:::RHMT::: Real Home Made Turbo

General Category => Fabrication => Topic started by: DSharp on December 21, 2011, 06:10:38 PM

Title: Building of an FSAE car
Post by: DSharp on December 21, 2011, 06:10:38 PM
I started fab about a week ago with the help of a few others.  We have less than 6 months to build test and tune this thing. 

Were using a water jet cut jig to hold suspension points and the base of the chassis in place.
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F1206111418.jpg&hash=8f72d57df8027c26da6838f60ca294b6dacf3b33)
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more to follow...
Title: Re: Building of an FSAE car
Post by: HiProfile on December 21, 2011, 08:27:23 PM
I'm just curious, what is the point of FSAE? To spend the most time building it, making the most intricate car, or winning the actual race?

I would presume they deduct if you arrived sporting fluxcore welds.
Title: Re: Building of an FSAE car
Post by: Passenger on December 22, 2011, 12:17:58 AM
I dig your table, Acorn?
Title: Re: Building of an FSAE car
Post by: DSharp on December 22, 2011, 01:15:12 PM
The point of FSAE is to develop better engineers.  I do it cause I love to build shit and i can waste time doing something other than class work.  I also learn a lot of shit in the process, and I get to use tools, programs, etc that I otherwise would never learn about. 

I don't know if they would let you race if your chassis was all boogered up with some RMHT style fluxcore.

yea that table is awesome.  I think its an acorn.
Title: Re: Building of an FSAE car
Post by: mandrel-bends on December 22, 2011, 02:53:43 PM
Do all the cars look different? I have all these posters from all our fsae sponsorships and none of them have that big hoop in the back.
Title: Re: Building of an FSAE car
Post by: snm95ls on December 23, 2011, 02:51:16 AM
Do all the cars look different? I have all these posters from all our fsae sponsorships and none of them have that big hoop in the back.

The current and past cars for our FSAE team uses a pretty significant hoop although not as tall as that one appears to be.

I really need to make time to contribute. It could make the whole school experience a bit more interesting.

Title: Re: Building of an FSAE car
Post by: chris on December 23, 2011, 03:39:26 AM
Im more interested in your guys motor program. So do you guys actually build the motors/design motor parts/flowbench etc


Title: Re: Building of an FSAE car
Post by: DSharp on December 23, 2011, 04:31:06 AM
yea this car is big.  We have big drivers too. At least half of our potential drivers are over 6' tall.

I'm going to need some U bends pretty soon for this header.  I'm going to build it once I have verified it on the dyno.
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2FCapture-1.jpg&hash=ecd15d20f9853b0d475f41a156dc8fcb1b48d301)

I got all the main tubes in the chassis in place today and started welding.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F1222112203.jpg&hash=aa188af910add60193223315ad2358938c652068)
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We have a engine dyno and a chassis dyno and some good CFD stuff.  This is our first car since the program ended in 2001, so we don't have as much as I would like.
Title: Re: Building of an FSAE car
Post by: Foowee on December 23, 2011, 08:22:16 PM
Is the rear of the chassis supposed to be a sort of passive suspension?  The square "X" in the back looks as if it's gonna allow a bit of movement independent of the front end...
Title: Re: Building of an FSAE car
Post by: DSharp on December 24, 2011, 12:14:58 AM
I didn't design the frame, I have been arguing to add tubes here cause I don't like it either.
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F1222112204-1.jpg&hash=59c70df02288b70fc260023713737a515be92aa1)
Title: Re: Building of an FSAE car
Post by: 92CXyD on December 24, 2011, 11:56:44 AM
Draw it up Engineering paper and use what ya learned in Dynamics and Statics and prove them wrong.  :noel:

(Assuming use already took Vector Mechanics, or Statics and Dynamics)
Title: Re: Building of an FSAE car
Post by: mandrel-bends on December 24, 2011, 06:23:46 PM
You guys seem to be pretty well equipped compared to most universities.
Title: Re: Building of an FSAE car
Post by: DSharp on December 24, 2011, 09:39:21 PM
Draw it up Engineering paper and use what ya learned in Dynamics and Statics and prove them wrong.  :noel:

(Assuming use already took Vector Mechanics, or Statics and Dynamics)
I might just add it in and be done with it.


You guys seem to be pretty well equipped compared to most universities.
We have had a baja program for a while, and a few failed attempts at a formula car recently, so we have a lot of cool stuff, but there is only about 5 people who work on the project..... so my grades really suck.  I have designed about half of this car and I'm the main fab guy at the moment, and I have to do better than a B average next semester or declare my major as something other than engineering, its bullshit if you ask me.  Hopefully this will count for something if it comes down to it.

I am going to need some parts from you guys here pretty soon when I start building the header.
Title: Re: Building of an FSAE car
Post by: Phate on December 25, 2011, 03:36:50 AM
I'm on my school's baja team, we deemed FSAE too expensive.  Hopefully the dipshits in charge of the club will get their shit in order so we can actually get our money for next semester and buy steel.  I'm hoping to make a build thread as well.

Baja doesn't get to play with the engines, but we can do just about anything else.
Title: Re: Building of an FSAE car
Post by: Passenger on December 25, 2011, 04:05:05 AM
Add the bars and be done with it.
Looks like it is coming along nicely, and I agree, you guys are very well setup.
Title: Re: Building of an FSAE car
Post by: snm95ls on December 25, 2011, 11:45:39 PM
Add the bars and be done with it.
Looks like it is coming along nicely, and I agree, you guys are very well setup.

This.  If that section is not supposed to allow flexure, then whoever designed it doesn't really understand how to properly utilize triangles.

Just my uneducated $0.02.

Title: Re: Building of an FSAE car
Post by: Passenger on December 26, 2011, 01:26:55 AM
In case I wasn't clear, I meant just add the bars, don't ask, don't tell, do it when no one is around. Its one of those its easier to ask for forgiveness then permission situations.
Title: Re: Building of an FSAE car
Post by: Joseph Davis on December 26, 2011, 11:07:38 AM
In case I wasn't clear, I meant just add the bars, don't ask, don't tell, do it when no one is around. Its one of those its easier to ask for forgiveness then permission situations.

Passenger is completely wrong.  You should not ask forgiveness, you should tell them FUCK YOU if they don't like it.
Title: Re: Building of an FSAE car
Post by: Joseph Davis on December 26, 2011, 11:08:56 AM
Anyway, what's the end-life use for a decommissioned FSAE car?  Looks like a cheap auto-x rig that would make the short course a lot more fun, and challenging, than a traditional car.
Title: Re: Building of an FSAE car
Post by: snm95ls on December 26, 2011, 11:24:36 AM
Anyway, what's the end-life use for a decommissioned FSAE car?  Looks like a cheap auto-x rig that would make the short course a lot more fun, and challenging, than a traditional car.

I think some do get sold eventually.  Our team tends to keep them around for development and driver training.

Title: Re: Building of an FSAE car
Post by: DSharp on December 26, 2011, 05:42:21 PM
I'm on my school's baja team, we deemed FSAE too expensive.  Hopefully the dipshits in charge of the club will get their shit in order so we can actually get our money for next semester and buy steel.  I'm hoping to make a build thread as well.

Baja doesn't get to play with the engines, but we can do just about anything else.

baja seems to be more fun and laid back, but I love tinkering with engines and going fast.... this doesn't happen in baja.

Now when I wanna go get muddy and jump shit out in the woods, I get on my bike and go to the trails.  thats close enough to baja for me.
Title: Re: Building of an FSAE car
Post by: DSharp on December 26, 2011, 05:46:09 PM
Anyway, what's the end-life use for a decommissioned FSAE car?  Looks like a cheap auto-x rig that would make the short course a lot more fun, and challenging, than a traditional car.

The problem is getting one.  Our cars are "state owned" and cannot be sold except through state auction.  I'm sure some just turn up missing every now and then.

Another problem is how much these cars break.  not very many of the cars make it through all the events at the competition.
Title: Re: Building of an FSAE car
Post by: Joseph Davis on December 26, 2011, 07:01:34 PM
What typically goes wrong?
Title: Re: Building of an FSAE car
Post by: Passenger on December 26, 2011, 08:00:56 PM
What typically goes wrong?

They are built by university students?
Title: Re: Building of an FSAE car
Post by: DSharp on December 26, 2011, 08:41:41 PM
What typically goes wrong?

They are designed and built by inexperienced students?

fixed
Title: Re: Building of an FSAE car
Post by: dvst8r on December 26, 2011, 08:52:02 PM
What typically goes wrong?

They are designed and built by inexperienced students?

fixed

That sounds redundant to me, a student by definition is someone that is inexperienced.
Title: Re: Building of an FSAE car
Post by: Joseph Davis on December 26, 2011, 09:33:46 PM
Well, I can't see a chassis that's undergone even halfassed FEA collapsing under itself, so I figured the kids were blowing the engines up because they lack the ear, or experience, to know that instrumentation can only be trusted so far.

If you need a tune or consultation, LMK.
Title: Re: Building of an FSAE car
Post by: DSharp on December 26, 2011, 09:44:43 PM
not all students are inexperienced.  Some of us just need that sheet of paper so we can get jobs.

here's some more shit I spent countless hours on....
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F1-5.jpg&hash=10b6baaae7269b3b2cb7d74aa43b23ebaba7d763)
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Title: Re: Building of an FSAE car
Post by: DSharp on December 26, 2011, 10:10:03 PM
Well, I can't see a chassis that's undergone even halfassed FEA collapsing under itself, so I figured the kids were blowing the engines up because they lack the ear, or experience, to know that instrumentation can only be trusted so far.

If you need a tune or consultation, LMK.

You should come check it out sometime.  Our engine dyno needs a little bit more work, and our only running engine is low on compression, was built from a pile of parts by some students who dont have much experience with engines.  Ive seen a few shitty Engine Management setups on these cars and quite a few who had engine related problems. 
Title: Re: Building of an FSAE car
Post by: Passenger on December 27, 2011, 12:14:06 AM
Well, I can't see a chassis that's undergone even halfassed FEA collapsing under itself

If its fit and welded by a knob its not a stretch.
Title: Re: Building of an FSAE car
Post by: Joseph Davis on December 27, 2011, 07:08:49 AM
Well, I can't see a chassis that's undergone even halfassed FEA collapsing under itself, so I figured the kids were blowing the engines up because they lack the ear, or experience, to know that instrumentation can only be trusted so far.

If you need a tune or consultation, LMK.

You should come check it out sometime.  Our engine dyno needs a little bit more work, and our only running engine is low on compression, was built from a pile of parts by some students who dont have much experience with engines.  Ive seen a few shitty Engine Management setups on these cars and quite a few who had engine related problems.

What needs done on the dyno?  I've always wanted to play with a water brake.
Title: Re: Building of an FSAE car
Post by: Phate on January 02, 2012, 04:01:07 PM
Well, I can't see a chassis that's undergone even halfassed FEA collapsing under itself

If its fit and welded by a knob its not a stretch.

We had to re build most of our frame last year for this exact reason.  The weld strength tests we are supposed to do to show that the car wasn't built by a moron showed just that.

Stuff gets broken a lot at baja competitions.  Generally its a combination of a lack of mechanical sympathy from drivers, errors in building (something was measured wrong and welded in and not noticed), parts being underbuilt for the application, or trying something new that doesn't work out.  In the case of the last thing, our full hydraulic steering setup (think replacing tie rods and steering rack with hydraulic cylinders), they were basically retrofitted in, rather than designed-into the front suspension, and there was a sideways component to the forces they saw, and we broke our cylinders.

I can imagine that aside from the jumping and crashing into stuff that we do at baja, all the other things apply, in addition to the can of worms that can come from people being allowed to screw with the engines.

Also, there may be some work done to stuff a bike motor into the old baja chassis for maximum death potential.
Title: Re: Building of an FSAE car
Post by: DSharp on January 05, 2012, 05:00:12 PM
There are a few spots on the chassis I am not satisfied with, but we did not get enough tubes to redo anything.   >:(

I seriously doubt it will break though its probably overbuilt and I don't think its usually an issue with formula.  Most failures I've see are in the suspension or drive train.
Title: Re: Building of an FSAE car
Post by: DSharp on January 27, 2012, 05:55:19 PM
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F0127120052.jpg&hash=e900a3193051cd8cd44a9b9e202959c0f23f5a75)
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Got a few parts machined last night.  Some injector bungs and part of a sprocket adapter.
Title: Re: Building of an FSAE car
Post by: Passenger on January 27, 2012, 07:13:54 PM
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi94.photobucket.com%2Falbums%2Fl83%2F935racer%2FHAAS.jpg&hash=bbdc581eb39934faf1d697a903f13cff5e9b5018)
Title: Re: Building of an FSAE car
Post by: DSharp on January 28, 2012, 09:57:30 AM
no, grinding wheel and a stick of HSS.  ;DDD
Title: Re: Building of an FSAE car
Post by: Passenger on January 28, 2012, 01:42:13 PM
no, grinding w

That actually makes a lot more sense, I was wondering why the axial surface was turned but the large rad looked poorly milled, you ground the whole rad on the tool and tried to just plunge cut it, tsk tsk.
Title: Re: Building of an FSAE car
Post by: DSharp on January 28, 2012, 05:37:21 PM
Yea it chattered a little bit when it had a lot of contact but it works!  how else do you do that on a manual machine?  We don't have a lot of tooling, just the basics. 
Title: Re: Building of an FSAE car
Post by: Passenger on January 28, 2012, 07:13:13 PM
Yea it chattered a little bit when it had a lot of contact but it works!  how else do you do that on a manual machine?  We don't have a lot of tooling, just the basics.

You haven't made yourself a rad turner yet? Look it up, you'll love it. Much better way of doing rads.
Title: Re: Building of an FSAE car
Post by: Passenger on January 31, 2012, 08:08:43 PM
Here you go:

http://www.practicalmachinist.com/vb/general/how-would-you-make-part-240356/ (http://www.practicalmachinist.com/vb/general/how-would-you-make-part-240356/)
Title: Re: Building of an FSAE car
Post by: DSharp on February 03, 2012, 01:31:59 AM
I looked it up after you mentioned it.  Ill make one next time I need to use it.  I have some other things in the works now
Title: Re: Building of an FSAE car
Post by: DSharp on February 05, 2012, 08:45:44 AM
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F0203122253.jpg&hash=7f52a1ef55ce6ad4a29b7d50ae9ce98fea803282)



Got the rotary table working, and made a motor mount for my cnc project.
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F0205120352.jpg&hash=fe6252a4682bee8e0033e54d262d2e3ac3ee9304)
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Title: Re: Building of an FSAE car
Post by: patsmx5 on February 05, 2012, 10:57:26 PM
Draw it up Engineering paper and use what ya learned in Dynamics and Statics and prove them wrong.  :noel:

(Assuming use already took Vector Mechanics, or Statics and Dynamics)
I might just add it in and be done with it.


You guys seem to be pretty well equipped compared to most universities.
We have had a baja program for a while, and a few failed attempts at a formula car recently, so we have a lot of cool stuff, but there is only about 5 people who work on the project..... so my grades really suck.  I have designed about half of this car and I'm the main fab guy at the moment, and I have to do better than a B average next semester or declare my major as something other than engineering, its bullshit if you ask me.  Hopefully this will count for something if it comes down to it.

I am going to need some parts from you guys here pretty soon when I start building the header.

Been there, done that. Was spending 70 hours/week doing fsae and just enough to get As and Bs. What helped me go from B's and C's to A's and B's was planning. I kept a calendar that showed when every homework/project/report/test/final was. Take any given task, and plan to work on it 30 minutes to 1 hour a day, then figure out when I had to get started to get it done on time. I used google calendars cause it's free, of course. Plus I had a 1 hour gap between most of my classes, so instead of fucking off during that time, I TRIED to make that time useful, though I still would fuck off half the time (work on the car).

Our school was soooooo similar. 4-5 people who gave a shit, few that were on the team but didn't do much, so it was me and 1-2 other guys basically building the car. Best way to get shit built faster is to get more people on the team and get them involved. But not just anyone, recruit people who have some skills. Cleaning is a skill, so is organizing and moving shit. :)

FSAE got me my job out of college, but I had to get good enough grades to pull my GPA up to a 3.0. Make SURE that no matter what, you keep or get above a 3.0 before your senior year.
Title: Re: Building of an FSAE car
Post by: snm95ls on February 05, 2012, 11:19:41 PM
I'll probably be back to turning wrenches when I graduate.

Haven't done any extracurricular activities, and my GPA is so-so.

Oh well.   Yet another huge waste of time and money.

Title: Re: Building of an FSAE car
Post by: DSharp on February 06, 2012, 01:48:25 PM
very true.  Time management is one of the most important things you learn in college.  I haven't quite got it down yet.
Title: Re: Building of an FSAE car
Post by: DSharp on February 12, 2012, 12:55:58 AM
I turned the sickest thing I've ever made the other day.  I made the restrictor for our car.  This was done %100 by me on our manual lathe. 

First I roughed it out step by step with a combo of drills and boring bars yea I went a little too far with one of the steps....
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2FP1010024.jpg&hash=bab52453cd3f34d66ebfdeb76fcba2015c37ea4f)

Then I used a carbide burr, emery cloth, and some polish and a lot of time...
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2FP1010028.jpg&hash=8a7b331efc93deb594c4fed40bc59360017b1e2c)

Then I roughed out the outside and used emery cloth and polish.....
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2FP1010030-1.jpg&hash=0c87391614955d5e5e83b4997f416f096fdb1ab0)
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Title: Re: Building of an FSAE car
Post by: pitobread on February 12, 2012, 01:02:46 AM
Really nice work!
Title: Re: Building of an FSAE car
Post by: DSMR on February 12, 2012, 11:41:08 PM
I had sex with it.
Title: Re: Building of an FSAE car
Post by: patsmx5 on February 13, 2012, 08:11:53 AM
Looks tits. I know that took a little planning and care to not fuck up. Are you going to thin the flanges down any more? Might could save a little weight on them.
Title: Re: Building of an FSAE car
Post by: DSharp on February 13, 2012, 01:26:26 PM
I had sex with it.
O0



Looks tits. I know that took a little planning and care to not fuck up. Are you going to thin the flanges down any more? Might could save a little weight on them.
  I did today, hard part was making the part rigid enough to turn it.
Title: Re: Building of an FSAE car
Post by: DSharp on March 03, 2012, 12:36:33 AM
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F0206121541a.jpg&hash=8abe97ece3a88554beb45202c8a37fb98c871404)
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Iv'e been kinda slack recently but Iv'e been hitting the books hard.  I'm going to do some serious work over the next week.
Title: Re: Building of an FSAE car
Post by: HiProfile on March 03, 2012, 11:47:25 AM
I had sex with it.

Lucky, I wouldn't even fit in the big end with lube. :-\
Title: Re: Building of an FSAE car
Post by: DSharp on March 18, 2012, 10:25:51 PM
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F0305122240-Copy.jpg&hash=1454f344e8d56ae353d06653ceb94350d1a7c319)
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Title: Re: Building of an FSAE car
Post by: MTZ on March 20, 2012, 01:28:52 AM
where did you learn how to do all that machining bro ? looks great
Title: Re: Building of an FSAE car
Post by: DSharp on March 22, 2012, 10:18:58 PM
I had one short class a few years ago, but mostly been teaching myself.
Title: Re: Building of an FSAE car
Post by: Quada on March 24, 2012, 11:07:19 AM
What made you guys go with a 600cc four cylinder over say a 525 single cylinder KTM? Do you plan on using the engine as a stressed member?
Title: Re: Building of an FSAE car
Post by: DSharp on March 25, 2012, 06:46:11 PM
we had one already, hondas are reliable, cheap and make decent power even with a crappy setup, not to mention they sound much better than a single IMO.
Title: Re: Building of an FSAE car
Post by: snm95ls on March 30, 2012, 03:28:08 AM
Doing some work!

Our team is spoiled as fuck methinks.  We have multiple CNC machining centers on campus.  lol.

Title: Re: Building of an FSAE car
Post by: DSharp on March 30, 2012, 11:04:45 PM
We have a 3 axis and a 5 axis, but the 5 axis belongs to school of technology. The 3 axis doesn't get used much, our machinist is overworked and underpaid so he doesn't have much time to donate to us, lolz.
Title: Re: Building of an FSAE car
Post by: DSharp on May 14, 2012, 10:17:03 PM
Car is finished.  and its fast as fuck.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff359%2Fdbsharp%2F0507120048a.jpg&hash=3529c8f2a4f8f88128dd368e4448a976d4771f73)
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Title: Re: Building of an FSAE car
Post by: 92CXyD on May 16, 2012, 01:24:09 PM
Looking good  :noel:
Title: Re: Building of an FSAE car
Post by: Quada on July 28, 2012, 10:08:23 AM
What did the final product weigh? Did you guys use the hand shifter or make paddle shifters? Did you compete? If so, how did you do?
Title: Re: Building of an FSAE car
Post by: DSharp on August 16, 2012, 09:58:10 PM
It was over 600 lbs :?:

We ran out of time and had lots of problems.  We missed more than half of the events, but we made it and got to race our car.
Title: Re: Building of an FSAE car
Post by: Phate on August 18, 2012, 10:41:02 AM
It was over 600 lbs :?:

We ran out of time and had lots of problems.  We missed more than half of the events, but we made it and got to race our car.

That's about how baja went this year.  Broke the trans the day before comp, had to track down a part, rebuild in the hotel parking lot.  Lost 6th gear, and by the time we were finally through tech and brake testing we missed maneuverability, pull, and the mud bog.

Was that 600lbs including the driver?  We were at 544 with no driver.  Some of the lightest baja cars were around 305lbs.
Title: Re: Building of an FSAE car
Post by: NoPistons! on September 09, 2012, 05:20:41 PM
Erection achieved.  I love this kind of shit.   Apparently i really want to go to school now for chassis fab.  Then again, a buddy of mine did and is working at a local machine shop vs building race cars for a living.


The intake manifold is hands down my favorite part of the car.   The front and rear cnc billet knuckles are beautiful pieces too.   I wish i could do that kind of stuff.