Verus' Shop BRZ - Development Thread

[VerusEric]

Did a tiny bit of welding after hours yesterday. I decided to weld the inside instead of the outside of the bung, keeps a really clean look in my opinion.









Taped off the sealing surface and sprayed some enamel on it to keep it from rusting.





Back to the Forester EOC (engine oil cooler), and it's proper routing. The Forester routing is indeed correct from the OEM, in that it has a suction and a pressure side. It is also getting the "coolest" coolant right after the t-stat though this likely does not make a difference for oil cooling.

Excuse my poorly drawn depiction of what is happening but this is the best I can do for the time being, just a tad busy haha.





The forester routing removes the plugged port and feeds the EOC with that (pressure) and then dumps it back into the heater hose (suction). I will be creating my own routing out of pushlok AN hose and capping one of the coolant lines for the TB.

Thanks,
Eric

[Uplink]

This might seem like a silly question, but on the ECU bracket, why did you go with a hole in the bracket for the fuel rail instead of L-notching that section out? Was it for strength in holding the top of the ECU?

[VerusEric]

Originally Posted by Uplink

This might seem like a silly question, but on the ECU bracket, why did you go with a hole in the bracket for the fuel rail instead of L-notching that section out? Was it for strength in holding the top of the ECU?

This will sound like an equally silly answer. I thought it looked best and cutting the entire end off seemed to leave it a bit skimpy in the material area there.

Weekend updates, sorry it takes a bit of time between updates. Business work comes first of course and time is hard to come by.

Installed belt shield, oil feed line. I had extra gold foil from the C&R Racing days so I covered the whole thing.




Radiator installed.






Oil pan going back on:




Crash bar installed:


Installed intercooler (kind of forgot to take a good pic of this ). But I did take the OEM foam from the OEM radiator and put it on the bottom of the custom radiator. This should help keep air going through the radiator instead of under and around it. May remake this using something stronger at a later date.

Manifold installed:




Weighed the turbo, 14.6 pounds! Extremely impressive for a full turbo, including wastegate, actuator, BOV, and solenoid!


To do list:
-Install turbo
-wire radiator fans
-Install Moto-East flex fuel
-Install clutch
-Install fuel pump
-Install P3 guage
-Install charge pipes
-Install intake
-Install exhaust

Try to knock more of this out after hours this week.

Thanks,
Eric

[VerusEric]

Inching closer!

Turbo on, intercooler tubes mocked up and cut the radiator support with tin-snips then painted it.









Thanks,
Eric

[Porterhausen]

Very cool, keeping my eye on this. Very cool to see some engineering going on instead of obvious guess work. I for one would be very interested in a well designed radiator setup/ maybe some info on what you were going for as improvements? Either way if you decide to go to market you have one potential buyer!!

[VerusEric]

Originally Posted by Porterhausen

Very cool, keeping my eye on this. Very cool to see some engineering going on instead of obvious guess work. I for one would be very interested in a well designed radiator setup/ maybe some info on what you were going for as improvements? Either way if you decide to go to market you have one potential buyer!!

Improvement was simple, increased heat rejection with a smaller overall package than OEM to make room for turbo kits. Heat rejection in a radiator is all conducted in the core. We are using one of the most efficient cores in motorsports, no other company in the world has access to such a core. I can boldly make that claim because I spent the better part of a decade working for the leading cooling system supplier for motorsports. The core has been and still is being used in NASCAR, WEC, Tudor Cars, etc.

Do we have data to back up those claims? No, we don't currently. The *only* way to properly do this is to place this core and the OEM core into a calorimeter and test heat rejection in a controlled environment. This cost starts somewhere around 5 grand and goes up from there based on what you want to know. Very few companies are able to utilize this besides high end core manufacturers that have these in house (Denso, Mezzo, Baer, PWR) and high end motorsports companies (NASCAR, F1). We likely won't be able to have this kind of data available. The only other test is to take a car overheating, install it, and see what happens. Not very scientific but it would prove increased heat rejection.

Updates:
Installed the Moto-East flex-fuel kit (sorry for taking off your badge guys, didn't flow with the colors in my engine bay though ). Made a simple little bracket, looks OEM-esque in my opinion, and I love that. Yes, some engineers can fabricate!
Arizona 91 octane piss water is 9% ethanol apparently. I then fed this output to the rear o2 sensor for an input to Ecutek for full flex fuel. Thanks again Moto-Phil! Great guy, always willing to help answer my questions and helped me out with my custom hose fitting needs.






P3 Gauge installed (please ignore FA20Club engraving ):



Received the ACT clutch, will take some pictures of that here shortly and try to install it in the next few weeks.

Thanks,
Eric

[Porterhausen]

Very cool, well like I said if you decide to go to market you have at least one buyer!!

[VerusEric]

Sorry for the lack of updates, been extremely busy with business lately and the shop car suffers as a result sadly. However, because it's Friday... and FullRace Friday sounds catchy, I snapped a few updated pictures for you guys!





Clutch came in from FT-86 SpeedFactory:





Got involved in another forum members dilemma of the clutch fork being extremely weak apparently? So I designed up a unit that will be machined and should be available soon-ish. As a result, clutch/flywheel won't be installed till I get prototypes of the fork.

Broken unit:


Initial design:




FEA on fork with 1000 lb pressure plate force:




Initial 3D Print (Yes it is prettier in pink ^_^):












Revised design printed after discussing with machine shop on how he was going to cut it. Basically told me he was cutting it from both sides of the part anyway, so revised it for a cleaner and more OEM install.





Have some VERY VERY exciting news coming in the next few weeks/month. Looking forward to sharing that with you guys shortly.

Have a good weekend,
Eric

[VerusEric]

To install the splitter, I drilled and tapped holes directly into the crash bar. I also had to modify the mounts slightly and then spray painted them black. I then had to modify the bumper a little with a dremel. Came out fairly clean, you have to look for it being modified.





Pictures of everything together, tidied up.



















Loaded her up on a base map that a friend helped me create and she is doing fine around town and for testing the brake duct kit. I still need to get the clutch installed (waiting for billet fork) and the fuel pump. There are a few other odds and ends as well that I'm likely forgetting.

[VerusEric]

Our newly released brake kit installed on the passenger side for testing.















Test data should be available within a week or so .

[VerusEric]

Anddddddd still finding hay....... @johan



Fuel pump installed and working.

[The Racers Line]

Love the build progress! A good friend is moving to Arizona this summer, I may have to come check meet you in person and check this car out. Haven't been lucky enough to install a Full Race kit yet!

1 little thing the OCD tech in me noticed:


Thats A LOT of silicone. Some of the FA20 failures have actually been factory over siliconing. A nice bead of Subaru Grey will do the job. My only complaint I promiss!

[VerusEric]

Originally Posted by The Racers Line

Love the build progress! A good friend is moving to Arizona this summer, I may have to come check meet you in person and check this car out. Haven't been lucky enough to install a Full Race kit yet!

1 little thing the OCD tech in me noticed:


Thats A LOT of silicone. Some of the FA20 failures have actually been factory over siliconing. A nice bead of Subaru Grey will do the job. My only complaint I promiss!

Sure thing! Feel free to let me know when and we can surely meet up for a beer or two .

Looks like more than it was, a very little bit squeezed out when I installed it. I've been doing this for 7+ years on 20+ builds without an issue (Toyota technician for 4 years). But everyone has their own install method, I'm happy to report no leaks or issues to date.

Brake kit thread has started with test date:
http://www.ft86club.com/forums/showt...=1#post2653597



Thanks,
Eric

[VerusEric]

Received some photos from the machinist on the first article billet clutch fork.







Brake duct video is up:
[ame="https://www.youtube.com/watch?v=u090pxKTs9c"]Velox Motorsports Brake Cooling Kit R&D - YouTube[/ame]


Getting the calibration dialed in on the street right now as well. Turbo feels very nice and responsive! Very impressed with it thus far. Wastegate currently spikes at .5 bar and goes down to .35 bar by redline. That will be remedied when we start messing with the boost control solenoid.

Thanks,
Eric