Re: New guy? Back to race in Lemons. Now a build thread!

Zacks wrote:
Lemon_Newton-Metre wrote:

If I have this correct:

Do you have any concerns about - in the case of rain during the event - water on the front of the projectors cracking the cover of a projector because of temperature differential?

[I thought that not only smooth air flow, but that this was a key reason for the lenses on these assemblies.]

I had the guts of a Cadillac projector mounted on a motorcycle years ago which got ridden in the rain, and it never cracked/broke fwiw.  Dunno if it was a good idea or what engineers designed ect but it worked.

Ok, follow-on question for Zacks:
What lamp lens material cover? Intensity / technology?

My knowledge is limited and dated.

I'm remembering cautions about handling halogen bulbs. I know that oils from fingers is different than rainwater, in that the oils can get really hot and yet stay in one place on the glass, but presumably any alcohol or water (from cleaning) initially on the bulb will evaporate before there's too great a temperature differential; but air temp rainwater on hot glass might have a different effect.

I freely admit ignorance about the headlamps, and I'm happy to defer to more knowledge.

127

Re: New guy? Back to race in Lemons. Now a build thread!

It was a headlight from a cts where the high beam and low beam are stacked vertical.  Halogen bulbs.  Dunno what the projector lenses are made out of. 
The bulbs get super hot but the lenses do not get nearly as hot.  If junk splashed around the lense and got on the bulb it probably would be bad for it but didn't do insane bike miles. Likely his rac3 car won't rack up daily driver miles.

Re: New guy? Back to race in Lemons. Now a build thread!

(That sounds cool for a bike - if I remember correctly what those lights look like.)

It's such an inventive and elegant cooling solution I was immediately intrigued; I'd just be concerned the lights might crack and fail - at a race, in the rain, at night.

129 (edited by khuebner250 2024-05-17 06:35 AM)

Re: New guy? Back to race in Lemons. Now a build thread!

Lemon_Newton-Metre wrote:

If I have this correct:

You're using the headlight housing assembly simply to hold the bulbs and projectors in place; and you've removed the lens and some of the back of the assembly to allow air flow through it, yes?

I have to say this is a VERY elegant solution.

Do you have any concerns about - in the case of rain during the event - water on the front of the projectors cracking the cover of a projector because of temperature differential?

I thought that not only smooth air flow, but that this was a key reason for the lenses on these assemblies.

No, I think they'll be fine? I'm not using incandescents or HIDs. I'll be running LED bulbs in these projectors.
My thought is the LED bulbs themselves don't produce a lot of heat, it's the emitters/housings that generate all the heat. And as long as I have good air flow across the heatsinks, they should be fine. However, I guess we'll find out.

Edit: Projector lenses are super thick glass. We'll see how they hold up over time. There are also rocks, Colorado hail and peoples racecar parts falling off on the track... to be concerned about.

Re: New guy? Back to race in Lemons. Now a build thread!

I hope.so.

A previous thread about: lights

Re: New guy? Back to race in Lemons. Now a build thread!

Sorry I've been absent the last 2ish weeks. We added a new grandkid to the mix, had a couple birthdays, graduation parties and been teaching my 2 youngest how to drive stick. All that to say, I haven't really touched the car in the last 1 1/2 weeks.

I did get everyone signed up, registered and paid for. So we are official for the BFE GP @ HPR. My brother has been working on the Livery for the car. Doing his graphic design magic.

Here is my revised punch list from earlier that keeps getting longer?

NEEDED
Set the shift light
Figure out what's up with the stupid fuel light, it has a mind of it's own
Verify chassis bolt torque
Witness mark bolts
Double check all fluid levels
Clean, wipe down, vacuum car
Clay bar the entire car
Maybe cut and buff
Setup suspension and do math (Comp, Rebound, Ride height/droop)
Redo alignment
Cut vents in rear lexan
Camera gopro mount or mounts
Cut out vinyl on cricut
Apply vinyl livery / theme on car
Change oil
Reroute oil cooler lines
Add chaffing and vibration protection if needed.
Night time number board lighting
12v power for above lights
Adjust headlights
Safety wire/pin harness buckles
reflush cooling system

COMPLETE
Livery / Graphic design
Positive terminal cover
Add a second battery hold down tab

Re: New guy? Back to race in Lemons. Now a build thread!

I got back to work this last Sat, Sun and Mon over the Memorial Day weekend. I figured i needed to tackle the suspension first, as it's the most time consuming.

This weekend turned into giant math equations. Followed by a multiday dance around the car on your knees, while rolling around on the concrete floor. Very painful.

Removed sway bar endlinks, springs and bump stops
https://i.ibb.co/QJ30475/PXL-20240526-143823974.jpg


Compression
https://i.ibb.co/WKwrkY1/PXL-20240526-143749455.jpg


Rebound
https://i.ibb.co/4PSYRDp/PXL-20240526-143802310.jpg


Adjust until shock is fully compressed and the wheel still spins. Just before the wheel makes contact. I had to massage the inner wheel wells with a hammer a bit. I repeated this same process up front, massaged the fender lip with a hammer and dolly and pulled the fender. Until I had a full steering sweep without interference while at full compression. Lock em down.
https://i.ibb.co/sjLSFWV/PXL-20240525-164016712.jpg


Then based on shock travel, motion ratios, where I wanted droop, I set ride height until I was at my desired droop measurement. I played with alignment as well and it's pretty close, within a tenth of a degree. I gotta get that finished up. There's a bunch more that goes into this but that's the gist of it.

Re: New guy? Back to race in Lemons. Now a build thread!

This last Saturday, my daughter and I headed down to Wine Country Motorsports. Got the family some final gear. Pretty good selection to try on and get fitted properly. When we got back early afternoon, I started hitting my punch list.

Set the shift light in the tach and started playing with the fuel light.
https://i.ibb.co/1Qn5wbd/PXL-20240602-164536735.jpg

Using a resistor to trigger when the light comes on.
https://i.ibb.co/Mp5k7T4/PXL-20240602-164534015.jpg
https://i.ibb.co/KNbgh5H/PXL-20240602-164522644.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

Sunday I finalized the alignment. Got my tenth of a degree back. I'm running -3.5* Front and -3.0* Rear camber. I'm still debating what I should run for Toe for awd? I'm thinking 0 front and maybe a 1/16 rear in.

Front
https://i.ibb.co/Zg76VZb/PXL-20240602-144532048.jpg

Rear
https://i.ibb.co/jMBTbW0/PXL-20240602-150404530.jpg

135 (edited by Zacks 2024-06-03 08:13 AM)

Re: New guy? Back to race in Lemons. Now a build thread!

I like how you painted the spreader plates blue but cage green that' looks great!

I've owned a ton of gd imprezas and iirc factory toe is 0.  We run our gc with 0 toe as well, and it's really balanced to drive.  We do need more camber judging by last races tire wear, but one of the judges mentioned last race how anything over 2.5deg in the front eats ball joints (he tracked a subie).  Idk. 

I do know that hub flex is why the 2005 sti moved to a 5x114 bolt pattern.  Apparently the 2004 5x100 resulted in hub flex and with the fixed brembos it would push the pads back into the caliper when turning (on the track)  so coming into the next turn you have no brake pedal!  Apparently some guys put springs in the pistons.

Re: New guy? Back to race in Lemons. Now a build thread!

Zacks wrote:

I like how you painted the spreader plates blue but cage green that' looks great!

I've owned a ton of gd imprezas and iirc factory toe is 0.  We run our gc with 0 toe as well, and it's really balanced to drive.  We do need more camber judging by last races tire wear, but one of the judges mentioned last race how anything over 2.5deg in the front eats ball joints (he tracked a subie).  Idk. 

I do know that hub flex is why the 2005 sti moved to a 5x114 bolt pattern.  Apparently the 2004 5x100 resulted in hub flex and with the fixed brembos it would push the pads back into the caliper when turning (on the track)  so coming into the next turn you have no brake pedal!  Apparently some guys put springs in the pistons.

I know the hubs/bearings are weaker in the WRX's but there's not really a good solution, I know you can upgrade to the STI stuff but that opens up all kinds of other issues. Hybrid axles, strut mounts, knuckles, etc. I think I'll just keep up on bearings and monitor hub conditions for now.  We'll reassess after I get through the first race.

I haven't heard about -camber eating ball joints? Subie's and all awd cars tend to do well with lots of -camber. I know TurnInConcepts runs -4.5 up front, -4 in the rear and recommends not to have more than 1* difference between the F and R on Subaru's.

Are you 0 toe all around or just in front?

137

Re: New guy? Back to race in Lemons. Now a build thread!

We are 0 toe all around.  Car feels stable at speeds to me (when we broke the wing the rear felt floaty until we got the old wing back on...)

That being said I haven't experimented with other amounts of toe, so maybe it could be better?

We also run much less camber due to adjuster limitations,  iirc we have 1.5deg front and 2deg rear on DIY fabricated adjusters,  next project is to increase front camber to 2.2deg.  I would have run 2deg before but we are on stock front adjusters.

Our hope is we need less than a GD chassis cause we are lighter (2400lbs)

I also ran 0 toe on my 04 STI, and had no issues, but that was a street car so...

Re: New guy? Back to race in Lemons. Now a build thread!

Zacks wrote:

We are 0 toe all around.  Car feels stable at speeds to me (when we broke the wing the rear felt floaty until we got the old wing back on...)

That being said I haven't experimented with other amounts of toe, so maybe it could be better?

We also run much less camber due to adjuster limitations,  iirc we have 1.5deg front and 2deg rear on DIY fabricated adjusters,  next project is to increase front camber to 2.2deg.  I would have run 2deg before but we are on stock front adjusters.

Our hope is we need less than a GD chassis cause we are lighter (2400lbs)

I also ran 0 toe on my 04 STI, and had no issues, but that was a street car so...

I think I'm going to throw it on a alignment rack just to verify. And go with zero all around or 0 front and 1/32-1/16 rear toe in.

Re: New guy? Back to race in Lemons. Now a build thread!

For this next little mod I broke out the multitool and heat gun. I stuck my stickers where I wanted them and got to cutting.
https://i.ibb.co/HrWf943/PXL-20240530-224335462.jpg
https://i.ibb.co/qsXJJdc/PXL-20240602-205416489.jpg

Then the heat gun and torch.
https://i.ibb.co/DC4xZqf/PXL-20240602-211418007.jpg
https://i.ibb.co/NyNbQgJ/PXL-20240602-211411506.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

ONE WEEK TIL TECH @ the BFE GP !

This is gonna be a big weekend for the car. I'll torque check and witness mark the car tonight. And attempt to get through the rest of my list. I'll post updates when I can.

Slowly been moving items to the completed portion of my punch list. 

NEEDED
Verify chassis bolt torque
Witness mark bolts
Double check all fluid levels
Clean, wipe down, vacuum car
Clay bar the entire car
Maybe cut and buff
Cut out vinyl on cricut
Apply vinyl livery / theme on car
Change oil
Reroute oil cooler lines
Night time number board lighting
Adjust headlights
Reflush cooling system

COMPLETE
Livery / Graphic design
Positive terminal cover
Add a second battery hold down tab
Set the shift light
Figure out what's up with the stupid fuel light, it has a mind of it's own
Setup suspension and do math (Comp, Rebound, Ride height/droop)
Redo alignment
Cut vents in rear lexan
Camera gopro mount or mounts
Add chaffing and vibration protection
12v power for above lights (pulled this off the light switch)
Safety wire/pin harness buckles

Re: New guy? Back to race in Lemons. Now a build thread!

One of my daughters came over this afternoon and wanted to clay, cut and buff the car. So, let's do it!
https://i.ibb.co/C7LfVc9/PXL-20240607-194119865.jpg
https://i.ibb.co/SN2PK7T/PXL-20240607-214104034.jpg
https://i.ibb.co/k2pxNc4/PXL-20240607-220357523.jpg
https://i.ibb.co/McMwrDn/PXL-20240607-214114933.jpg

In my list previously, I said the camera mount was done. You can see it in these pics. It hints towards our theme. We'll see if anyone pics up on it.

Re: New guy? Back to race in Lemons. Now a build thread!

Polished!

Still, 50 shades of blue.

https://i.ibb.co/YcxcDSK/7dea0283-6175-4a01-9ccc-19cba1bf8820.jpg

https://i.ibb.co/HNNNGnj/74eb1731-1058-4204-9871-17536ce4701e.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

I was digging through my gear and happened upon some old patches. I found a pic of the old gashole from '16. This is the year we won the IoE.
https://i.ibb.co/qdxypKc/PXL-20240608-013353612.jpg
https://i.ibb.co/QK4DNF8/IMG-20160603-185010334.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

Went to the shop and threw it up on the rack this morning. Did the torque check and witnessed all the nuts and bolts with some dycem torque seal.

Found a couple bolts that were lite on torque. A brake flex line that moved and was just about to touch the rear axle shaft. Also, the RR caliper banjo was just barely moist, a half turn cleared that up.

https://i.ibb.co/60PF8zN/PXL-20240608-170600098.jpg

https://i.ibb.co/kq48Qx4/PXL-20240608-170609855.jpg

https://i.ibb.co/ZWdGTN5/PXL-20240608-170617300.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

Before I went to the shop, I stopped by metal distributors in Fort Collins and picked up some aluminum drops. Then when I got home I started on the number board lights!

Aluminum
https://i.ibb.co/WP9jt5M/PXL-20240607-122000663.jpg


Brake
https://i.ibb.co/FD7RBkt/PXL-20240607-122010728.jpg


Layout
https://i.ibb.co/Ks385hy/PXL-20240608-150136026.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

A little cutting, a little grinding.

https://i.ibb.co/3STgTdd/PXL-20240608-183531120.jpg

https://i.ibb.co/3m2H5LH/PXL-20240608-183914759.jpg

https://i.ibb.co/hXQ5WbG/PXL-20240608-185357627.jpg

Dimple dies
https://i.ibb.co/dKLGBPM/PXL-20240608-193310896.jpg

Amazon lights
https://i.ibb.co/5vZ7nKZ/PXL-20240607-122018613.jpg

Coming together
https://i.ibb.co/C5gY0LN/PXL-20240608-201828131.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

Threw on a little paint
https://i.ibb.co/XZxH8qv/PXL-20240608-201156150.jpg

Grommet
https://i.ibb.co/tpF2BqW/PXL-20240608-201830923.jpg

Fitting
https://i.ibb.co/tKkgpnH/PXL-20240608-201859561.jpg

Fitted
https://i.ibb.co/K0152Lt/PXL-20240608-214820849.jpg

Gotta make sure the door opens
https://i.ibb.co/pzPsPxN/PXL-20240608-223233830.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

And working
https://i.ibb.co/rmdVVhC/PXL-20240608-214027735.jpg


I have them wired into the headlight switch.
https://i.ibb.co/J25Bcg5/PXL-20240608-214151850.jpg

Re: New guy? Back to race in Lemons. Now a build thread!

One week till race day!

150 (edited by khuebner250 2024-06-08 04:20 PM)

Re: New guy? Back to race in Lemons. Now a build thread!

I still have to gather fuel, fuel drums from work, packing lists(car, team, trailer, personal, spare parts, fluids, safety equipment, tools).

I still need to figure out a camper! I have a truck and trailer but need to figure out where we are going to sleep. Nobody wants to hang out in a 100* enclosed trailer with no A/C.

Updated list

NEEDED
Double check all fluid levels
Clean, wipe down, vacuum car
Cut out vinyl on Cricut
Apply vinyl livery/theme on car
Change oil
Reroute oil cooler lines
Adjust headlights
Reflush cooling system
Loose weight, lol.

COMPLETED
Livery / Graphic design
Positive terminal cover
Add a second battery hold down tab
Set the shift light
Figure out what's up with the stupid fuel light, it has a mind of it's own
Setup suspension and do math (Comp, Rebound, Ride height/droop)
Redo alignment
Cut vents in rear lexan
Camera gopro mount or mounts
Add chaffing and vibration protection
12v power for above lights (pulled this off the light switch)
Safety wire/pin harness buckles
Verify chassis bolt torque
Witness mark bolts
Clay bar the entire car
Cut and buff
Night time number board lighting


The punch list is getting smaller.