Converting BSR to GT Racer
06-12-2012, 03:55 PM
#16
Yeah we're trying to make some carbon fiber parts, as well as just general custom mechanicals for the car that could be brought to market. Problem is the parts are so darn expensive to make all over the car that it is becoming cost prohibitive, especially when there is such a small market when you are all done. The car has taken too long to build already and the side projects and time needed to manufacture new goods just add to the downtime on the car. Results in a lot of one off's with a stack of diagrams and drawings laying around...oh well.
06-12-2012, 05:53 PM
#17
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"The dual side intakes have been discussed but we were a bit worried about the resulting engine compartment temps. Any advise or data you would care to share? I've also seen them in the rear trunk, a large box on one side... "
If you can imagine, we scoop the air in from both sides via custom side scoops. The air is then routed back through the rear quarter panels into the trunk via large flexible hoses, approximately 4-5 inch in diameter. These two hoses feed directly into a custom airbox that is sealed and airtight as possible. Within the box there is a large oval K&N filter that has a intake diameter that is equal to the 3.6L throttle body. We placed it in the trunk in an area that would give us the least amount of turns into the throttle body. As your picture shows the 3.6L throttle body will bend slightly toward the passenger side of the trunk. Our placement goes straight in with a very slight bend but nothing close to a 90 degree turn like OEM. We believe the airbox would be pressurized by the positive airflow into the sealed box.
Regarding engine room cooling...with "stock" class off the table we took two electric radiator fans and mounted them on the engine cover with a custom cover so you can't see them from inside the car. These fans blow fresh air straight down over the engine and out the bottom of the car. The new air comes in from intakes that are routed in through the custom fan shroud.
Oil and engine water temps have all stayed normal with this design, even with Hot Humid Florida days.
If you can imagine, we scoop the air in from both sides via custom side scoops. The air is then routed back through the rear quarter panels into the trunk via large flexible hoses, approximately 4-5 inch in diameter. These two hoses feed directly into a custom airbox that is sealed and airtight as possible. Within the box there is a large oval K&N filter that has a intake diameter that is equal to the 3.6L throttle body. We placed it in the trunk in an area that would give us the least amount of turns into the throttle body. As your picture shows the 3.6L throttle body will bend slightly toward the passenger side of the trunk. Our placement goes straight in with a very slight bend but nothing close to a 90 degree turn like OEM. We believe the airbox would be pressurized by the positive airflow into the sealed box.
Regarding engine room cooling...with "stock" class off the table we took two electric radiator fans and mounted them on the engine cover with a custom cover so you can't see them from inside the car. These fans blow fresh air straight down over the engine and out the bottom of the car. The new air comes in from intakes that are routed in through the custom fan shroud.
Oil and engine water temps have all stayed normal with this design, even with Hot Humid Florida days.
06-20-2012, 01:07 AM
#19
Looks like a nice set up, thanks for the pictures! If we do place the filter and air box in the trunk, we were planning on using that same wiring harness passage in the firewall in the corner like you did. It looks like you can make a pretty easy shot through there. I'm gathering some tubing, a filter, and a coupler now so hopefully I'll get it together soon.
06-20-2012, 01:29 AM
#20
Evan has ben spending some time working these used 996 flairs into something usable on a Boxster. I think they are coming along pretty nicely, but still a little ways to go. Eventually he'll create some molds off of these so we can duplicate fresh ones in the future.
06-20-2012, 02:35 AM
#21
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Just looking at the pics makes me start to itch again. I still haven't quite figured out how I got talked into making theses but I like how they are turning out. Haha
Last edited by Evan Fullerton; 06-20-2012 at 03:15 AM.
08-11-2012, 06:26 AM
#28
Been busy but have some progress to share. We're trying to get it on the dyno midweek next week so it will be a long weekend. Need to get the Pectel ECU tuned, motor broken in, and GT classification runs done. Next challenges are exhaust system, shift cables, and fuel system.
Just finished off the rear fender flares today.
Just finished off the rear fender flares today.
08-11-2012, 06:31 AM
#29
Also got the front brakes together. The new cup uprights had a wider caliper bolt spacing. Outfitted them with 996tt/997s calipers and some Pagids. The fitment required making some shims for the rotor to center in the caliper.
Removed the power brakes and ready for dual masters.
