09-30-2011, 12:30 PM
updating this thread and progress on projects:
now that i have a new puppy here, and training here is a very time consuming job, i am pretty much pinned for the next couple of months. this gives me a focused opportunity to get back to a number of projects i've had on the back burner.
upper strut bearings:
i've been working on new upper strut tower bearings. making some progress on that. i don't like the solid plates that are out there now, as they transfer too much impact load from bumps for a comfortable ride in a street car. the compression settings on most struts are too high to allow for a firmer bearing assembly. it isn't an issue on the track so much, but it sure is on the street. it results in the dash rattling, and a lot of harsh bumps.
the OEM units are actually very good at being the "middle man" in bump control. unfortunately they are ridiculously expensive.
also, the OEM units have mounting hardware that is too soft to be able to handle a stiff strut tower brace. i have seen countless cars with stripped threads as a result of the pulling on them that occurs with braces that are too stiff.
so, i am working on a new assembly that more follows the OEM design, and will have better hardware.
oil cooler:
the OEM oil cooler is extremely efficient, but is a bit small for track duty, or even a really hot day of canyon carving, where oil temps are known to get up to 280 degrees. i've personally seen 265 at a D.E. event when it was 100 degrees outside. this is well beyond the ability of oils to provide adequate lubrication. many oils break down at 260. i'd like to see this dropped 30 degrees or so, and stay down in the 235-240 range.
so, i'm working on a new oil cooler that will fit directly into the OEM location, using the OEM mounting points, and will mate up to the OEM hoses. it will also have an input and output tap point for sending units so you can monitor the temperatures.
splitter:
i plan to remove my splitter in the next few weeks and get it replicated.
motor mounts:
i have given this on a lot of thought, and fiddled around with mounts. the OEM mounts do an excellent job of isolating vibration, and since this is a torque tube car, there is far less torque loss through the mounts than a more traditional setup would have. the OEM mounts aren't that expensive, and anything i have tried so far transmits too much vibration for a street car to retain its comfort.
i do have a design for race cars, but i really don't do that, and don't think the market would justify the setup expense.
so, i am not inclined to pursue this project for street.
glove box repair kit:
done and will be on the Design 1 Racing site soon
rear shock coilover kit:
making some real progress on this and will have news in the next couple of weeks
battery relocation kit:
done and will be on the Design 1 Racing site soon
firewall repair kit:
done and is on the Design 1 Racing site
front trailer hooks:
design done. prototype being made now. should be available before xmas
larger sway bars:
design done. prototype working great. should be up on the Design 1 Racing site soon
stiffer strut tower brace:
for those who can run camber plates, or other solid upper strut bearings, or the new ones i am working on, i am planning to make a stiffer strut tower brace. this cannot be used with the OEM strut tower bearings. i had to design in .005" of lateral deflection to accommodate the inadequate hardware of the OEM mounts, and prevent the threads from stripping. this is not needed with any of the aftermarket bearing assemblies.
the design is now done, and i should have a prototype in the next few weeks, and should be available before xmas. it will also allow for the incorporation of the new firewall brace. there is a possibility that i can make this also retrofit the existing brace assembly.
pricing and information about all of these will be on the Design 1 Racing website as soon as it is available, but i expect things to move along pretty quickly, since i have the time right now.
now that i have a new puppy here, and training here is a very time consuming job, i am pretty much pinned for the next couple of months. this gives me a focused opportunity to get back to a number of projects i've had on the back burner.
upper strut bearings:
i've been working on new upper strut tower bearings. making some progress on that. i don't like the solid plates that are out there now, as they transfer too much impact load from bumps for a comfortable ride in a street car. the compression settings on most struts are too high to allow for a firmer bearing assembly. it isn't an issue on the track so much, but it sure is on the street. it results in the dash rattling, and a lot of harsh bumps.
the OEM units are actually very good at being the "middle man" in bump control. unfortunately they are ridiculously expensive.
also, the OEM units have mounting hardware that is too soft to be able to handle a stiff strut tower brace. i have seen countless cars with stripped threads as a result of the pulling on them that occurs with braces that are too stiff.
so, i am working on a new assembly that more follows the OEM design, and will have better hardware.
oil cooler:
the OEM oil cooler is extremely efficient, but is a bit small for track duty, or even a really hot day of canyon carving, where oil temps are known to get up to 280 degrees. i've personally seen 265 at a D.E. event when it was 100 degrees outside. this is well beyond the ability of oils to provide adequate lubrication. many oils break down at 260. i'd like to see this dropped 30 degrees or so, and stay down in the 235-240 range.
so, i'm working on a new oil cooler that will fit directly into the OEM location, using the OEM mounting points, and will mate up to the OEM hoses. it will also have an input and output tap point for sending units so you can monitor the temperatures.
splitter:
i plan to remove my splitter in the next few weeks and get it replicated.
motor mounts:
i have given this on a lot of thought, and fiddled around with mounts. the OEM mounts do an excellent job of isolating vibration, and since this is a torque tube car, there is far less torque loss through the mounts than a more traditional setup would have. the OEM mounts aren't that expensive, and anything i have tried so far transmits too much vibration for a street car to retain its comfort.
i do have a design for race cars, but i really don't do that, and don't think the market would justify the setup expense.
so, i am not inclined to pursue this project for street.
glove box repair kit:
done and will be on the Design 1 Racing site soon
rear shock coilover kit:
making some real progress on this and will have news in the next couple of weeks
battery relocation kit:
done and will be on the Design 1 Racing site soon
firewall repair kit:
done and is on the Design 1 Racing site
front trailer hooks:
design done. prototype being made now. should be available before xmas
larger sway bars:
design done. prototype working great. should be up on the Design 1 Racing site soon
stiffer strut tower brace:
for those who can run camber plates, or other solid upper strut bearings, or the new ones i am working on, i am planning to make a stiffer strut tower brace. this cannot be used with the OEM strut tower bearings. i had to design in .005" of lateral deflection to accommodate the inadequate hardware of the OEM mounts, and prevent the threads from stripping. this is not needed with any of the aftermarket bearing assemblies.
the design is now done, and i should have a prototype in the next few weeks, and should be available before xmas. it will also allow for the incorporation of the new firewall brace. there is a possibility that i can make this also retrofit the existing brace assembly.
pricing and information about all of these will be on the Design 1 Racing website as soon as it is available, but i expect things to move along pretty quickly, since i have the time right now.
94 Midnight Metallic Blue Cab Porsche 968 w/deviating cashmere/black interior and WAY too many mods to list - thanks to eric for creating www.968forums.com
"It isn't nearly as expensive to do it right as it is to do it wrong."
(This post was last modified: 09-30-2011, 12:32 PM by flash.)
