You should know that you will likely see some changes to the FFR PDG GTM as far as the diffuser is concerned this year. This is not due to functionality, but because most governing bodies require that the diffuser not protrude past the rear bodywork of the car. (see most other examples posted above) Since we will be running some other race series this year, we will likely have to change the diffuser and possibly the splitter as well. Again, many series rules have a limit as to how much a splitter can extend past the front of the car.
As I have mentioned in the past, when looking at other examples of people doing something on a race car it is important to understand not only what you are seeing, but the context, as far as rules are concerned that maybe limits what the builder is able to do.
What I have done on the FFR PDG GTM and is shown in that picture is essentially lengthen the body in the rear via wing and diffuser placement.
Thanks Mike. I was actually pretty impressed by the size of the splitter. Are there restrictions in the unlimited class? You could always follow McLaren and do a 'longtail' bodywork mod.
Funny, I've been thinking about a rear trunk since I made this render back in 2011..
Plenty of room for a pair of duffel bags on EACH side.
You say you need 10 of the 5qt Mobil 1 oil and 4 gallons of antifreeze from the auto parts store? Leave the truck at home next time and put half your haul in each trunk with room to spare (although I wouldn't put that much weight in the trunks).
The blue Cobra look great, been trying to decided how I want my doors to open do great to see you trying new ideas, keep it up as I am interested in how they come out. I was looking a some type of lambo hinge but still not sure yet..
Someone up north did lambo door hinges and had a lot of trouble making it work, maybe it was Tino? My doors are basically Honda and I deleted the front wheel vent, I think it was the wheel vent that gave him the trouble?
Yup, its Tino in Canada that did Lambo style doors on his GTM. I remember reading that as one of the first build threads I was reading before I ordered my kit. He is a very nice guy and answered all my newbie questions early on, so I'm sure he would be glad to share more about his door setup.
Thanks Mike. I was actually pretty impressed by the size of the splitter. Are there restrictions in the unlimited class? You could always follow McLaren and do a 'longtail' bodywork mod.
For the endurance racing things are wide open, but the FFR PDG GTM is looking to run a full season of Trans-Am this year. They allowed us to run two races without making changes, but now they want us to conform to the rules. They are very particular. We are making some changes. Mainly to the wing, splitter and diffuser.
Got the axles done.
Started by prepping the Porsche CVs per Crash's video with his air grinder attachment. Man, what a difference. Definitely going to keep some metal debris out of the CVs.
Went with about a 50/50 mix of BelRay and Swepco 101. They look similar but the Swepco is thicker.
As discussed in another thread, I broke down and made a tool for installing the Corvette CVs over the c-clip. Turned a painful, messy procedure into a chip shot. I'm mailing the tool to Shoeless, get ahold of him if you need it.
These RioRand DC motor controllers are great for HVAC fans, infinitely adjustable instead of 3 or 4 fixed speeds. Running one for passengers, one for windshield defog. Printed a simple mount that will zip tie to the chassis.
Some little things here and there. Mocking up the three-point seat belt for the driver's side. This will be interesting, both the driver and passenger side 3 point seat belts will come from right to left. In the Cobra, I only have five point seat belts. And sometimes it's nice to just hop in and go, so I definitely wanted 3 point seat belts as well. These are Toyota.
Confirming ergonomics, just about ready to wrap up wiring, literally.
Headlights are back together and sealed with LED low / high beams and LED Switchback DRL / turn signals.
Porsche Le Mans ignition location for quick departures...
Yes, that is a temporary tablet bezel, printed it part of the way up so I could check fitment, final bezel will be full surround, at least that's the plan at this point.
3 point seat belt mounting studs welded in. I was able to tie into the driver's harness bar for the shoulder portion. Just need to either weld or 3d print guides on either side of the shoulder strap to keep it from sliding around and pretty it up a little.
Yes, that is a temporary tablet bezel, printed it part of the way up so I could check fitment, final bezel will be full surround, at least that's the plan at this point.
Beeman, on this rainy southern western Ohio day I spent it reading and being amazed by your build. Not only is your build very interesting but the pics, your writing and documentation of what you are trying to do are very well done. Also of note is your skill and skill set increasing over time. Thanks for the time you took and are taking as you continue to completion. Very excited to see the progress to come!
3-D printing is a a completely new way to take a look at parts, and its fun as well. Make toys of grand kid's as well as parts. It amazes me to watch you are doing in your build. You will have a car no one has ever see before and I bet I will really stand out as a one of one. Keep up the great work and I will keep checking the progress, think you have posted and lessons learned along the way help all of us builder out. Thanks
I love me some 3D printing, especially since I spent the last two years at work on a killer project. Now that patents have been filed and we are about to make a public notice, I can share a little bit about it. If you get bored take a look at the below video of the P&W TJ150 Engine. Our project was to 3D print the entire static hot section of this engine and then perform engine testing. We combined the Diffuser, Turbine Nozzle, Combustor, Fuel Manifold/Injectors, Exhaust, and Combustor case into one 3D printed part. We successfully reduced the part count by 99% and ran up to temps in excess of 2000 deg F and ran it more than twice the mission life.
I love me some 3D printing, especially since I spent the last two years at work on a killer project. Now that patents have been filed and we are about to make a public notice, I can share a little bit about it. If you get bored take a look at the below video of the P&W TJ150 Engine. Our project was to 3D print the entire static hot section of this engine and then perform engine testing. We combined the Diffuser, Turbine Nozzle, Combustor, Fuel Manifold/Injectors, Exhaust, and Combustor case into one 3D printed part. We successfully reduced the part count by 99% and ran up to temps in excess of 2000 deg F and ran it more than twice the mission life.
It's amazing that additive manufacturing can have that kind of strength and durability. Maybe one day that type of machine will be in people's homes. Any idea what that machine costs? I've mentioned it before, I saw an early 3D printer about 15 years ago at a biotechnology company for prototyping that I don't believe had much more capability than mine. They paid close to $500,000 for it! So we're at 1/500 the cost in a little over a decade...
It's amazing that additive manufacturing can have that kind of strength and durability. Maybe one day that type of machine will be in people's homes. Any idea what that machine costs? I've mentioned it before, I saw an early 3D printer about 15 years ago at a biotechnology company for prototyping that I don't believe had much more capability than mine. They paid close to $500,000 for it! So we're at 1/500 the cost in a little over a decade...
It is pretty amazing the capability that is out there. We printed these engine parts on an SLM280 machine out of Inco 625 and I would say this equipment setup was in the neighborhood of $1 million. That's not including the heat treat furnaces to perform stress relieve, solution heat treat, and HIP (Hot Isostatic Press). I wish I could share the CFD, but its highly proprietary,the stresses this system handled were absolutely amazing.
I can't wait to start messing around with CF skinning and vacuum bagging some parts. Looking forward to what you are working on.
BTW, I pulled out axles out of the boxes today and inventoried all the parts to put it all together. Looking like I'll be able to start working on them this weekend.
FYI - you can start a nice vacuum bagging setup with the vacuum pump sold at harbor freight. Just buy a few fittings and hose from a composites warehouse and you’re good to go.
Modifying cabin means I need to seal it from the engine bay. Should be a much better seal than as-delivered. Making interior templates. Will be 040 aluminum/lightweight thermal-noise barrier/Alcantara interior.
Twin fan heater core. One fan for cabin, 2nd for dedicated windshield defog. Marine exhaust fans. These move a ton of air.
3D print and engineers dream and a great design tool, really like seeing them being used outside industrial setting to help builder like us in a private setting. Keep the ideas flowing and I will keep reading your design changes and build that is completely off the wall you your own design...
I fabricated a male hatch latch, the receiver is Toyota Celica. Bonded it to the hatch. Tomorrow it will get a few layers of fiberglass cloth to complete the construction.
Interior paneling is coming along, it is 040 aluminum, I corrected that above. This Harbor Freight electric metal shear is great, it cuts like butter. Will smooth everything out once it is cleco'd in. Ordered another 50 clecos, ebay has used ones $25/50.
Done panel beating for a while. This was one of those projects that I was not at all looking forward to, I'm really happy with how it turned out. No fumes will be coming forward.
Will do some form of roll bar padding over the entryway unless someone has a better idea. Here's the kit Longacre pad for an idea.
Modified the seat belt guide to replicate OEM to smooth out the belt travel and eliminate any binding.
No airbags in the GTM obviously, so I'm using rear seat 3 point belts. I'd be careful with OEM seat belts that are designed in conjunction with an airbag (like the C5). Most of the OEMs have a warning sticker on the belt reel like this C6 belt:
On the main rear hatch, I didn't countersink the rivnuts into the fiberglass so I made some aluminum plates to spread out the hinge forces. I should have just recessed the rivnuts...
Got the trunk hinge plate/studs finished and etch primed, prior to priming I used a cutoff wheel to create a cross hatch pattern for more bite.
The 8115 is a cinch to use, 90 min working time. Hand mixed it. To bond the 2 plates, I used about 15% of the cartridge and even wasted about 25-30% of what I mixed up. So it should last a long time.
To keep the mix correct, I measured the plunger depths.
Cleco'd for positioning plus a couple added clamps. Can handle in 4 hours. So should be able to apply overlying glass this afternoon.
I'm almost embarrassed to post this pic, but it shows the complexity of incorporating the C5 gauge cluster in a Honda dash. I've cleaned up worse rat nests...
Everything seems to be functional at this point. I have an unhappy DIC full of warning messages. As it should be. I was glad to see it start firing off orders at me.
Back to arts and crafts time. Created a single fender vent in CAD, was initially thinking parallel, even vents. But I changed that to slightly angled vents (angled away from the cabin slightly) and tapering in size. Printed the first vent, mocked up the additional vents with paper, then back into CAD to create each vent. The remaining vents are on the printer now.
So I've pretty much convinced myself that I will be making molds of my hood and fascia due to the amount of changes made and body filler/fiberglass layers added.
I think this works. Does anyone think anything looks off with the vent layout or position? I just laid them on this morning, will contour them and blend them in. The nice thing about PLA is that it softens easily with a heat gun to contour to the fender.
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Originally Posted by beeman
