Mark's 1G Winter Projects - Page 40

Mark Leasure · 09-28-2015

I called dss, the only way to get an upgraded u joint in the rear is to buy a 1 piece carbon fiber shaft, which they recommended to upgrade to a 1 piece shaft anyway. I can better control the pinion angle now too. It will be better now for next year!

Mark Leasure · 12-23-2015

It’s been a while since my last update. I had a 1 piece carbon fiber driveshaft made by dss after I destroyed my dss aluminum HD shaft. This allowed me to move up to a stronger 1310 style u joint too. It's crazy long, I can't wait to see how the CF reacts vs the old 2 piece.

I also needed to strengthen up the mounting of the rear end, the brace in the rear broke once, the torque literally ripped it apart. Check out how the chromoly ovaled.

I increased the tube wall thickness to .120 from .083, and machined end caps that will be all welded up.

And the factory mounts were weak too, so I made stronger ones out of DOM 1026 tube:

Luckily I have a lathe for all this type of stuff.

Also I’m upgrading to a 72mm Gen2 PTE turbo this winter, it will make the car even more crazy!

**asshanson** · 12-24-2015

That CF driveshaft is sweeeeet. And I can't believe you're bending the mounting pieces, that's crazy power, hopefully the 50% thicker wall holds a bit better haha.

URV8SUX · 12-24-2015

Looks good Mark those new insert will do a lot better. It seems like your downgrading by going to smaller turbo.

Mark Leasure · 12-24-2015

Quote:

Originally Posted by URV8SUX

Looks good Mark those new insert will do a lot better. It seems like your downgrading by going to smaller turbo.

Love it. You beat me in eliminations at map's event. You're on to something with a smiller turbo, I thought I would give a try....

turbotalon1g · 12-24-2015

Nice work.

Mark Leasure · 12-28-2015

Finished up the stronger rear 3rd member mount. Just need an alignment now.

My tube notching skills are improving. I started using a digital angle finder, the results are below:

I added a center support to the mounting locations, to make sure there were no issues with the design, in regard to the bolted joint preload. The rear end was used as the fabrication jig for these:

And finish cut:

And the final product installed:

**Kracka** · 12-29-2015

Good Lord that's pertty!

A//// Guy · 12-29-2015

Beautiful fab work!

bramagedained · 12-29-2015

Are your outer CVs 930s?

**Goat Blower** · 12-29-2015

I remember Marco going with a tubular subframe after he bounced his pumpkin down the track ten years ago. Yours looks like it can handle the abuse.

Also, the carbon fiber must take up some of the shaft harmonics as I remember Brent was having issues with his one-piece aluminum driveshaft years ago and then he sold it to me.

Mark Leasure · 12-31-2015

Thanks for the kudos guys.

Quote:

Originally Posted by bramagedained

Are your outer CVs 930s?

I'm not sure, they are dss pro axles made to work with the 3kgt rear. This is the dss description on their site:

"These axles feature much larger aerospace grade 36 spline bars (factory are 30 spline), billet ball & cage inner CV, and a Porsche-style 108mm outer CV"

Quote:

Originally Posted by Goat Blower

I remember Marco going with a tubular subframe after he bounced his pumpkin down the track ten years ago. Yours looks like it can handle the abuse.

Also, the carbon fiber must take up some of the shaft harmonics as I remember Brent was having issues with his one-piece aluminum driveshaft years ago and then he sold it to me.

Carbon fiber has about a 50% better critical speed than aluminim. An aluminum driveshaft that long will violate critical speed guidlines, significantly, causing severe vibration/harmonics. There are dsm'ers that have successfully used 1 piece cf driveshafts to over 180mph, it's proven to work. It's a good rotational weight savings too. I didn't weigh the exact difference, but it's noticeable.

bramagedained · 12-31-2015

Quote:

Originally Posted by Mark Leasure

I'm not sure, they are dss pro axles made to work with the 3kgt rear. This is the dss description on their site:

"These axles feature much larger aerospace grade 36 spline bars (factory are 30 spline), billet ball & cage inner CV, and a Porsche-style 108mm outer CV"

The mostly likely are the Porsche 930 CVs then.

Some people on Hybridz seemed concerned about their strength in the setup that went in my car, despite the fact they get used in a lot of stuff.

Which I thought was kind of silly.

Pushit2.0 · 01-01-2016

Great work man, Rock falls the start of the 2016 season right?

evotuner · 01-01-2016

MY GOD!! Youre just a machine with this car!

Mark Leasure · 01-10-2016

Thanks for all the feedback!

I'm kind of excited to see the improvements at Rockfalls this spring. Traction should be better with concrete.

I installed the new snail, and went from a 3.5" down pipe to a 4" too.

The exhaust wheel is way more efficient and 10mm larger, should make more power everywhere in the power curve. The Garrett is a 10 blade vs. The 11 blade on the pte.

I need to finish up the exhaust and install my 300m output shaft. That's all that's planned for this winter.

DSM MN · 01-10-2016

So beast!

turbotalon1g · 01-10-2016

Love it!!
Have you seen the grudge events at CFR for 2016?

Mark Leasure · 01-31-2016

Made some progress last weekend, I dropped my transmission and installed a 300m output shaft. The new shaft is on the right:

I also finished up the ss to aluminum joint transition on the exhaust and routed it under the oil pan. 4"is a very tight fit. It's lessential than 1/4 inch of clearance between the transfer case and oil pan, measure twice and cut once!

The oil filter looks a lot closer than it really is, over an inch away.

I need to get one more vband aluminum flange to finish up the exaust. I really like the Vibrant quick vband clamps with male and female flange sections for alignment.

Pushit2.0 · 02-03-2016

It's nice they have that on the aluminum pieces, I have used their SS v band and it's very nice. Great progress man.