E46 Jaffster Build

[clopez95m3]

Huh? Unless there is a new AlumaSteel filler rod, no.

Well there is brazing...

-Carlos.

[JMT]

Gee Carlos, and I figured you for a JB Weld kind of guy.

James Posig
JMT TrackCars
#231 GTS 2 (for sale with trailer and spares)

[mijgilbert]

Yes James - we have designed a new 'racing' bulkhead sealer panel!

The panel is made of 100% formed JB weld, with bondo to smooth out the corners... It only weighs 162 lbs but holds itself in place.

[Dino Antonov]

I want to see pics of the wing . Whats your daily driver steve?

[clopez95m3]

Gee Carlos, and I figured you for a JB Weld kind of guy.

Super glue baby!!

-Carlos.

[jmitro]

hey, that e-brake handle is extra weight. just kidding.

can't wait to see your car finished. it's going to be awesome

[Steve J.]

Ebrake system has been off for a couple weeks now that it is done being moved around...plus its going on this once it arrives:




Daily driver is wrx wagon.

Wing pics will be posted once I get the element(s) in. I'm waiting to hear back from the composite guy on his schedule.

[Steve J.]

steve, it is about that time to deal with the cage. you know everyone will be gunning for you when the design comes out. it had better live up to the hype.

What hype? I have not posted anything about it other than some A pillar ideas. I know all the guys with too much free time are going to be using their sophisticated windows paint programs to modify pictures of the cage, so I might just wait a while after its all done to post pics. 13 months off of welding though, I need to get back on the ball with that stuff.

12. LKHEAD - A sealed metal bulkhead between the passenger
REAR BU
compartment and the compartment containing the fuel tank is required on
cars using a fuel cell or where the fuel tank is not totally under the car floor
(i.e., is required in 1600/2002 models). A bulkhead is highly recommended
on cars where the fuel tank is under the body (i.e., E36).

NASA folks got a little testy when I asked about using CF for that. NASA and SCCA specifically require metal too. Just a note.

A carbon shear panel will be plenty! If they want i'll structural adhere a piece of .020 aluminum to the back side Its not 'carbon panel,' it'll be a carbon shear panel (honeycomb core). Maybe even toss a layer of carbon-kevlar in there for some extra impact strength. Its easy enough to make one out of Aluminum though, roll some nice ribs into it (maybe in a bmw pattern ).

[M3 Muscle]

Ebrake system has been off for a couple weeks now that it is done being moved around...plus its going on this once it arrives:




Daily driver is wrx wagon.

Wing pics will be posted once I get the element(s) in. I'm waiting to hear back from the composite guy on his schedule.

That's a little more high-tech looking than the one I made!

[onasled]

Yea, that roto is sweet. Great for a one man shop I bet Steve. I built mine also. Cost me all of $0.00.

[Roktgr]

What hype? I have not posted anything about it other than some A pillar ideas. I know all the guys with too much free time are going to be using their sophisticated windows paint programs to modify pictures of the cage, so I might just wait a while after its all done to post pics. 13 months off of welding though, I need to get back on the ball with that stuff.



A carbon shear panel will be plenty! If they want i'll structural adhere a piece of .020 aluminum to the back side Its not 'carbon panel,' it'll be a carbon shear panel (honeycomb core). Maybe even toss a layer of carbon-kevlar in there for some extra impact strength. Its easy enough to make one out of Aluminum though, roll some nice ribs into it (maybe in a bmw pattern ).

Doesn't sound like they are worried about structural piece but a fire barrier. Carbon isn't a fire barrier, resin tends to burn pretty good.

[PEI330Ci]

Ebrake system has been off for a couple weeks now that it is done being moved around...plus its going on this once it arrives:




Daily driver is wrx wagon.

Wing pics will be posted once I get the element(s) in. I'm waiting to hear back from the composite guy on his schedule.

Where did you source this from?

[txse46m3]

A carbon shear panel will be plenty! If they want i'll structural adhere a piece of .020 aluminum to the back side Its not 'carbon panel,' it'll be a carbon shear panel (honeycomb core). Maybe even toss a layer of carbon-kevlar in there for some extra impact strength. Its easy enough to make one out of Aluminum though, roll some nice ribs into it (maybe in a bmw pattern ).

I agree that CF is completely appropriate for the application, but rules is rules. It's a safety item, so you wont make it through your annual tech.

[Steve J.]

It'll be fine. Rules are meant to evolve. I'm going to try and help bring some affordable solutions (or even just ideas) into clubracing with this project that have only been used/proven in professional racing applications. Safety is the one place that no matter if you are pro or grassroots, it works the same. Just using misc devices that are proven in different venues/applications doesn't make sense to me.

As for the Rotisserie, check the pictures URL for your answer

OnaSled, where did you source free steel from? Unless you stole it from someone elses shop, you paid for it in one way or another. Plus the 10-20hours you probably spent making it, I made up for in time saved. Does yours have a CG balancer and Hydraulics? This costs $895 btw, assembled, casters, powderacoted, hydraulics...plus i can sell it knowing people will pay for a professionally built product, not something i made myself that i can't get replacement parts for quickly I bought it with the intention of selling it once I am done.

[Roktgr]

Curious as to why you used square tubing for parts and then on other stuff you used died sheetmetal? Why not use the sheetmetal for everything or atleast with round tubing? Looks cleaner imo.

[Steve J.]

Curious as to why you used square tubing for parts and then on other stuff you used died sheetmetal? Why not use the sheetmetal for everything or atleast with round tubing? Looks cleaner imo.

Can you be more specific?

Doesn't sound like they are worried about structural piece but a fire barrier. Carbon isn't a fire barrier, resin tends to burn pretty good.

Not the composite I was looking to use

I'll see when the time comes, thats several months away. I might just make a quick alum template to use for the time being and to get it out there testing. Not something I'm going to spend much thought on to be honest. I don't see any material thickness specified in the rules for the bulkhead though, so I could prob use a very thin sheet of alum?

[Roktgr]

A
Finished Cell cradle (minus one sheet metal peice underneath)

Well for instance in this picture, why not run some tabs off the floor area and use tank straps (bent flat strap would work)? Sorta of inverted to hows it's shown in the pic below. The surrounding sheetmetal looks good but the angle iron is ugly. Looking at your tank again it's a bit different design then I was thinking it was. This is an example of a pretty clean fuel cell install. It's a custom made unit though.



Also with the seat support and piece of round tubing with tabs would look cleaner and probably be lighter too.

As for the rules on the rear bulkhead, I'm not super familiar with your rules but we have similar rules for our baja racing. It's comes down to a couple things for use, most composite sheets are not fire resistant, and if they are it is hard to prove that they are and that it's what your running. Metal on the other hand is pretty easy to determine if it's metal and the fire resistance is pretty well known. With our rule set they don't list a minimum thickness either so we run as thin as we can and still rivet it to the firewall, I think it's 0.035 or 0.020" thick aluminum.

[PEI330Ci]

I'll see when the time comes, thats several months away. I might just make a quick alum template to use for the time being and to get it out there testing. Not something I'm going to spend much thought on to be honest. I don't see any material thickness specified in the rules for the bulkhead though, so I could prob use a very thin sheet of alum?

I've already been through this with my build, we ended up going with a thicker piece of aluminum than what was required.

NHRA specifies 0.032" thick aluminum to be used as bulkhead material, I went with 0.045". I'm quoting NHRA, because that's what most sanctioning bodies in my area refer to if there's ever any grey areas. (The MPH is usually greater, thus the mechanism of injury higher)

Yes, there is suitable CF sheeting that can be used, but most people aren't going to fork out the $800+ for a 4' by 4' sheet. (Minimum order)

[onasled]

......
As for the Rotisserie, check the pictures URL for your answer

OnaSled, where did you source free steel from? Unless you stole it from someone elses shop, you paid for it in one way or another. Plus the 10-20hours you probably spent making it, I made up for in time saved. Does yours have a CG balancer and Hydraulics? This costs $895 btw, assembled, casters, powderacoted, hydraulics...plus i can sell it knowing people will pay for a professionally built product, not something i made myself that i can't get replacement parts for quickly I bought it with the intention of selling it once I am done.

Steve, wasn't busting on your roto, ... I really DO love it and wished I had one that was so adjustable. Mine was a bare bones that needed a lot of muscle to rotate the car. The metal was in fact all given to me and my buddy and I built it in a day or two. I did buy the wheels so I guess I did lie.. ... a little

[Steve J.]

Next time i'm building a Baja Buggy I'll call you For this project, I think I'm fine thanks.

The composite I was thinking to use I have personally held a 2500 degree open flame to and it not only did not ignite, but the other side of the material was only about 70 degrees 1/2" away...not your ordinary stuff Oh yea, plus its structural!

You also should have figured out by now...I'm not most people lol

[ssburns]

I know all the guys with too much free time are going to be using their sophisticated windows paint programs to modify pictures of the cage...

Pot meet kettle

[rmm3]

Steve,

I have the same roto you just got, it works really good for what it costs. Best part is it takes very little effort to spin the car, and of course makes working under the car much easier.

-Rick

[Steve J.]

Awesome! Glad to hear! For $1085 SHIPPED to my door, on a liftgate, includes hydraulics, powder coat, unibody brackets, etc...its a steal!

Plus, I'm going to be selling it shortly after this project most likely, so its definitely worth it.

I'm going to be ordering the Millermatic 212 soon as well, so when the rotisserie gets here I can crank away on it.

[Stealthauto]

wow ........... I found it the Jaffster cage!





I Kid, I kid............we all can't wait to see you cage !


Keep up the amazing work!

[szed]

LOL

What the hell?