff today.
01-12-13, 11:52 AM
#170
9/30/10
And, did a little machine work at FD3S Engineering. Two throttle bodies were modified, one with 54mm secondaries blades and stock primary. The other one with 54mm secondaries and 50mm primary throttle blades. Need to find out what material the OEMs use to seal the back side of the blades. Once I get around to it I will do a A to B to C comparison to see which provides the best overall performance and retain drive-ability.
Also started on my 95 rear suspension/diff frame conversion.
