Verus' Shop BRZ - Development Thread

[VerusEric]

It is finally time to start a thread regarding Velox Motorsports' (now Verus Engineering) company vehicle as we move into 2016.





















The goal with the car is to have a fun street car you can take to the track, though currently it is a glorified parts getter. The ultimate goal is to do track days with it for development, testing, and most importantly fun. This will come in time when we have more time (and money) for these activities.

This is a bit long winded so I apologize before hand but not many people know about Velox Motorsports and where our roots stem from.

Purpose:
This thread will serve as a chronological log for the parts we design, build, and test on our own shop car and give insight on the company under the surface. We will do our best to bring an in-depth view of what we do here. If you feel we have left out some information or key aspect of the company, do not hesitate to let us know and we will gladly answer those questions.

Modification List:

Costmetic:
-Debadged
-Heated Seats Cover
-Velox Motorsports Cam Sensor Covers
-Velox Motorsports Fuel Rail Covers
-RPAC quick release bumper kit

Aerodynamics:
-Velox Motorsports Street Front Splitter
-Velox Motorsports Splitter Race Upgrade
-Velox Motorsports Rear Diffuser
-Velox Motorsports Rear Diff/Suspension Covers
-Velox Motorsports Front Wheel Deflectors
-Velox Motorsports Front Splitter Endplates
-Velox Motorsports Tunnel Cover
-Velox Motorsports Side Splitters
-Velox Motorsports Rear Spats

Cooling
-Velox Motorsports Modular Hood Louvers
-Velox Motorsports Brake Cooling Kit
-Velox Motorsports Radiator w/ Fans
-Forester XT OEM Engine Oil Cooler Plate

Engine/Exhaust/Trans:
-Full-Race Turbo Kit
-Borg Warner 7163 Twin Scroll EFR Turbo
-Full-Race/Turbosmart Internal Wastegate
-Velox Motorsports Fuel Rails
-Velox Motorsports AOS
-Velox Motorsports Rear Cam Cover with Drain Back Kit
-Velox Motorsports Lightweight High Torque Carbon Driveshaft
-Velox Motorsports Billet Clutch Fork
-ACT XT Street Clutch with Lightweight Flywheel
-Amsoil fluids throughout
-Trying Neo Sythetic 75W-90 in Trans right now
-Tomei Type-80 Currently, will be building another 3" aluminum exhaust someday.

Suspension/Chassis/Brakes:
-Velox Motorsports Lightweight 7075 Aluminum Rear LCA
-Velox Motorsports Rear Toe Control Links
-Velox Motorsports Brake Cooling Kit
-Velox Motorsports Camber Plates
-Racecomp Yellow Springs on Stock Dampers
-AP Racing Sprint Kit

Wheels & Tires:
-18x9.5 +45 Wedsports SA-72R Blue Light Chrome
-3mm Spacers on front to clear spring perch currently
-255/35/18 Bridgestone G-Force Sport Comp 2

About Velox:
Velox Motorsports is a company built around the idea that aftermarket components should be engineered and well crafted. We do our best to use the tools we have available during the development stage to design and manufacture high quality, high-performance components.

Velox is Latin for swift or speed. Without speed, none of us would have the love of automobiles we all possess. Speed is what brings us together and strive for perfection in the components we produce. We wanted to bring that passion to our company’s name.

Our team is comprised of passionate engineers dedicated to redefining aftermarket components and company involvement in the aftermarket community. We focus on educating the end user with knowledgeable information based off data and not speculation. Specializing in aerodynamics, heat transfer, and FEA, we build functional, aesthetically pleasing components that are backed with real engineering. Contacts we pull from involve staff on NASCAR and IndyCar teams, another was from Nissan’s GT-R LM Nismo team (now disband), others from OE manufacturers, and finally a high-performance engine calibrator well versed with Subarus.

We are a small company still, @plucas and I are the main people involved, so research and development is not lightning quick, but as we hire more full-time employees, this should change. Properly engineered and developed components also take a bit longer to come to fruition. This is our passion and we plan on sticking around for a long time .

CFD Experience:
We have compared results with published aero analysis (Perrinn LMP1 model, Ahmed model, and DrivAer models to name a few) to back our ability and prove our accuracy. On each analysis we were within a few percentages of published values. Below are a few photos from our analysis on the Perrinn LMP1 model and Ahmed model. CFD and aero is a subject many refer to as black magic and honestly it is to some extent. Without actually testing components, most components are a shot in the dark as far as functionality or how it will affect the vehicle aero balance.

CFD Software

A Look Inside Velox CFD - Validation

A Closer Look at Splitters and Air Dams





FEA Experience:
Using Finite Element Analysis, we were able to design the lightest and one of the strongest rear lower control arms for the FR-S/BRZ/GT86. We then backed up our analysis by testing it on a load cell one of our contacts was able to use. Our FEA analysis estimated a fatigue failure at 3.5G bump load at 50k cycles, actual was 46k cycles, which to us proves we were fairly accurate as predicting surface conditions and other parameters can be difficult to estimate. These are now in production.

FT-86 Lower Control Arm FEA

FT-86 Lower Control Arm Validation







Heat Transfer:
For the better part of a decade, we have worked for the leading cooling system supplier for all motorsports. F1, IndyCar, NASCAR, WEC, Tudor, IMSA, V8 Supercar, NHRA, ProMods, etc. With this knowledge, we have a widespread understanding of a system not many people know about fully.

TLDR: Hi.

[VerusEric]

Forced Induction Future:
We decided to go with Full-Race for our turbocharging needs. For those that don't know about Full-Race, over the course of the past 14 years they have established themselves as a leader in the turbocharging industry and set the standard time and time again. They have some of the best quality turbo manifolds in the aftermarket used in all forms of racing, be it drift, road course, time attack, or drag. We decided to go with them for their reputation, their quality, the completeness of their kit, and Borg Warner's EFR turbo technology used in the kit.

Borg Warner
We decided to go with the 7163 from Borg Warner's EFR lineup. This turbo is designed specifically for competitive racing use and is Borg Warner's newest addition to the EFR family. Utilizing the latest generation compressors combined with state of the art 'Mixed-Flow Gamma-Ti Turbine Wheel' design allows for remarkable spool and huge powerbands. This unique turbocharger is an off-the-shelf Indycar turbocharger, used by all 2014/2015 IRL teams. To say this doesn't get out engineering minds buzzing would be an understatement. Packed with the latest technology, we knew we had to go with this specific turbo.

Features:
-Mixed Flow Gamma-Ti turbine wheel
-Forged milled extended tip compressor wheel
-Military-grade dual ceramic ball bearing assembly with silver plated metal cage
-Stainless steel turbine housing
-Water cooled light-weight Aluminum bearing housing
-Large internal wastegate
-Compressor re-circulation valve
-Boost control solenoid valve







We're very excited to get this kit on our shop car and see how it can perform. We will update with more info as the kit begins to trickle in.

Update 03/09/16:

Received the turbo kit! Pictures below. The turbo kit is absolutely gorgeous. The fabrication and welding is extremely well done. The kit is thorough and includes all the components you could want or need for the install including 3" downpipe, overpipe, AND front pipe! Wish I could weld like this.

We decided the twin scroll would benefit us most so we decided on a 7163 twin scroll kit. Twin scroll turbocharges are proven to increase transient response and power throughout the power band. There is a reason nearly all OEMs go with twin scroll .

Header:







Front pipe:



Intercooler tubing:



Engine heat shield:



Hose/Clamps/Gaskets:



Intercooler:





Update 03/17/16:

Turbo is in and is gorgeous! Pictures below.

















Update 03/27/16:

Coated the charge air cooler. Purely for cosmetics, it came out pretty well.


Exhaust Components Came Back from Black Ceramic Coating:





Turbine came back from ceramic coating:








Thanks,
Eric

[weederr33]

Do the Velox fuel rails require any special tuning?

[_gt86_user]

Originally Posted by weederr33

Do the Velox fuel rails require any special tuning?

Was wondering this too. LMK

[VerusEric]

Originally Posted by weederr33

Do the Velox fuel rails require any special tuning?

Originally Posted by _gt86_user

Was wondering this too. LMK

No, they do not from our testing. Fuel trims changed 3-4% from OEM but that could have been from the difference in air temperature/gas temperature from when I turned the car off to when I turned it back on a few hours later.

A local turbo car noticed a bit more consistent fuel delivery top end, but realistically the benefits from the fuel rails are:
-Aesthetics
-A bit of weight savings
-The ability to run a return system

[ichitaka05]

Nice BRZ!

I'll be interested to read all the research stuff (if allowed) to educate all of us

[Drakiv]

Sweet!

[VerusEric]

Turbo kit arrived, below are some pictures. Extremely happy with the parts.

Header:







Front pipe:



Intercooler tubing:



Engine heat shield:



Hose/Clamps/Gaskets:



Intercooler:

[8R6]

damn that turbo is gorgeous

[VerusEric]

Waiting for the turbo to come in and exhaust components to be ceramic coated but I installed the fuel rail covers this weekend! Between the two of them, they reduced weight by over 4 lbs and look pretty nice compared to the nasty stock black steel pieces. These work with OEM and our rails as well.

Passenger side cover and ECU bracket:






Driver side fuel rail cover:








Both sides:


Finalized a design on the radiator I want to build for my car. Unsure if we'll bring it to production, but being the cooling snob I am, I had to design and build something for my car.


And finally she ate some hay on Saturday night on the freeway. Splitter saves the day, this is the second time the splitter saved my bumper from certain damage. Arizona freeways are rough!

[200hp/tonne]

Where can I buy the ECU bracket/cover?
That is beautiful.

[Takumi788]

Originally Posted by 200hp/tonne

Where can I buy the ECU bracket/cover?
That is beautiful.

Ditto.

Not available yet on FT86 Speedfactory....and says out of stock on the Velox site...I just looked myself.

[gl2filmerguy]

Originally Posted by Takumi788

Ditto.

Not available yet on FT86 Speedfactory....and says out of stock on the Velox site...I just looked myself.

They told me they will be updating on FT86SF soon.

[FRSKEV]

That turbo is sweet, so am I understanding that it has an internal wastegate and internal bov basically?