Decay's Ultramarine Trackrat

[Ultramaroon]

Conical washer to distribute load to an even greater radius than a flange bolt.

http://www.grainger.com/product/GRAI...4?s_pp=false&=


edit: I think Belleville washers are the inch-sized equivalent.
http://www.grainger.com/category/dis...log/N-mga?bc=y

[Decay107]

Originally Posted by Ultramaroon

Conical washer to distribute load to an even greater radius than a flange bolt.

http://www.grainger.com/product/GRAI...4?s_pp=false&=


edit: I think Belleville washers are the inch-sized equivalent.
http://www.grainger.com/category/dis...log/N-mga?bc=y

That would probably work... if someone made a conical washer able to deflect to flat at about 10000lbs

65 Ft*lbs / (.16[friction modifier] * .0395 ft (bolt major diameter) = 10000lbs clamping force.

[Ultramaroon]

Originally Posted by Decay107

That would probably work... if someone made a conical washer able to deflect to flat at about 10000lbs

65 Ft/lbs / (.16[friction modifier] * .0395 ft (bolt major diameter) = 10000lbs clamping force.

Yeah, good point. My math and references agree now that you shamed me into doing it.

[PERRIN_Chris]

Hey Doug,

Bolt or stud doesn't matter at all. The thickness of the washer or use of a flange bolt would fix this problem. What is strange is we have been selling and testing this part for about 2 years, and tested this on STI's for a year (hundreds of launches) and not seen that happen. How tight were the bolts tightened? Also I wonder if the washers changed and we didn't know. We will look into this and report back.

[Decay107]

Originally Posted by PERRIN_Chris

Hey Doug,

Bolt or stud doesn't matter at all. The thickness of the washer or use of a flange bolt would fix this problem. What is strange is we have been selling and testing this part for about 2 years, and tested this on STI's for a year (hundreds of launches) and not seen that happen. How tight were the bolts tightened? Also I wonder if the washers changed and we didn't know. We will look into this and report back.

Woah, missed this response. Anyway, the included washers appear to be standard thickness grade 8 hardware (.05-.08"). I've most recently switched out to .12" grade 8 hardware ( mcmaster carr part number 98025A132) and this seems to help, but not totally eliminate the problem. A flange bolt would be wonderful!

The bolt vs stud is just a preference as I've spent a good deal of time trying to properly center the hole in the motor mount over the slot in the subframe where a stud would have just dropped through.

I'm torquing down to 65ft*lbs with graphite lubricant on the threads which ends up being around 10klb clamping load. If I've got some time next week I'll play around in cad and see what some of the localized stresses look like.

[Decay107]

Just bought most of the rest of the parts needed to install my oil pressure gauge

-Nylon web wire sheathing
-Subaru threaded oil galley plug
-ATI vent gauge pod

Now all I need is 3 fuse taps to cleanly tie the gauge in to the electrical system.

I also finally got in all the gaskets I need to change my drive-line lubricants, so I hope to knock that out this weekend.

[Ultramaroon]

Save the debris from your plugs. Once we get it dry we can weigh to see if there's a significant difference between ours. I have a gallon of acetone here.

[Decay107]

Originally Posted by Ultramaroon

Save the debris from your plugs. Once we get it dry we can weigh to see if there's a significant difference between ours. I have a gallon of acetone here.

I'll be sure to save them, but not sure if I have access to a scale that would be able to weight such a small amount of fine metal shavings. I was hoping to carry out a much more subjective comparison including the following

Apparent differences in amount of shavings on magnetic plug
Size and shape of shavings viewed under a microscope
Color of fluid and looking for any other particulate matter

Might send mine out for a UOA if I observe anything more alarming than others are seeing.

[Decay107]

Holy crap! Can't believe there is no service interval on drive line fluids for this car. Changed out the trans and diff fluids with amsoil for preventative maintenance. Here is what came out

That's transmission oil in the jar and differential oil in the gatorade bottle, both are very dark and allow almost no light transmission. As an example here is the old stuff lined up beside the new stuff.


Quite a lot of metal on the magnetic diff plug...


Not as much on the trans plug...

[Ultramaroon]

Blecch!

[Jonesy86]

I did this while in Montana. My old man said it was pretty normal. I can't wait to drain my diff/trans next time to see if it is any better! It was good seeing you again!

[Decay107]

Originally Posted by Jonesy86

I did this while in Montana. My old man said it was pretty normal. I can't wait to drain my diff/trans next time to see if it is any better! It was good seeing you again!

Hey you too! How'd the test drive go?

I'm sure the wear is normal as I haven't had any of the issues lots of people have been reporting. I was just rather surprised at how similar the drive-line oils looked in my 14K FR-S to other cars I've changed with over 100K on the factory fill.

[Decay107]

Did the @Ultramaroon slave cylinder mod today. Huge difference, clutch feels much heavier (a good thing) and the bite point is clearly defined. As an added bonus, the increased travel of the slave relative the master allows me to run the clutch pedal much lower than I could previously, basically the clutch begins to engage with pedal about an inch off the floor, fully engages over the next inch, and has about half an inch free play at the top of it's travel.

Afterwards, I took Scoot Seven out for a long ride now that I've finally got her running again (this means about 10 miles, she's slow)

It's funny, everyone seems to think that they need $3000 wheels to get noticed, but I've had more people take pictures and randomly strike up a conversation with me when I'm riding #7 than with all my cars combined

...And I'm only in it a total of negative $30 (including gas).

[Ultramaroon]

Yaay clutch!

Sweet bike.