Project SM2 Autocross S2000
07-31-2008, 10:34 PM
#27
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Re: (White Smoke)
hey john 
im in for some more progress,
but im sure ill be in and out of the shop constantly between now and the time my motor goes in so i can peep it IRL lol
see you in a few days when i get back from Colorado!
-Ian
im in for some more progress,
but im sure ill be in and out of the shop constantly between now and the time my motor goes in so i can peep it IRL lol
see you in a few days when i get back from Colorado!
-Ian
08-01-2008, 12:04 PM
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Ok, progress! 
But first, Q&A's...
happycorey: actually, 2 new sets of wheels...
the CE's are sold... so they are on to a better place. But whats wrong with lavender scented tires? my GF didn't seem to mind.. haha!
4DoorLife: You can buy the motor stand oil pan from Summit Racing (www.summitracing.com)
dinko: it wouldn't be a big turbo... not much lag, really big tires, anti-lag program on the computer... yea, it'd be fine But for now, i'll be playing with n/a...
si vtec ftw: Hey Ian! Yea, it'll look really good when done.. Have fun on your trip!
ok, so now for some updates!
-----------------------------------------------------------------------------
Ok, so i need to make fender flares for my car, and i want them to look nice, and not look like they were an afterthought.
I have a friend who i normally go to in Orlando that does this kind of thing for a living, and has always done a BRILLIANT job on the projects that he has helped me with... but right now, he doesn't have the time due to other projects, and then to make matters worse, i now live in Melbourne, and he is in Orlando... so i'd have to take my car over there to have this done... he's not confident in being able to get them done in the timeframe i need (VERY fast)... so my only fall-back, is that i use what he has taught me, and do it myself... eeek! Thankfully, he was a great teacher, and i pick up on things pretty fast
So, here's where we're at... normally, this would be done with a foam spray gun that he has, but i don't have that wonderful little invention... so i have to figure something else out for the base. So, i had an idea, and ran it by him... he hadnt really heard of it being done, but figured it could work, so here i go!
THIS IS NOT THE ACTUAL PART!!! There, got that out of the way before someone comes on complaining about how crappy it looks... LoL! :banghead:
Here is the plan for this round: This part won't look good, the dimensions are going to be wrong, and so forth.... is is JUST to prove the idea that i can make a fender flare blank with poured foam... then basically shape it like a surfboard, until i have the desired shape, then glass over one side of it, and then dissolve the foam out leaving a nice fiberglass shell that i should then be able to make work, clean up, and should look fairly decent...
Well, thats the plan anyway... so, heres how i'm going to carry out with the plan.
Before i go out and spend a buttload of money on wood and mold making parts, and the time required to do all of it, i wanted to make sure that this could even be done, and come out how i want it to....
If/when i do it for real, i'll use a wooden buck/form to simulate the wheel,and then have a board that will simulate the very outer edge of the wheelwell... then, i'll have "blockers" both front and back to control where the foam goes... then, line the whole thing with plastic, making it fairly water-tight, and then pour the foam in... the foam will form around the mock-tire, creating the inside edge and arch around the tire opening, and then the outer form will be my outer dimension... then, i just have to shape the top part, the front, and back of each fender, and create a way for it to mount...
First things first though, is to do it the ghetto-way to see if it is even feasible...
So, i grabbed a box, a trash bag, and some tape, and some tires to help hold the box (this foam pushes kinda hard when it expands).
I set it up so that the box is my "outer limit", and then just put the bag right in the middle, and taped the top of it to the car and the box:
Then, i taped up some more, and set up the tires... in hindsight, i should have put more support inside the actual box, but its ok, it did its job still...
Then, it was time to POUR! THis stuff is a mess, and there is no time to take pics while pouring... so here is the aftermath of that:
Then, once that was cured, i popped it off the wheel... and also found out that the bag broke... grrr! but it'll clean up...
See how the inside follows the contour of the body and wheel pretty nicely? This is working gooood
So, the next few steps involved my band saw, and a hand sander... about 2 hours worth of cutting, sanding, and whatever, i came up with this:
Here are the leftovers...
It isn't how i really wanted it to look, but it doesn't matter, since i'm not using it anyway... but i learned that i needed the pour to go higher, so that i could shape the top more (notice how flat it looks on top), but with more shaping and time spent on it, the other parts of it could turn out very very nicely... so that made me happy.
All in all, i'm not happy with the way this particular part looks... but that wasn't the point. I AM happy with the fact that this shows that the concept is a sound one, and i can make a fender flare using this process...
So, the "proof of concept worked"... Next up... create the form, and begin making the flares!
Also, i got the motor back from the machine shop, so now its off to order some bearings, rings, etc and make this puppy SCREAM!
My wheels should be done on Monday...
And i'll be ordering KPro for it very shortly.
Its getting there
But first, Q&A's...
happycorey: actually, 2 new sets of wheels...
the CE's are sold... so they are on to a better place. But whats wrong with lavender scented tires? my GF didn't seem to mind.. haha!4DoorLife: You can buy the motor stand oil pan from Summit Racing (www.summitracing.com)
dinko: it wouldn't be a big turbo... not much lag, really big tires, anti-lag program on the computer... yea, it'd be fine
But for now, i'll be playing with n/a... si vtec ftw: Hey Ian! Yea, it'll look really good when done.. Have fun on your trip!
ok, so now for some updates!
-----------------------------------------------------------------------------
Ok, so i need to make fender flares for my car, and i want them to look nice, and not look like they were an afterthought.
I have a friend who i normally go to in Orlando that does this kind of thing for a living, and has always done a BRILLIANT job on the projects that he has helped me with... but right now, he doesn't have the time due to other projects, and then to make matters worse, i now live in Melbourne, and he is in Orlando... so i'd have to take my car over there to have this done... he's not confident in being able to get them done in the timeframe i need (VERY fast)... so my only fall-back, is that i use what he has taught me, and do it myself... eeek! Thankfully, he was a great teacher, and i pick up on things pretty fast
So, here's where we're at... normally, this would be done with a foam spray gun that he has, but i don't have that wonderful little invention... so i have to figure something else out for the base. So, i had an idea, and ran it by him... he hadnt really heard of it being done, but figured it could work, so here i go!
THIS IS NOT THE ACTUAL PART!!! There, got that out of the way before someone comes on complaining about how crappy it looks... LoL! :banghead:
Here is the plan for this round: This part won't look good, the dimensions are going to be wrong, and so forth.... is is JUST to prove the idea that i can make a fender flare blank with poured foam... then basically shape it like a surfboard, until i have the desired shape, then glass over one side of it, and then dissolve the foam out leaving a nice fiberglass shell that i should then be able to make work, clean up, and should look fairly decent...
Well, thats the plan anyway... so, heres how i'm going to carry out with the plan.
Before i go out and spend a buttload of money on wood and mold making parts, and the time required to do all of it, i wanted to make sure that this could even be done, and come out how i want it to....
If/when i do it for real, i'll use a wooden buck/form to simulate the wheel,and then have a board that will simulate the very outer edge of the wheelwell... then, i'll have "blockers" both front and back to control where the foam goes... then, line the whole thing with plastic, making it fairly water-tight, and then pour the foam in... the foam will form around the mock-tire, creating the inside edge and arch around the tire opening, and then the outer form will be my outer dimension... then, i just have to shape the top part, the front, and back of each fender, and create a way for it to mount...
First things first though, is to do it the ghetto-way to see if it is even feasible...
So, i grabbed a box, a trash bag, and some tape, and some tires to help hold the box (this foam pushes kinda hard when it expands).
I set it up so that the box is my "outer limit", and then just put the bag right in the middle, and taped the top of it to the car and the box:
Then, i taped up some more, and set up the tires... in hindsight, i should have put more support inside the actual box, but its ok, it did its job still...
Then, it was time to POUR! THis stuff is a mess, and there is no time to take pics while pouring... so here is the aftermath of that:
Then, once that was cured, i popped it off the wheel... and also found out that the bag broke... grrr! but it'll clean up...
See how the inside follows the contour of the body and wheel pretty nicely? This is working gooood
So, the next few steps involved my band saw, and a hand sander... about 2 hours worth of cutting, sanding, and whatever, i came up with this:
Here are the leftovers...
It isn't how i really wanted it to look, but it doesn't matter, since i'm not using it anyway... but i learned that i needed the pour to go higher, so that i could shape the top more (notice how flat it looks on top), but with more shaping and time spent on it, the other parts of it could turn out very very nicely... so that made me happy.
All in all, i'm not happy with the way this particular part looks... but that wasn't the point. I AM happy with the fact that this shows that the concept is a sound one, and i can make a fender flare using this process...
So, the "proof of concept worked"... Next up... create the form, and begin making the flares!
Also, i got the motor back from the machine shop, so now its off to order some bearings, rings, etc and make this puppy SCREAM!
My wheels should be done on Monday...
And i'll be ordering KPro for it very shortly.
Its getting there
08-01-2008, 10:12 PM
#32
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Re: (ComposiMo)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ComposiMo »</TD></TR><TR><TD CLASS="quote">Ok, progress!
But first, Q&A's...
happycorey: actually, 2 new sets of wheels... the CE's are sold... so they are on to a better place. But whats wrong with lavender scented tires? my GF didn't seem to mind.. haha!</TD></TR></TABLE>
Oh I didn't know that. I am however excited to see the wheels you've selected. Maybe if I stop by in the next week or so before you take pictures I can see this thing+the ruckus. I wasn't making fun of the tires though.. Well kinda.. Hahah how do they smell when you burn them?!
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ComposiMo »</TD></TR><TR><TD CLASS="quote">
:banghead:
</TD></TR></TABLE>
Hahhaa hammerhead!
But first, Q&A's...
happycorey: actually, 2 new sets of wheels...
the CE's are sold... so they are on to a better place. But whats wrong with lavender scented tires? my GF didn't seem to mind.. haha!</TD></TR></TABLE>Oh I didn't know that. I am however excited to see the wheels you've selected. Maybe if I stop by in the next week or so before you take pictures I can see this thing+the ruckus. I wasn't making fun of the tires though.. Well kinda.. Hahah how do they smell when you burn them?!
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ComposiMo »</TD></TR><TR><TD CLASS="quote">
:banghead:
</TD></TR></TABLE>
Hahhaa hammerhead!
08-03-2008, 01:29 PM
#33
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Re: (happycorey)
Looks like its going to be a fun little project.
About the IC set up. FMICs look good, but the cooling properties of the a WTA cant be forgot.
Here is a pic I took from IA08 of a s2k with a WTA
swade
About the IC set up. FMICs look good, but the cooling properties of the a WTA cant be forgot.
Here is a pic I took from IA08 of a s2k with a WTA
swade
08-04-2008, 03:43 AM
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swade: If you'll read my posts, you'll have found out that i'm not going to do turbo for another few months... i'd rather try to keep towards the top of the points standings in my class this year, and switching classes mid-year won't let me do that... not to mention, getting the car prepped as it is for the BSP class is going to be hard enough, let alone taking it the steps further to make it a full-on SM2 car... so no turbo this year.
Ian: np...
Ian: np...
08-04-2008, 03:52 PM
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What i did on my Monday...
Well, today was the first day of the new fender flares for the S2k... i know you Ruckus guys don't want to hear that, but not to worry... the S2k became a slight priority at the shop, but it'll be done soon, and then its back full-tilt-boogy on the Project Ruckus... thats the deal i made, so thats whats going to happen.
So, to the S2k... here is where she sits... i rearranged things quite ab it in the shop to get the car over to the fabrication area... you can see inthe background in front of the S2k is the Project Ruckus... i had to rotate the motorcycle lift 90-degrees to have enough room for the car.
The first major mod that i started planning out was the air induction... i thought a lot about running an aftermarket intake, but i did not like any of the ones out there, so in true Panducky fasion, i'm just going to make my own badass air intake... The start of this, is a huge 75mm throttle body! I was contemplating buying an ITB setup, but i really think that this could work just as well, if not better... so i'm going to give it a go, and if it fails me... then... well... oh well, it won't have cost me $3000 either.. haha!
75mm tb:
Along with the Throttle Body, i'm going to cut the air intake open and increase the plenum volume slightly, and also send the intake manifold to a local porter to have the runners and velocity stacks smoothed out a bit, and everything port-matched
Another mod that will be happening, is i need to put extended wheel studs in the front... yes, front... this way, i can run the same offset wheels in the front and back of my car, so that way i'll be able to actually rotate my race and street tires! It is a great idea that came about thanks to Jason Uyeda, and John from CCW who is making the new 18x11's for this car. Here are the studs that just came in:
Next up, is the BIGGIE... the fender flares!
After the test i did, i felt increasingly confident about the construction method that i had in store for building my fender flares. It was going to be a bit of a tough challenge to make the forms, but i think it came out great!
Here is the beginning of the form... a bunch of wood.
I also picked up all the mixing buckets, and random things i'd need for the job...
So, i got to work... i throught through a LOT of random ideas for making this work... in the end, this setup seemed to work for me... a simple blocking plate to keep the foam from going into the wheel area, and then a form with a 'floor' so that the foam control would be a bit better... also, it'll cut down on waste.
I first got to work making the 'blocker', that i'll tape to the wheel well before pouring the foam...
Then, it was time for the BIG TAMALE!
The form... this will be the basis for all of the fender flares. I'll be able to weight it down, and it will provide me with a perfect wheel arch to trim to. also, you'll see that the lower floor is cut out so that the 'floor' can wrap around the tires, and go under the car a bit. This will help control the flow of foam, and reduce waste... it'll also provide a nice pre-shape to make sanding and shaping a LOT easier...
And then here is a mockup with everything in place... the 'blocker' taped to the wheel well opening, and the form in place.
The only thing that would have to be done other than this is to add some 'filler' inside the wheel opening (basically an empty box) to reduce wasting foam, and then add the plastic to control where the foam goes... now all i need to finalize, is how far out i want each flare to stick... i SHOULD have my wheels by Wednesday according to CCW, so i will know for sure at that point... yay!
Well, today was the first day of the new fender flares for the S2k... i know you Ruckus guys don't want to hear that, but not to worry... the S2k became a slight priority at the shop, but it'll be done soon, and then its back full-tilt-boogy on the Project Ruckus... thats the deal i made, so thats whats going to happen.
So, to the S2k... here is where she sits... i rearranged things quite ab it in the shop to get the car over to the fabrication area... you can see inthe background in front of the S2k is the Project Ruckus... i had to rotate the motorcycle lift 90-degrees to have enough room for the car.
The first major mod that i started planning out was the air induction... i thought a lot about running an aftermarket intake, but i did not like any of the ones out there, so in true Panducky fasion, i'm just going to make my own badass air intake... The start of this, is a huge 75mm throttle body! I was contemplating buying an ITB setup, but i really think that this could work just as well, if not better... so i'm going to give it a go, and if it fails me... then... well... oh well, it won't have cost me $3000 either.. haha!
75mm tb:
Along with the Throttle Body, i'm going to cut the air intake open and increase the plenum volume slightly, and also send the intake manifold to a local porter to have the runners and velocity stacks smoothed out a bit, and everything port-matched
Another mod that will be happening, is i need to put extended wheel studs in the front... yes, front... this way, i can run the same offset wheels in the front and back of my car, so that way i'll be able to actually rotate my race and street tires! It is a great idea that came about thanks to Jason Uyeda, and John from CCW who is making the new 18x11's for this car. Here are the studs that just came in:
Next up, is the BIGGIE... the fender flares!
After the test i did, i felt increasingly confident about the construction method that i had in store for building my fender flares. It was going to be a bit of a tough challenge to make the forms, but i think it came out great!
Here is the beginning of the form... a bunch of wood.
I also picked up all the mixing buckets, and random things i'd need for the job...
So, i got to work... i throught through a LOT of random ideas for making this work... in the end, this setup seemed to work for me... a simple blocking plate to keep the foam from going into the wheel area, and then a form with a 'floor' so that the foam control would be a bit better... also, it'll cut down on waste.
I first got to work making the 'blocker', that i'll tape to the wheel well before pouring the foam...
Then, it was time for the BIG TAMALE!
The form... this will be the basis for all of the fender flares. I'll be able to weight it down, and it will provide me with a perfect wheel arch to trim to. also, you'll see that the lower floor is cut out so that the 'floor' can wrap around the tires, and go under the car a bit. This will help control the flow of foam, and reduce waste... it'll also provide a nice pre-shape to make sanding and shaping a LOT easier...
And then here is a mockup with everything in place... the 'blocker' taped to the wheel well opening, and the form in place.
The only thing that would have to be done other than this is to add some 'filler' inside the wheel opening (basically an empty box) to reduce wasting foam, and then add the plastic to control where the foam goes... now all i need to finalize, is how far out i want each flare to stick... i SHOULD have my wheels by Wednesday according to CCW, so i will know for sure at that point... yay!
08-06-2008, 03:55 PM
#41
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Today was MOTOR PULLING DAY!
yAy!
So, today was a really busy day at the shop. Not only did we have the Lotus in for work, but i needed to get the motor out of my car so that way when the parts show up tomorrow from Honda, we can build the other F22 motor, and start putting the accessories from this motor onto that motor, and maybe even start getting it into the car tomorrow night....
SO.
I slacked off on the pictures for most of the day, but i finally got the motor loose and on its way out.
Then, i brought the motor over on a motor stand, and started pulling stuff off of it...
Here is the intake manifold that is going to be modified heavily to fit the 75mm TB onto it, and to increase the plenum volume.
Motor with a little bit less on it:
Pulled the valve cover off... not much wrong here.... yet
Then.... i flipped the motor over, and pulled the oil pan off of it... and thats when i saw the horror...
No lie, when i initially drained the oil from the pan when i started to pull the motor out of the car, i could hear chunks of metal falling into the oil pan... bearings don't show up on magnets, but i still managed to pull a LOT of shavings and chunks off of the magnetic oil drain plug. Before i dump the oil, i intend to go through it with a very stronjg magnet to pick up all of the metal shavings out of it. This was catastrophic damage
Well, here is where the car is sitting now.. i'm going to clean the engine bay up really good, and then start prepping the chassis for the new motor and everything else... This thing has a hard road ahead of it
Tomorrow i'll pull the oil pump, and get the rods disconnected, and show pictures of the REAL damage... should be FUN!
yAy!
So, today was a really busy day at the shop. Not only did we have the Lotus in for work, but i needed to get the motor out of my car so that way when the parts show up tomorrow from Honda, we can build the other F22 motor, and start putting the accessories from this motor onto that motor, and maybe even start getting it into the car tomorrow night....
SO.
I slacked off on the pictures for most of the day, but i finally got the motor loose and on its way out.
Then, i brought the motor over on a motor stand, and started pulling stuff off of it...
Here is the intake manifold that is going to be modified heavily to fit the 75mm TB onto it, and to increase the plenum volume.
Motor with a little bit less on it:
Pulled the valve cover off... not much wrong here.... yet
Then.... i flipped the motor over, and pulled the oil pan off of it... and thats when i saw the horror...
No lie, when i initially drained the oil from the pan when i started to pull the motor out of the car, i could hear chunks of metal falling into the oil pan... bearings don't show up on magnets, but i still managed to pull a LOT of shavings and chunks off of the magnetic oil drain plug. Before i dump the oil, i intend to go through it with a very stronjg magnet to pick up all of the metal shavings out of it. This was catastrophic damage
Well, here is where the car is sitting now.. i'm going to clean the engine bay up really good, and then start prepping the chassis for the new motor and everything else... This thing has a hard road ahead of it
Tomorrow i'll pull the oil pump, and get the rods disconnected, and show pictures of the REAL damage... should be FUN!
08-06-2008, 06:45 PM
#42
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Re: (ComposiMo)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ComposiMo »</TD></TR><TR><TD CLASS="quote">
So, today was a really busy day at the shop. Not only did we have the Lotus in for work,
</TD></TR></TABLE>
That thing is always at the shop wtf
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ComposiMo »</TD></TR><TR><TD CLASS="quote">
but i needed to get the motor out of my car so that way when the parts show up tomorrow from Honda, we can build the other F22 motor, and start putting the accessories from this motor onto that motor, and maybe even start getting it into the car tomorrow night.... </TD></TR></TABLE>
You guys work fast
So, today was a really busy day at the shop. Not only did we have the Lotus in for work,
</TD></TR></TABLE>
That thing is always at the shop wtf
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ComposiMo »</TD></TR><TR><TD CLASS="quote">
but i needed to get the motor out of my car so that way when the parts show up tomorrow from Honda, we can build the other F22 motor, and start putting the accessories from this motor onto that motor, and maybe even start getting it into the car tomorrow night.... </TD></TR></TABLE>
You guys work fast
08-06-2008, 07:08 PM
#43
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Re: (happycorey)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by happycorey »</TD></TR><TR><TD CLASS="quote">That thing is always at the shop wtf</TD></TR></TABLE>
Not really... The yellow Lotus is doing AWESOME actually... its in the shop having a hinge kit installed on it so that the whole rear section of the car will tilt backwards so he can work on the engine easier, or show it off or whatever
The Orange one is there right now all the time, because it's my daily driver until the S2k gets fixed
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by happycorey »</TD></TR><TR><TD CLASS="quote">You guys work fast</TD></TR></TABLE>
We try but it'll depend on when/if the parts we need arrive tomorrow.
Not really... The yellow Lotus is doing AWESOME actually... its in the shop having a hinge kit installed on it so that the whole rear section of the car will tilt backwards so he can work on the engine easier, or show it off or whatever
The Orange one is there right now all the time, because it's my daily driver until the S2k gets fixed
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by happycorey »</TD></TR><TR><TD CLASS="quote">You guys work fast</TD></TR></TABLE>
We try
but it'll depend on when/if the parts we need arrive tomorrow.
08-06-2008, 07:22 PM
#44
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Re: (ComposiMo)
Right on, that Lotus is gonna be crazy, and then you can actually see that turbo kit. Haha
Otherwise that S2 looks like such a tight fit. I didn't see the tranny on it either? Was it just hidden behind it in all the pictures? Or did you take it off before?
Otherwise that S2 looks like such a tight fit. I didn't see the tranny on it either? Was it just hidden behind it in all the pictures? Or did you take it off before?
08-07-2008, 09:40 AM
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Its not worth the hassle to try to pull them both out at once... its way easier to just do them separately...
-------------------------------------------------
Woo Hoo! My CCW Wheels finally arrived!
Now i can get crackin on the rest of the fenderflare project. After physically measuring, i'll be having the front flares extend out 2.5", and the rear flares will extend out 1.25"
The new wheel:
Mounted on the car showing the offset difference:
From the back:
Front Wheel:
Rear Wheel:
These things are LIGHT for thier size... Weeeee!
-------------------------------------------------
Woo Hoo! My CCW Wheels finally arrived!
Now i can get crackin on the rest of the fenderflare project. After physically measuring, i'll be having the front flares extend out 2.5", and the rear flares will extend out 1.25"
The new wheel:
Mounted on the car showing the offset difference:
From the back:
Front Wheel:
Rear Wheel:
These things are LIGHT for thier size... Weeeee!
