Verus' Shop BRZ - Development Thread

[VerusEric]

Originally Posted by kask2_6.0

You know you want to..

That's the next step! I just want a bit more control, running 10-12 on 91 octane is a bit worrisome to me.

[GSpeed]

Originally Posted by VeloxEric

That's the next step! I just want a bit more control, running 10-12 on 91 octane is a bit worrisome to me.

Switch to an M150 with knock sensors and you won't have those worries anymore.

[johan]

Originally Posted by kask2_6.0

You know you want to..

Yup! This combined with a 4-port solenoid will give you complete control over boost.

[Nickosport]

I did some work with ANSYS and ANSYS LS-Dyna in college. Ansys has to be the most un user friendly software on the planet. The GUI is terrible. Super powerful software, but very difficult to use and not intuitive at all. Good luck sir, I do not envy you.

This was always my favorite Ansys FEA:

[ame="https://www.youtube.com/watch?v=-apBdyxcWZA"]https://www.youtube.com/watch?v=-apBdyxcWZA[/ame]

[VerusEric]

Originally Posted by GSpeed

Switch to an M150 with knock sensors and you won't have those worries anymore.

Someday... someday. Hopefully sooner than later. If we had the funds we would already be running one for sure!

Originally Posted by johan

Yup! This combined with a 4-port solenoid will give you complete control over boost.

Good to hear .

Originally Posted by Nickosport

I did some work with ANSYS and ANSYS LS-Dyna in college. Ansys has to be the most un user friendly software on the planet. The GUI is terrible. Super powerful software, but very difficult to use and not intuitive at all. Good luck sir, I do not envy you.

ANSYS has changed significantly from when I was in college just 3-5 years ago. It has become quite a bit more user friendly in my opinion but this is coming from people who didn't use GUI on the previous analysis software. OpenFOAM is similar to that of programming, there was no GUI.

Compared to say a Solidworks FEA analysis or similar, yes it's significantly more involved. However, it needs to be to allow all the variety of cases we can test.

CFD analysis is sped WAY up, once we get the hang of it.

[VerusEric]

Weekend install project are RPAC bumper quick release pins. The gap was starting to form from multiple removes/installs and why not make it easier to install/remove going forward?

Should be fun putting more holes in the car -_-.

Fabrication bug hit as well, should have a finished part by weekend's end as well. Not sure why melting metal together is so much fun but it is.

Thanks,
Eric

[Infinity]

I love this build you guys are doing! I am very interested in the Full-Race turbo kit for myself.

1. Do you mind going into your choice of 7163 for the turbo? What are your ultimate power goals with it? How do you think it would compare to the 6258 or 6758? I have seen a blog post by Perring showing the 7163 spooling slightly faster than the 6258 and 6758, but this doesn't seem to make since to me.

2. Have you guys posted a dyno anywhere? The only dyno I can find for this kit is in this article here: http://dsportmag.com/the-tech/full-r...spirated-fa20/. They also use a 7163, but the graph is not useful at all. The numbers are not even visible. I am super curious to see when the Full-Race kit spools, etc.

[VerusEric]

Originally Posted by Infinity

I love this build you guys are doing! I am very interested in the Full-Race turbo kit for myself.

1. Do you mind going into your choice of 7163 for the turbo? What are your ultimate power goals with it? How do you think it would compare to the 6258 or 6758? I have seen a blog post by Perring showing the 7163 spooling slightly faster than the 6258 and 6758, but this doesn't seem to make since to me.

2. Have you guys posted a dyno anywhere? The only dyno I can find for this kit is in this article here: http://dsportmag.com/the-tech/full-r...spirated-fa20/. They also use a 7163, but the graph is not useful at all. The numbers are not even visible. I am super curious to see when the Full-Race kit spools, etc.

That's awesome to hear. I'm quite impressed with the quality of the kit and the turbo!

1) There are a few reasons I went with the 7163 over the 6758 (my initial choice). Some reasonable, some more emotional haha.

-The 7163 is the newest of the new as far as EFR tech goes. Mixed flow turbine wheel being the biggest benefit, which offers killer spool and large power!
-It's used in IndyCar, how cool is that? CHRA is an IndyCar turbo and that kind of strikes home with me.
-Aluminum center section. I'm not competitively racing but having light stuff is always nice.
-Even though the turbo is new, there are some dynos out there. The dynos show that the 7163 spools nearly identical to the 6758 with an immense powerband at hand. The choice was simple really when seeing the 7163 spools near the same as the 6758 with significantly more power on tap if the need arises.

My goals are 350-375 for now. We all know that is pushing the stock engine/trans so I'm trying my best to play it safe.

2) I have not dyno'd the car yet. I find that most people rush to the dyno to see numbers. I take a fairly methodical approach as in my experience it is rare that all things go well right out the door. IE: I am still working on getting my boost control down. I am out of fuel currently on E85. I am getting close though, promise! After injectors and dual port IWG I think I'll be full steam ahead towards a dyno date, which should be getting to me somewhat soon!


Alright, so onto the weekend's progress!

So the fab bug hit me, from time to time I have to do something that doesn't really do much but makes me feel better! So I made a 3" intake with tubing I had laying around and a 3" Amsoil intake filter. Pictures below comparing the Full-Race 2.5" vs. mine. Nothing is wrong with the Full-Race unit, I just wanted to make something.















Finished up the install using the RPAC quick latch bumper install... very happy with the lack of bumper gap now!





A few more fabrication projects to come and some videos .

Thanks,
Eric

[GSpeed]

Nice Al welding!

[VerusEric]

Originally Posted by GSpeed

Nice Al welding!

Thanks. By no means is it production worthy but it's satisfying to put two pieces together and build something yourself ^_^.

While we've been focusing most of our efforts on learning ANSYS SpaceClaim, Fluent, and their meshing software, the printer got some upgrades! I finally took some photos so figured I would share.

-Roller bearings were getting very very loud, so I went to some bronze sintered units which greatly reduced the noise and tightened up the movements a bit. It was primarily for noise and I can say it's a huge difference!

Before: https://www.facebook.com/veloxmotors...0353579538084/

After: https://www.facebook.com/veloxmotors...0353579538084/

-Printed out a Velox backing plate.


-I typically print with PLA, which likes to be cooled as it's printed, this is referred to as active cooling. Lucky for me, my printer is common so I was able to download a unit that bolts directly onto my printer and print it out. Tape is on the left half because I typically only use the right extruder and that increases flow to the right. Wired in a new fan, added a line of code to the slicer program, and we have active cooling!





-Finally, I saw the nasty tip clearance of the fans, so I drew up a press in velocity stack and now the printer is a certified race printer!





While Paul was in town for ANSYS training, we did some flow visualization testing. While we weren't able to do as much testing as we wanted, we gathered some information and it's pretty clear to say that flow is staying attached to the main diffuser surface and quite a bit of the up-turn radius at only moderate speeds.





I'll grab some more photos when I remove the diffuser as there was a neat vortex coming off the center exhaust cutout location. We'll probably attempt to re-test in this fashion when I get some more diff/suspension covers in as we think that will help flow even more. Interesting to test none-the-less and it's neat to see flow attachment similar to how our CFD analysis shows.

Thanks,
Eric

[VerusEric]

Back at modifying the car after a lot of work!

Some custom parts starting to form. Any ideas?


Stopped by Full-Race to install a few prototype components and picked up these!




Prototype photos from the Eco-Boost they have. No one else has seen these; but, you guys are special .

















Have some more work ahead of me to get the car back on the road but it should be soon; then hopefully a dyno day after boost control is dialed in.

Thanks,
Eric

[civicdrivr]

Are those pieces to some sort of cooling shroud?

[VerusEric]

Originally Posted by civicdrivr

Are those pieces to some sort of cooling shroud?

Yessir!

I got the radiator ducts cut out and bent up. I'm somewhat satisfied with the appearance (not the greatest fabricator) but I'm thrilled with how they will function. Pictures below of them, let me know if you guys have any questions.




Driver's side


Passenger's side


Center, poorly bent , duct


Driver's side with bumper installed


Passenger side

With these installed air will be forced through the cooling stack at speed. Very excited to compare logs from highway speed tests.

Warning, boring info below. Worked on two more blogs when I was flying over the past month. Just a few informative blog posts.

Oil Cooling Information - A blog post detailing the two styles of cooling engine oil. Most of the information is from years and years of experience working at C&R.

Mesh Defined - We realized not many people understand what it means when we say "We performed a mesh study." or "We meshed the model." Well, we did our best to describe mesh and why it is necessary in what we do.

Thanks,
Eric

[johan]

Those shrouds are awesome. I've wanted to do something like that on past cars I've owned. What is that rubber piping you're using to seal them off? Is it self adhesive or did you use some kind of contact cement?