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Hey guys,

 

As I mentioned in my thread in the Newbie Intro section, I'm back on the forum with a new account and username. Used to spend a lot of time on here years ago as Hanaldo, so some of you may remember me and my car. The old build thread is here:

 


That thread essentially covers everything I did to the car while it was my daily for 12 years. In September last year I got yellow stickered, and that was the end of that! I want to write this build thread to cover it's new life as a motorsport development car for my business (I will try to do that without breaking any forum rules). It is unfortunately going to be a slow build I think, I don't have a lot of time to work on the car these days, nor a significant budget for it. But hopefully once the Covid restrictions are lifted and we can get back out on the track, I can start to post some results and do some development. 

 

Power-wise, the last time it was on a dyno the car made 419rwhp @22psi on E85. There was plenty more in it, but it was suffering badly from ignition break-down at higher boost levels, and was just about on the limit that the clutch could handle. I bought an R35 GTR coil kit from Platinum Racing Products to take care of the ignition, and while upgrading the clutch to an NPC cushion button I also discovered that every single nut on the exhaust manifold was hand-tight and the gasket was blown - had probably been that way for months if not years. So we replaced that, along with the studs and nuts. While that was all underway, I decided I'd had enough of the old Link G4 plug-in, and decided to go all out with a G4+ Thunder and an MXS Strada dash. Unfortunately since wiring in the Thunder, we haven't had an opportunity to get the car back on the dyno for a tune, so that is about where things stand currently, but I am hoping to be up around the 480rwhp mark if not maybe sneak into the 500's. We will see, it is a factory bottom-end at the end of the day so I don't want to push it too far, and I'll be happy with where it ends up for a bit. I don't plan to build the motor anytime soon unless it breaks with a bit of track use, but it's always nice to know what it can do.

 

Ultimately the car will be aimed at Time Attack, built to compete in Tuner Class in WA Time Attack (the same regulations as Clubsprint in WTAC). I decided to build it for this category, as I am actually already sponsoring a car being built for Racer (Open) Class and investing heavily in that, so I wanted to do something different with my car and not be in direct competition with something I certainly can't compete with! Tuner Class also appeals to me for the challenge of developing the aero to perform in what is really a non-aero class. It is quite 'easy' to develop aero components for cars competing in Open Class as the regulations allow so much more, but in Clubsprint the regulations on aero are quite restrictive and will require a bit of ingenuity to get the performance out of it. I will be doing the CAD and CFD in-house, but my intention is to use the Thunder to get creative with data logging, so hopefully I can back up any lap-time progress/regress with data to show what is working and what isn't. CFD is nice, but real-world data is king!

 

That's about it for now, I will upload a few pictures soon and start taking more photos of anything that goes into the car so hopefully I'm not just posting walls of text! 

 

 

Edited by Unzipped Composites

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Keen to see your developments as they progress.

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Little bit of progress over the weekend, the interior has now been stripped out, just need to find the time to take care of the sound deadening (shudder) and gut the unnecessary stuff from the dash/doors/etc.

 

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Don't let anyone tell you otherwise, race cars pay for themselves

 

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All of the aircon gear has also been deleted, which was initially a bit hard to stomach for me... 

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ABS is also gone

 

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Still need to get rid of the heater box from under the dash, but will wait to drain the coolant first. It's amazing how much room just the aircon and ABS takes up in the engine bay, it's already significantly neater in there. 

I also decided I wasn't going to mess around with the OEM wiring harness anymore, and it's time for a full motorsport spec harness for the car. OEM engine harness is out

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Absolute reliability is my goal, as I've seen enough motorsport to know that electrical issues can be one of the most expensive parts of having a race car. Making my own harness has been a long-term dream of mine, so I'm looking forward to the challenge. I also need the wiring to be capable of evolving with the setup as I develop the car; because I plan on using it to develop performance aero products I want to be able to log as much data as I can in relation to those products. I am already developing some laser ride height sensors in order to log downforce, and in the future I would like to be able to run additional sensors for things like pre-radiator temps for oil/water/air etc in order to work out how well my ducting is performing. 

 

While I'm at it, I've decided to convert to DBW throttle as well, to save having to modify that part of the harness later.

 

All of this means that I am running out of AVI's on the ECU quite quickly. If I wired everything direct to the ECU, I would already have used all 16 AVI's with just the current sensors, 4 laser ride height sensors, and the DBW. The MXS Strada dash has 8 AVI inputs that I can make use of, but unfortunately doesn't have logging capabilities, and it is a bit hard to stomach the $1700 for the logging kit from AIM at the moment. So as an interim, I have setup the ECU and the dash on the bench, and am trying to workout how I can wire the non-critical sensors like ride height into the dash, and then stream that data to the Thunder via CAN in order to log it.

 

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Seems like such a simple idea, both units are able to transmit and receive CAN data, and the CAN channel is a loggable channel in the ECU. In practice, it's quite a lot of dicking around. AIM haven't made this dash very user friendly, so it isn't quite as straight forward as "receive this, transmit that". I may end up having to write a custom CAN protocol in order to get it to work the way I want, but the initial results seem to indicate that it can be done. This will free up a few AVI's on the ECU for future expansion.

 

Next up, I've decided to pull the motor out. It's been 8 years since the motor was last out, and I'm looking forward to sorting out the things I did wrong back then, as well as cleaning up the engine bay again, probably weld up some unnecessary holes in the firewall, and making it a lot easier to route the new harness when it's done.

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So you'r doing all new electronics in your car?  I'm doing same with my car. 😄 I'm personaly using PDM-box for all lights etc (I get rid of fuses and relays) and stand alone ECU. Maybe fuel tech, becouse there is ECU, dash display and data logger at the same. Those PDM (CAN stuff) are so easy to do wiring and programm and prices are low enough for normanl builder to buy things at these days. So I personally don't see any reason to do wiring with old relays and fuses anymore. 

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Yeh full rewire.

 

I'm not going to PDM though, just going to simplify and reorganise the fuses and relays. PDM's are great, but just not quite a priority yet. One day when I've had enough of fuses and relays, I'll redo it with a PDM. Gotta leave myself something to do in the future :P

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I rewired by 32 and put a smartwire PDM in (only fuses remaining are main ones near the battery under bonnet and only relays are the Ignition and ECCS ones), made it massively easier. You would not believe how many fuses and relays there are in these cars.

BTW thanks for the thread and I;m enjoying the fibreglass chat elsewhere that I don't understand a word of :)

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Yeh most of the cars I work with are PDM, they're very good. I just can't quite stretch the budget there yet, this is already turning into one of those 'oh shit I got a bit excited' parts of the cars life 😅

 

And hopefully I'll have a bit more composites chat coming soon! As much as I enjoy talking turbos and 'Milspec' wiring - composites are my field and what will set this build apart! 

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