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My GT2 build over the last year
Since Champion Motorsport doesn't post here, I've taken the liberty of compiling posts about my car into one thread here ala Ranger. Enjoy!
Originally Posted by Tom@Champion
(Post 3157575)
So March seems like GT2 month at Champion Motorsport. Our yellow GT2 from last month is back for round II of mods, a white GT2 is on the way, and in the meantime, this amazing meteor gray beauty is only just beginning it's transition into a true race car. A race car that will compete in one of the most legendary endurance races in the US....the One Lap Of America. One Lap is 8 days of grueling races and testing that push both the driver and car to the limit. It not only requires a capable car, but performance that's both reliable and repeatable, principles that we've based our entire tuning program on.
The story begins about 3 weeks ago when the owner of this GT2 contacted me looking for some guidance on building a powerful race car to compete in the One Lap of America event for 2012. He had already decided on the GT2 to be the base platform, and after some lengthy discussions about the possibilities for improving both power output and, perhaps more importantly, versatility and reliability, the search began for the perfect GT2. As fate would have it, this meteor gray gem was for sale about 20 miles from our location. Only 1900 miles on the odometer, bone stock, completely loaded with carbon fiber and deviated stitching EVERYWHERE, and even a full leather PCM....we'd found our car! Within a short time, we took delivery and the fun begins! Here's a couple pictures on delivery... http://farm6.static.flickr.com/5259/...7de8e26c_b.jpg http://farm6.static.flickr.com/5096/...003bfebd_b.jpg http://farm6.static.flickr.com/5100/...b2d53162_b.jpg This will be one of the most complete turbo builds we've done in a long time, where we'll be addressing both power and handling, along with a few other precautionary and reliability-based mods. The team here knows a thing or two about endurance racing ;), so some of that expertise will definitely be coming into play. The power package of choice will be our 68mm VTG turbochargers with complete power package. Maintaining low end power will be key to staying competitive in several of the One Lap events. Because One Lap uses a variety of venues, from skid-pad testing to road course racing, we'll also be creating a suite of ECU programs using GIAC's flashloader technology to accommodate high power and low power programs in both race and pump fuel. This will be one heck of a fun build, and I'll be making updates daily or whenever possible. Work began a couple days ago as the engine and trans come out for round I of mods. Stay tuned for more as the build moves on... http://farm6.static.flickr.com/5175/...72b4993e_b.jpg http://farm6.static.flickr.com/5015/...0005bb66_b.jpg
Originally Posted by Tom@Champion
(Post 3158022)
This little beauty just arrived yesterday. The Guard GT2 Pro 60/40 limited slip differential. :)
http://farm6.static.flickr.com/5175/...2320edd9_b.jpg http://farm6.static.flickr.com/5173/...7d92db0e_b.jpg
Originally Posted by Tom@Champion
(Post 3161823)
Some more goodies that are going into this GT2 arrived the other day. Engine goes back in the car this week to prep for a visit and test drive by the owner. :)
Then it's on to the suspension and safety equipment... http://farm6.static.flickr.com/5269/...2b68a763_b.jpg
Originally Posted by Tom@Champion
(Post 3162143)
New Guard GT2 Pro LSD on it's way in...
http://farm6.static.flickr.com/5139/...c474d86c_b.jpg http://farm6.static.flickr.com/5296/...5bb83560_b.jpg
Originally Posted by Tom@Champion
(Post 3165693)
Time for a major update on the One Lap GT2. Engine should be back in and running by tomorrow, but in the meantime here's some pretty cool pictures of the LSD and tranny upgrades we've done to this car, and a few other trick mods. ;)
First...as some Turbo and GT2 owners know, the car is plagued from the factory by faulty coolant distribution pipe. From the factory, the fittings are only held onto the pipe by epoxy, which almost always fatigues under heat and can cause the fittings to detach from the pipe. The result is an ugly mess. So to prevent this, we've taken the time to remove the pipe, and weld the fittings so that they can't come loose. It was a bit of a tedious process, requiring some machining of both parts to allow them to be welded together, but DEFINITELY a worthwhile process if your engine's already out. http://farm6.static.flickr.com/5174/...f9a19b5c_b.jpg http://farm6.static.flickr.com/5182/...50c000b8_b.jpg Moving on to the transmission, we installed the Guard GT2 Pro 60/40 limited slip differential, along with a CMS billet aluminum differential cover. The CMS cover is designed to reduce flex in the transmission housing, which can lead to premature ring and pinion wear. Again...something that anyone doing a LSD upgrade should also consider. Before installing the new Guard LSD, measurements have to be taken to determine the correct installation height on the new LSD. Installing a new LSD is NOT as simple as taking out the old one and installing the new. We use the lathe not for machining purposes, but just to take extremely accurate measurements so we can calculate the width of shims that need to be used. In this case, the difference was less then .0005 of an inch on one side, but .025" on the other, which accounted for a diff and side cover change. http://farm6.static.flickr.com/5145/...c41d7269_b.jpg Here's a picture of the beautiful new CMS billet side-cover. http://farm6.static.flickr.com/5030/...b2e92083_b.jpg In this picture, you'll notice that the CMS cover also incorporates an adjustable brass safety stop, which is designed to prevent the ring gear from flexing away from the pinion under full load. This feature is typically found in racecar gearboxes...exactly like the GT1. http://farm6.static.flickr.com/5059/...7e044805_b.jpg http://farm6.static.flickr.com/5059/...ecf45094_b.jpg And ready to go back in the car... http://farm6.static.flickr.com/5222/...123205ca_b.jpg |
This is a pic of the back, engine installed. As you can see clearly, the CM intercoolers fit like OE.
https://farm6.staticflickr.com/5143/...65020cae70.jpg Installed ERP suspension arms. I think the Heims are Aurora but correct me if I'm wrong. https://farm6.staticflickr.com/5263/...10602c745a.jpg I requested the largest OE brake ducts available. https://farm6.staticflickr.com/5029/...9552ed814e.jpg How the car ended up, "Stage 1." April 2011. Most people would be esctatic with this as an end result. Interior changes include but not limited to GT2 leather carbon bucket seats, GMG rollbar, Schroth 6 point harnesses, Rennline track mats, and a Aimsports Solo DL wired in. https://farm7.staticflickr.com/6031/...6c5b1bd283.jpg |
From April through the summer I tested, and tested. And I wasn't the only one. Another CM customer was testing too with virtually the same build. Later in the summer Champion discovered several problems with the OE block- most importantly they discovered that the case halves were fretting. This is what happens when you make "real" power and actually use it.
So I decided to go whole hog, and go with the 3.8l kit. I also hated the OE shocks and springs. Those had to go, and luckily Champion had a solution sitting in the shelf, unloved... https://farm7.staticflickr.com/6023/...dacc2cdea2.jpg The solution- anti shuffle dowel pin guides at every bearing, plus some... https://farm7.staticflickr.com/6004/...5cc99b50ee.jpg They also improved the windage of the stock case halves. https://farm7.staticflickr.com/6007/...47a63bbedb.jpg Now onto the rods. Champion spec'ed 997 turbo rods from Carillo. Funny thing is, with all the 997 turbos in the world with Carillo rods, there was NO 997 turbo specific rod from Carillo! As you can see below, the bearings are captured differently between the 996 and 997. I wonder what all the other companies are doing? https://farm7.staticflickr.com/6140/...179d6a6130.jpg The other thing Champion did was strengthen the rod- increased the wall thickness over the 996 Carillo rod. These 997 specific rods are available from Champion now. I think Carillo now produce a 997 generic rod due to the development with Champion. https://farm7.staticflickr.com/6001/...340fc9f667.jpg Onto the heads. They are ported. We use Ferrea oversized valves and the whole spring/retainer kit. https://farm3.staticflickr.com/2426/...2c167f4a1d.jpg https://farm4.staticflickr.com/3568/...3ab2b39a66.jpg Pistons- Mahle 3.8l kit with lightweight wristpins. https://farm6.staticflickr.com/5020/...6981b64fa0.jpg SLA rapid prototype of oversized MAF tubes. https://farm4.staticflickr.com/3646/...3ea6722a5f.jpg I didn't like the Sachs pressure plate/four puck solid disc/AASCO flywheel clutch, so we went with a RPS/ERP triple plate carbon clutch. Much better engagement in my opinion. https://farm4.staticflickr.com/3253/...5b1874b7ab.jpg And now the Ohlins CS kit. This was sitting on their shelves from another build where the spec was changed. Their loss is my gain! Four way fronts, 2 way rears. https://farm5.staticflickr.com/4002/...f03dc2fc98.jpg And the final spec as shown in Champion Motorsport's showroom. This is after the final change- RS steel fenders and RS fender lips to clear the much bigger than OE tires and a GT2 RS lip spoiler. Tinted windows, and full front clearbra finished it off. I also found a used set of Champion RS184 five spoke rims in the same offset as my RS98's right here on RL- track wheels without futzing with offset changes between the two sets! https://farm6.staticflickr.com/5331/...8f6390f565.jpg Hope you enjoyed it! |
Awesome build, thanks for posting and enjoy it.
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Nick,
Are you running the Ohlin 700/1300 spring rates or did you change rates? If so, how do you like them? thanks Paul |
Originally Posted by 997gt3north
(Post 9550542)
Nick,
Are you running the Ohlin 700/1300 spring rates or did you change rates? If so, how do you like them? thanks Paul Rears are 80/230nm. The car is in Chicago. Worst roads I have ever seen apart from some third world locations. The spring combo is fine, for me, but I like a firm ride in my sportscars. |
Holy crapp, man, SPECTACULAR! I am definitelyy taking you on on your offer to let me drive her one day... :evilgrin:
And yes, Chicago roads are even worse than Dallas roads.. |
VR, there are a whole host of items I didn't even mention, not including the loosely named Champion "Stage 1" kit which is 68mm VTGs, big TB, big injectors, carbon y pipe, carbon turbo intake pipes, non cat exhaust...
Inconel exhaust manifold blankets over the CM exhaust manifolds Two separate ECUs programmed with 6 different maps 4 completely different alignment specs to gauge how sensitive the chassis is 3 separate updates to the ECU programming to improve drivability Changes to base fuel pressure from 5 bar back to 3 bar to increase reliability Engine makes peak power@6500rpm but has a 7500rpm redline for overrev drivability. The crank bearing surfaces have been nikasil coated (OE is not, just polished!) . The valve seats are a beryllium hybrid. And there are a bunch of details that I've been sworn to secrecy... ;) |
Originally Posted by Nick Wong
(Post 9550607)
VR, there are a whole host of items I didn't even mention, not including the loosely named Champion "Stage 1" kit which is 68mm VTGs, big TB, big injectors, carbon y pipe, carbon turbo intake pipes, non cat exhaust...
Inconel exhaust manifold blankets overnight CM exhaust manifolds Two separate ECUs programmed with 6 different maps 4 completely different alignment specs to gauge how sensitive the chassis is 3 separate updates to the ECU programming to improve drivability Changes to base fuel pressure from 5 bar back to 3 bar to increase reliability Engine makes peak power@6500rpm but has a 7500rpm redline for overrev drivability. The crank bearing surfaces have been nikasil coated (OE is not, just polished!) . The valve seats are a beryllium hybrid. And there are a bunch of details that I've been sworn to secrecy... ;) |
Nick that's awesome. The best and only the best. I have come to know the feeling with my .1 RS 4.2L build. The guys at Champion Moptorsport are the best and I've known Louis for 17 years. As solid and honest as a friend can be.
Oh and btw Mr. Raptor when my "little project" is done and on track you can take a few laps :D. Ranger (Sua Sponte) |
Mille grazie, Ranger... ;)
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Ranger, when I move permanently to Central Florida next year we will have to get together... These two cars deserve some on track frivolity!
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Nick- Awesome! Very nice package. Well done. What took you so long to post this? Sheesh! Blown 3.8 with suspension, I'd love to do a few laps in that bad-boy. Thanks for sharing.
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Originally Posted by savyboy
(Post 9550691)
Nick- Awesome! Very nice package. Well done. What took you so long to post this? Sheesh! Blown 3.8 with suspension, I'd love to do a few laps in that bad-boy. Thanks for sharing.
1. I'm quite busy a lot of times (self involved, haha). 2. I was supposed to run One Lap, now for the last two years, and didn't for reasons beyond my control. 3. One Lappers who aim for the sharp end are a bit secretive about their cars. We're an odd, car loving lot. 3. I'm halfway around the world and had nothing better to do today. 4. I was enjoying my Bose subwoofer that came with the car and was embarrassed the hardcore guys would thumb their collective noses at me... :D 5. The real reason- its finally at a stage of development where it does everything I ask reasonably well. |
Wow, awesome build.
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