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Topics - jayb

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181
FE Technical Forum / Dedicated Upper Manifold for the Intake Adapter
« on: December 19, 2014, 03:34:36 PM »
Despite the current delays at the foundry, I've been relatively happy with how the FE intake adapter project has gone over the last year or so.  By March or April I'm hoping to be all caught up on deliveries of these, and sometime in January I expect to put the new timing covers up for sale.  So, I'm looking to start another casting project this year, and one that comes to mind right away is a dedicated intake manifold top, or upper manifold, to fit on the intake adapter.

Doing a dedicated upper manifold for my adapter has some advantages over using a standard 351C intake.  One advantage has to do with port alignment; because of the smaller bore spacing of a 351C engine, the outboard ports in the adapter are angled somewhat to get the #1, #4, #5, and #8 ports in the heads to line up with the same ports in the 351C manifold.  This doesn't seem to have a major effect on power production up to 650 horsepower or so, but of course at the limit a straighter port is better, and since I can easily change the porting programs for the adapter, I could cast a custom upper manifold to fit without requiring the angled ports.  I also like the idea of making the upper manifold a two piece unit, that could be split apart down the center of the plenum for porting purposes.  And with control of the casting, I could add material to allow widening the intake ports towards the center of the engine, and also to raise them if desired.  Material could also be added to allow machining holes for fuel injectors in case EFI was used, and also to leave enough material at the flange so that the upper manifold would work with either the standard medium riser adapter, or the high riser adapter.  Finally, with control of both the intake adapter and the upper manifold, I could cut the upper manifold for O-ring grooves, and use O-rings to seal the upper manifold to the intake adapter, eliminating the need for another set of gaskets.

I've been thinking about this for a few months now, and the problem that I've been wrestling with is what upper manifold to build.  I have three different ones in mind, and at some point I may end up building all three, but for now I just need to get started on the design and tooling for one of them.  So, I put the poll up to get some feedback from forum members on which one is of most interest.  Here are some details on the upper manifolds I'm considering:

** Single Plane Dominator Flanged Spider Intake - This would be similar to an Edelbrock Victor intake in appearance, but it would end up being quite a bit taller, at least 2" and maybe more.  Designed for 4500-8500 RPM operation with a Dominator carb.  The idea is to be a step above the Victor in single plane performance.

** 2X4 Single Plane Intake Similar to a Tunnel Wedge - This would be an upper manifold that basically duplicated the design and performance of the tunnel wedge intake, and also duplicated the carb position so that it would fit under the hood of most FE vehicles.  I would envision a carb mounting pad that would allow the standard 4150 carb arrangement, or mounting 4150 carbs sideways so that a couple of double pumpers could be used if desired.  And of course the carbs would be spaced so that the ubiquitous oval air cleaners would fit.

** 2X4 Tunnel Ram, in Sheet Metal Intake Style - this upper manifold would feature straight runners and a V-shaped plenum like a new sheet metal intake, but would be cast aluminum instead.  It would probably be a three piece design, with a billet aluminum top and cast runners/plenum.  I'd design it to work with the factory distributor location, rather than with an offset distributor.  Runner length would be optimized for tuning at 7000 RPM.

All of these upper manifolds would have the features described earlier.  One caveat, though, is that I don't know for sure if, or when, I'd make one of these upper manifolds available.  Its something I'd like to do, but its tough to predict availability of the time and funds for this kind of project.  So, no promises of any sort on this.

Which manifold do you think I should build?

182
Today at the PRI show, Hot Rod announced the basic outline of the 2015 Engine Masters rules, and the new finalized rules for Drag Week.  About a month ago the proposed Drag Week rules had come out, and they eliminated the class that I've been running for the last few years, Modified NA.  They also eliminated normal drag tires in favor of drag radials, and made changes to the Super Street, Pro Street, and other classes.  Most of the Drag Week guys I know were less than enthused with the new rules, and of course I was pretty unhappy with them because it knocked my Shelby clone out of the competition.  Hot Rod accepted emails over the last month or so asking for feedback on the proposed rules, and according to Freiburger at the meeting today, lots of people wrote in.  The upshot was that they basically changed the rules back to the way they were; the Modified NA class is back, and looking at the rules as they were posted on Hot Rod's site tonight, my Shelby clone still fits in the Modified NA class.  I was very, very happy to see that; what a relief!  I'll be going back again next year with the Shelby clone, once I get the big SOHC back together  8) 8)

Since Popular Hot Rodding is no longer a magazine, Hot Rod has taken over the Engine Masters contest.  Barry R was waiting with great interest, of course, for today's look into next year's rules.  Unfortunately for Barry, and for all the rest of us for that matter, the new rules have made competition with an FE almost hopeless.  They are proposing to change Engine Masters to five separate classes, as follows:

- Chrysler Hemi class - only Chrysler hemis allowed to compete
- Spec Small Block class - Naturally aspirated small block engines, plus AMC, Buick, Pontiac, and Olds engines.  Specific heads will be required, but porting is allowed.  Modular Ford, LS, and Chrysler hemi prohibited.
- LS and Mod Motor class - 6.2 LSE and 5.0 Ford Coyote engines, with stock shortblocks.  Hot Rod will provide the short blocks at the event; the competitors have to bolt on their top end components prior to running on the dyno.
- Vintage V8 - Pre-1955 engines only
- Xtreme big block - Naturally aspirated, 505 cubic inch limit, scored RPM range 4000-8500.

The only class an FE fits into is the Xtreme big block class, and with the high end components available for other engine types, even a top shelf FE making 1000 HP is going to fall 200-300 HP short of the top level competitors.  Barry R is fit to be tied with this set of rules, especially in light of the fact that Pontiacs are allowed to compete as small blocks, but FEs have to compete as big blocks.  FEs of course were available in cubic inch displacements down to 332", and bore spacing on an FE is only 0.005" larger than a Pontiac.  So it really makes no sense that  Pontiac engine can compete in the small block class and an FE can't.  I had dinner with Barry and some other guys tonight, and as a result of these rule changes Barry is considering moving to Drag Week, rather than competing in Engine Masters, which would be a shame for all of us FE guys, of course.

Hot Rod is accepting input from the competitors about these rules from the Engine Masters competitors, and they are sure to get an earful from Barry.  One thing that we thought about at dinner would be that if Hot Rod allowed an SOHC to compete in the Chrysler Hemi class, that would offer an avenue for an FE to compete in a class other than the Xtreme big block class, and that it would be pretty fun to see those old 1960s engines duking it out in that class.  They are accepting input for the next week, so let's hope they give that idea some consideration, or at least let the FE compete in the small block class with the other engines of similar size, like the Pontiac.

183
FE Technical Forum / PRI Show
« on: December 11, 2014, 09:45:13 PM »
Kevin R (thatdarncat) and I spent Wednesday night and Thursday morning driving from Minneapolis to Indianapolis to attend this year's PRI show.  I made an arrangement earlier to kind of share part of Barry R's booth, so he is displaying my intake adapters, timing covers, and timing chains at his booth this year.  Kevin and I arrived around 1:00 PM, fought through the downtown traffic to finally find a parking garage that wasn't full, and got into the show around 1:30.  First stop was the Survival Motorsports booth.  It is kind of cramped for space, so not everything is out on display yet, but tonight I picked up some literature display stands at Office Depot that should give us a little more room. 

We spent some time after arriving talking to Barry and several potential customers who came by the booth.  After a while Kevin and I hit the show, working through a list of people I needed to talk to.  One of the first places we ran across was SCE gaskets, and Ryan Hunter (Marc's brother) showed us his new FE head gasket.  It looks really good, and I happen to have a motor going together right now for testing the intake adapters with various 351C intakes, so Ryan said he'd send me a pair to try out on that motor.  The gaskets have those built in silicone O-rings for sealing around the water jackets and the oil passage in the head, and also have the built in oil drainback hole for SOHC engines.  I'm looking forward to trying them out.  Ryan has a 1970 Mustang funny car with a blown Boss 429 in it as the centerpiece of his booth; pretty cool, and I'll get some pictures of it tomorrow and post them here.

For the last three months the block for my big SOHC engine has been at a machine shop in northern MN getting repaired.  I got the news this week that all the welding was done, and all the machining came out right, so the block is now ready for re-assembly.  This was the news I was waiting for before starting to collect the parts to reassemble the engine, so one of my first stops at the PRI show was at the Darton Sleeve booth.  I had a few special requirements to talk to them about, so I was able to talk to their tech guys and confirm that they could meet my requirements.  I also stopped by the CP piston booth to talk to them about a new set of pistons, and maybe a set of Carillo rods for this engine, rather than going back to the Crowers.  The Carillos are more expensive than the Crowers, but they are supposed to be a better rod, so I may end up going that route.

After stopping at a few other spots I stopped back at the Survival Motorsports booth to chat some more with Barry.  I also got to meet Ray Paquet who stopped by the booth about then.  What a treat that was!  I've been following Ray's exploits for 20 years or more, and to meet him in person was a real thrill.  I also met Adney Brown, Barry's crank grinding guy, who I've heard nothing but good things about.

I'll get a bunch of pictures from the show posted tomorrow night.  If any of you guys happen to be attending the show, stop by the Survival booth and introduce yourselves;  I'll be in and out of the booth, but I'll be there quite a bit on Friday and Saturday.   Looking forward to meeting some forum members at the show - Jay

184
Non-FE Discussion Forum / Pearl Harbor Day
« on: December 07, 2014, 11:29:47 AM »
Let's not forget the sacrifices of our armed forces during WWII, starting of course on December 7, 1941.  My wife's great uncle was on the USS Arizona, and was blown clear in the explosion.  He survived that day, and the war, and lived a long life as an Iowa farmer.  When  he died in 1989, they took his ashes and scattered them over the wreck of the Arizona in Pearl Harbor.  He was the first sailor that survived from the Arizona that had that done; last time I was at the Memorial there were probably 30 names on the plaque memorializing those who had their ashes scattered there, and he was the first one.  I never had the honor of meeting him, unfortunately (didn't meet my wife until 1992).

On the WWII topic, there's a new movie coming out called "Unbroken", about Louis Zamperini, an Olympic athlete turned soldier, castaway, and prisoner of war in the Pacific Theater.  I've read the book, and it is outstanding.  The movie looks pretty good too, judging by the commercials...

185
FE Technical Forum / FE Block Filler
« on: October 20, 2014, 09:14:56 AM »
So, my grenaded 577" Shelby block is slowly being repaired; the shop is moving slowly and deliberately on this project to make sure we cover all the bases.  The plan at this point is to hard-block the block after all the repairs are made, to add some strength to the bottom end and support to the bottom of the cylinder sleeves. 

On three of the back cylinders in this block, when the block was originally offset bored in 2008,  the boring broke through the aluminum casting, making the three press-in sleeves for these bore wet sleeves.  To fix that during the last go-around on this block I used sleeves with an O-ring at the bottom, to keep water from leaking between the sleeve and the aluminum of the block casting, down into the crankcase.  Assuming we proceed with the hard block option, my machinist points out that the hard block will cover these holes, and could potentially seal them up, if the hard block material had the same heat expansion rate as the aluminum block.

I have never used hard block before; does anybody know if there is a hard block material available that has the same expansion rate as aluminum?

186
Barry Rabotnick finished 20th overall in this year's Engine Masters with a score of 2536, using the same FE as last year and after running it all summer in his Torino!  Great job, and Barry really answered the doubters who say that Engine Masters engines are not real street engines.

Mark Dahlquist ran another Pontiac this year and finished 10th overall with a score of 2710, following up on his 9th place finish last year.  With that kind of back to back success Mark is obviously a serious EM competitor.  Lest anyone forget, for some strange reason FEs and Pontiacs share a lot of similarities, such as bore spacing (FE 4.63, Pontiac 4.625) and head bolt locations (an FE head will bolt onto a Pontiac block with nine of the ten head bolts).  Pontiac Ram Air V engines and FE Tunnel Ports are very similar designs.  I've kind of got a soft spot for Pontiacs LOL!

Once again the same group of contestants dominated the top six spots, led by first place finishers BES.  It sure would be nice to see some new faces in this group; maybe next year Barry or Mark will break into that elite group.  Great job guys!

187
FE Technical Forum / Here's a follow-on question about building an SOHC...
« on: September 18, 2014, 10:05:12 PM »
It looks from the poll results in the previous post that the high cost is the major barrier to entry, although that may not be the only barrier.  So here's a question:  What if you could buy ALL the parts necessary to build an SOHC for $15K?  Still too expensive, or getting to the point where it may be do-able?

Here is what I'm thinking.  Start with a run of the mill 390 block, bored .030 or .040 over.  Cross bolt it if you want to make more than 600 HP.  Add a stroker crank kit, like the ones available from Barry or Doug, but with SOHC pistons.  Probably adds $300 to $400 to the price of the kit.  The 390 cylinder bores would have to be notched for the intake valve to clear, but if you ran 2.25" intakes it would be less problematic than with the 2.300" intakes.  By the way, a good friend of mine is running an SOHC with a 390 block right now, so I know it can be done.  Then, the trick is just to get the SOHC specific parts down to a reasonable price.

I'm asking about this because one of the manufacturers of SOHC parts has offered to sell me the tooling to build them.  Not exactly a project I was looking to take on, but I wanted to at least gauge some interest from the FE community.  Having some experience under my belt now with casting up the intake adapters and the timing covers, doing all the SOHC stuff doesn't look that far out of reach.  I have a pretty good local casting outfit, and an excellent local pattern maker that I could use to modify the patterns if necessary.  I could do the machining myself, at least for the most part, to bring the price of the parts down.  For example, I think I could sell a pair of the heads for $3000, not $5500 like they are going for now.  Probably sell the intake manifold for $750, the front cover for $500, etc.  I would want to cast non-adjustable ductile iron rockers like the original factory ones to keep the cost down, which would be something new but definitely do-able.  I'd go with Comp billet cams and a good timing chain set with a .250" pin roller chain.

I've added up all the parts required to build such a motor, from carbs to pan, and including gaskets, rings, and bearings, and I think the total parts cost would come in right around $15K.  About $10K of that is SOHC specific, and the remaining $5K is the short block and dual carbs.  Additional expenses would be any machining costs and assembly costs if you had someone else build it for you.

This may never happen (and probably won't), but if it did, would the reduced price make building one of these engines substantially more attractive? 

188
FE Technical Forum / Why aren't more people building SOHCs?
« on: September 17, 2014, 12:40:46 PM »
It's been about 5-6 years since the aftermarket started stepping up with SOHC parts, so that it would be possible to build a complete SOHC engine from aftermarket parts.  The SOHC is definitely the king of the FE engines, and I for one figured that we would start to see a whole bunch of them in various 1960s Ford vehicles once the aftermarket parts became available.  There certainly are more of them out there than there used to be, but not as many as I figured there would be by now.  What gives?  Why aren't more people building these killer engines?  I posted the poll above to try to get an idea of what people are thinking on this.  If you have a different reason than those listed, please post in this thread to explain.  I'm very curious about this...

189
The Road to Drag Week 2014 / 577 SOHC Post Mortem
« on: September 12, 2014, 09:34:55 PM »
Before I forget and get into all the gory details of the teardown, here is a dyno plot of the power this engine made on the dyno in August:




After getting home from Drag Week Monday night, I decided I needed to take a few days to get my shop cleaned up after the big thrash, before I tore down the engine to see what the problem was.  This took me all of Tuesday and Wednesday, and most of Thursday, but at the end of the night on Thursday I got the car pushed into the garage.  I pulled the valve covers on Thursday night, and everything looked fine.  I spun the engine over and all the valves seemed to open and close normally, no excessive lash, etc.  Then I decided to do a compression check on all the cylinders, still hoping that everything would be fine there.  Unfortunately it wasn't, cylinder 5 had zero compression.  I had been thinking that if the compression in all the cylinders had looked good, maybe I could just pull the pan and fix whatever was wrong with the engine still in the car.  That was obviously out of the question now, so I left the shop Thursday night knowing that the engine had to come out.

I spent most of the day today getting the engine ready to pull.  Finally got it out around 4:00, and started the teardown.  Found quite a few surprising things; I made this short video to hit the highlights:

http://youtu.be/H4R6wZu8wdg

At the track last Sunday I had assumed that I had not damaged the block because the water jackets had not been breached.  Obviously, that was not correct, and I think I'm lucky that the cracks in the block did not extend into the water jacket; that will make repairing the block much easier.  The remnants of the #5 connecting rod spun really easily on the journal, which was a big surprise also.  Obviously I had a beam failure.  These are not cheap rods, they are Crower billet steel connecting rods, $1400 a set and supposedly good for 1000 HP and 8000 RPM.  At the track, with the weather conditions last Sunday, I was probably running 900 HP and the rev limiter was set at 7800 RPM.  To say that I'm surprised and disappointed by this rod failure is an understatement.  I took the remains of the rod off the crank, and also removed the #1 rod.  On the #5 rod the top rod bearing was real shiny, indicating it had been beaten pretty hard as the broken rod stub repeated smashed into the side of the block, but the cap side looked perfect, and in fact still had the coating on the rod bearing.  Also, the rod journal looks perfect; see the pics below:





That is a Crower billet steel crank, and I'll bet there is nothing wrong with it; I'll have it magnafluxed and checked for straightness, but I'll bet I can re-use it.  The number 5 piston is jammed into the bore at the bottom, and that may have saved the heads; here's a picture of the stuck piston with part of the connecting rod still attached:



After all this trauma I would have bet my bottom dollar that the timing chain would have broken; imagine the stress forces and harmonic shocks going through that thing with the broken rod spinning around hitting the block and oil pan!  But Paul Munro's chains are really strong, and the chain tension is still right where it is supposed to be. Amazing.

Thinking back about the pass where the failure occurred, I started off by doing the burnout at 5000-6000 RPM on the tach, and shifting from first to second to get a good burn on the tires.  Everything about the burnout was normal. I pulled to the line and footbraked the car while holding the RPM at 3000, the smashed the throttle and released the brake at the last yellow.  The car left the line and started missing almost immediately; I think that is when the rod broke.  But I don't think the engine was missing; what I think I was hearing was the broken rod flopping around in the engine.  After the 1-2 shift, the "missing" stopped and the engine seemed to accelerate normally, and I'll bet that's when part of the rod beam broke off the big end and exited through the oil pan.

For the #1 and #5 cylinders I will definitely need new sleeves for the block, and new pistons, but so far the other six pistons and sleeves look OK, and might be re-usable.  I haven't pulled the heads yet but am hopeful that there is no damage to them, or to the valves, because everything looks good up top, and all the spark plugs look good too.  I'll find out tomorrow when I finish the teardown.  I was also pleased to see the condition of the bearings, and the fact that there weren't any bolts missing or anything dumb like that.  The worst thing would have been to find that I made some stupid mistake assembling the engine and paid for it with this failure, but this is clearly a component failure, not any problem with assembly.  Of course it is possible that I set the rev limiter too high at 7800 RPM; I picked that number because it represents a piston speed of 6000 feet per minute, which I've run before successfully.  But maybe I was on borrowed time with that, and need to reduce the rev limit to 7500 (piston speed 5750).  I guess I'm not sure.  I've had the rods since 2008, and ran them on the dyno several times, and at Drag Week in 2009, where I kept the same 7800 RPM rev limit.  Maybe I've just stressed them to the point where the one rod fatigued and let go.

In any case, I'll be looking at a new set of rods for this engine.  I spent some time talking to Blair P about this tonight, and his thoughts were that due to the heavy piston required for the SOHC, maybe the rod was not good for 1000 HP and 8000 RPM, and also that fatigue may have set in since I've been running these rods pretty hard since 2009.   We're going to be talking to Crower next week about a custom rod with a thicker beam section that may handle the requirements of this engine a little better.

Depending on the lead times it may take me up to several months to get this engine back together, but that will give me some time to build a new set of headers to try on the dyno, and maybe a new sheet metal intake too.  Since the car is pretty much done now, once the engine is finished up it should go back in the car with a minimum of fuss, and hopefully I can be out to the track a little earlier next year.  Assuming I can get into Drag Week in 2015, I plan to go back with this combination again.

Once again, thanks to all you guys for the moral support on this project.  I'll get this program sorted out in the end - Jay


190
The Road to Drag Week 2014 / Drag Week 2014, Registration and Test 'n Tune
« on: September 07, 2014, 10:03:30 PM »
Steve and I were up at 6:30 this morning, and after breakfast at the hotel we hit the road for the track.  The track gates were supposed to open at 7:30, but  we wanted to get there a little early so we were on the road by 7:00.  We rolled up to the track at 7:20 and they had opened the gates early, and it looked like there were already 150 cars on the grounds.  We quickly parked the truck and trailer, got the car unloaded and hooked up the Drag Week trailer, and then headed for the registration lines.   By the time we got into line it was 8:00.  Later, at 1:25, I finally reached the registration tent.  Registration is SO slow at Drag week.

On the other hand, waiting in line gives you a chance to check out all the other cars and catch up with old friends.  Pulling in right behind me was Bill Fowler in his 71 Mustang convertible with the 1000 HP 385 series engine.  Pics of Bill's car and his engine are below:





Bill spent the summer trying to get his Fox body Mustang ready to transplant the big engine into, but he ran out of time so he was back again with the 71.  He has the car plumbed for nitrous and is waffling between running BB/NA and BB/PA.  While I was talking to Bill, Tom Posthuma showed up, so we talked for a while.  Tom was looking around for Joel, aka Captain Stabbin, but he hadn't appeared yet.  Finally I called Joel and he and Kevin (thatdarncat) were at a Lowes or a Home Depot or something, because Joel's horn wouldn't work and he needed a switch to use as a backup in case he couldn't get it fixed at the track.  A horn is required to run in Drag Week.

A couple of minutes later I bumped into Curt Johnson.  Curt is back with his Fox body Mustang with big block Chev power, and last year ran a bunch of 9.0s in BB/NA with that car.  He is running the same class this year.  (Bill, if you are reading this, maybe you should go BB/PA  ;)  The "prom queen's ride" has no shot in BB/NA unless Curt breaks.)  Curt and I talked for a while and caught up, and I told him about my rod knock scare, which still had me shaking my head.  One of Curt's friends is here and running in my class; his name is Brad and I remember him from DW'09, when he looked to have a pretty competitive car but broke part way through the event, if I recall correctly.  I was sure that Brad would be fast.  Shortly after that I ran into Dustin Hasse, who was one of the original gang at Drag Week 2005, and we started talking about maybe getting all the guys from 2005 together at some point during the week.  There were a bunch of us there, and there has never been a better Drag Week than the first one in 2005, so it would be fun to get together and rehash old times over a couple of beers.

A couple of minutes later Joel and Kevin finally arrived; here's a picture of Joel's 67 Oldsmobile, and another shot of him working on the horn wiring under the hood:





The line was moving slowly, so I was able to leave the car for several minutes at a time and walk up and down the registration line talking to folks.  I ran into a guy with a really nice Torino Cobra running in the event; here are some pics of the car:





There was also a 66 Galaxie painted up to look like an old NASCAR racer:



Tom Posthuma came by again and pointed out Alan Casida's Galaxie, which I had driven right by but missed.  I went over to get a couple of shots; it is a really nice looking car:





A little later Alan came by and we had a nice chat.  By this time I was hanging out pretty close to the car, because the registration line was moving more frequently.  Here's a picture of the registration line at about 10:00 AM:



Lots of people were stopping by to look at the car, and finally a guy with a serious looking camera and tripod came up, said he was from Hot Rod, and wanted to get a video of me opening up the hood on my car.  He had me do it twice, from a couple of different camera distances; it will be interesting to see if/when that shows up on the Hot Rod website.

A little while later Joel came by; he had managed to get his horn fixed and hung around for a while while the line moved.  There were two lines at registration, one for Daily Driver and the Unlimited cars, and one for everybody else.  The Daily Driver line moved much faster than the line I was in, and despite arriving quite a bit later than I did, Joel had made it through registration much faster.  While hanging around by my car he decided to reprise his "Captain Stabbin" role, and try to get the locking spears through the holes on my Drag Week trailer in one push.  I tried to get him to bet on it, but he hadn't done it in a while so he wisely declined; he ended up trying it five or six times without success.  Here he is prior to the first try:



Finally we made it to the head of the line and got through the registration process.  I said hello to Hot Rod editor David Freiburger and told him I was hoping to reverse three years of bad luck at Drag Week this year.  He thanked me for coming and wished me luck.  I drove out from the registration tent, picked up my Hot Rod "goodie bag" and Drag Week t-shirt, and then Steve and I headed for the concession stand.  It was getting to be pretty hot at the track and the sun was really beating down, and we needed some refreshment.

The test and tune portion of the program had gotten going around 1:00, so after getting some drinks Steve and I headed up to the stands and watched the racing for a while.  Finally we got going back to the car, to get it ready to make a pass or two at the track.  There were a lot of changes to the car since the last time I had run it a few weeks ago, including new tires, a new converter, a new four link location, and new race fuel, VP Q-16.  I'm always nervous driving for the first time at a new track, and with all these changes to the car I tried to be very deliberate getting it ready, and making sure everything was right before Steve and I got into the car and headed for the staging lanes.  The lanes were also moving very slowly, and it took a half hour or so before I finally made it up to the line.  This was the first burnout for the new tires, so I did a fairly long one, and then pulled to the line and launched the from a footbrake as usual.  Right off the bat there was a problem; the car was missing badly in first gear.  I hadn't ever had that happen before with this engine.  The shift light flashed and I went to second, still missing, but then it cleaned up and ran out the end of the quarter sounding pretty good.  Slowing down after the stripe, and approaching the return road, I was already thinking about what the problem could be. 

Two possibilities immediately came to mind.  First, when I changed plugs earlier this week, after street driving the car for a couple hundred miles, the plugs were very black, indicating that the EFI tune for street driving was really rich.  I had changed the plugs, but then drove the car about 50 miles to the alignment shop and back, and I was wondering if the plugs had turned black already and were not working at high engine speeds.  The other possibility I thought of was the new fuel.  VP said that this fuel, which was oxygenated, needed to be run about 5% richer than standard race gasoline.  So, when I filled up the tank I had richened the EFI fuel map by 5%.  But it almost seemed like the car was running rich, and that maybe I shouldn't have done that despite the fuel.  I idled down the return road and picked up my time slip, which was a miserable 10.38 at 130 MPH.  My pit was right at the end of the track, so I pulled in there and shut the car off.  Steve was going to wait in the stands until Joel ran and then come back, so I got out of the car and started pulling the plugs.  I got #1 through #4 out and they looked pretty good; no serious carbon fouling or anything like that.  It seemed like the plugs were not the problem.

About this time another guy I knew from some previous Drag Weeks came by and said hi.  He asked what was wrong with the engine, and I told him about my suspicions.  He said that I'd been trailing a lot of smoke starting at the halfway point of the track, which surprised the heck out of me; I'd had no idea.  He said, "Look at the left front tire."  There was a bunch of oil on the tire and the lower control arm.  Uh-oh...

I thought maybe that the dry sump catch can had filled up during the pass and had been puking oil out of the breather, but the breather felt dry.  Where was that oil coming from?  I looked in the top of the dry sump can, and was surprised to see that it was nearly empty.  What the hell?  I crawled under the car and looked around for a valve cover leak or a dry sump line leak, but didn't see anything.  Then I looked at the oil pan:



I'm sure you can just about imagine the shock I felt when I saw the hole in the oil pan.  I was done; another Drag Week disaster.  I kind of sat back in shock for a while, as Steve and Joel and Kevin came over.  For the life of me I couldn't reconcile the reason for this problem, but now it seemed like the noise I'd heard on Thursday night may have been a rod knock after all.  But I hadn't heard that noise all day today; it didn't make any sense. 

After calming down a little I started thinking about the circumstances surrounding this failure.  I have a low oil pressure warning light that points straight at me from the dash, with a bright red bulb in it.  I never saw it lit up going down the track, coasting down from the pass, or on the return road.  So I must have still had some oil pressure all the way up until I shut the car off.  If I'd had a catastrophic engine failure like a broken connecting rod, for example, I'd have thought that one of the plugs would be destroyed, so I pulled the #5 through #8 plugs, but they all looked OK.  #5 looked a little blacker than the rest, but that was the only difference.  Curt Johnson showed up and suggested I crank the engine with the coil wires off to see if we could hear any knocking.  The engine sounded perfectly normal during cranking.  I had Kevin watch the chain through the plexiglas window while I was cranking the engine, and he said the chain looked fine.  We began to think that maybe something had come loose in the engine, hit the reciprocating assembly, and got punched through the oil pan.  The oil was completely gone from the dry sump system, but maybe there had still been some oil in the tank while the engine was running, and after I stopped the car it all drained out through the hole in the pan; I hadn't seen the hole until 15 minutes after I'd parked the car. 

Kevin suggested that we pull a valve cover and see if we could see anything wrong in the top end; maybe a rocker adjuster broke, fed down through the timing cover to the pan, and got kicked out.  But I was going back to the pass down the track; the "miss" may not have been a miss at all, it may have been a broken component that finally came loose halfway down the track and freed up the engine to rev normally.  The whole thing was bad karma.

At Drag Week in 2007 I blew up a supercharger on the drive down to the event, and then after replacing that broke the transmission at the test and tune, and Joel and I stayed up all night pulling the transmission, having a local trans guy fix it, and re-installing it so we could race the next day. But at 56 years old, those days are behind me; I wasn't up for a massive thrash that may or may not fix the car.   After all the work I'd put into this car over the last few months, I had already decided that if I developed a major problem at Drag Week I wasn't going to bust my hump to get it fixed.  And this was obviously a major problem. 

So, Steve and Kevin and I packed up the truck, and with the help of a bunch of other guys rolled the car onto the trailer and tied it down.  On the way out of the track a bunch of the guys waved at me, but I just didn't feel like talking to them.  We should really go to the track tomorrow for the first day of the race, but I just have no desire to explain to an endless group of people why I'm out of the race already.  Steve and I will hit the road for home tomorrow morning.

Since I have the week off I'm going to spend a couple days cleaning up the shop, because it is just a disaster after the Drag Week thrash.  Then, I'm going to take the engine apart and figure out what went wrong.  With luck the reciprocating assembly will be intact, but I'm not holding my breath.  One positive is that the water jacket is intact, so whatever happened didn't compromise the water jacket of the engine.  I will try to put a post up here next weekend with what I've found.

Now that there's no point in keeping secrets anymore, this engine made 970 HP at 7200 RPM on the dyno.  It hit 950 at 6500, and was still making around 955 at 7500, which was as far as I ran it on the dyno.  It was a little lower than I was hoping for, but the intake manifold and headers were definitely not optimized for the engine's RPM band, so I was reasonably happy with the result; I have never had a naturally aspirated engine that made more power.  At the track a couple of weeks ago the best pass was 9.32 at 147.5, and the converter was stalling around 6000 RPM, which was about 500 RPM too low for this engine.   The 60 foot time was only 1.46 for that pass, which is way, way low; should have been a good two tenths faster, and probably 3 tenths faster for the ET, if I'd had the suspension tuned properly, and a decent set of tires plus some track prep.  The car should have run 9.0 at Drag Week, and my goal was to get into the eights sometime this week.

Once again, thanks to all you guys for the encouragement and support on this project.  I'll get the car fixed and get it back on the track next year, and we'll see what it will really do...

191
The Road to Drag Week 2014 / The Road to Drag Week 2014 - September 6
« on: September 06, 2014, 10:47:02 PM »
After the trauma of Thursday night this week, when I thought the engine had a rod knock, and the relief I felt having that possibility dismissed on Friday afternoon, I had a hard time getting too much done on Friday night.  Steve was over to give a hand around 6:00, but I had hardly slept a wink on Thursday night so I told him to go home because I needed to rest for a while.  We figured we could get everything packed up on Saturday morning and head out around 9:00 or so.  After crashing in the house for a couple hours I got back out to the shop, and put the car in race trim in preparation for putting it on the trailer.  I also readjusted the four link setup to where I thought it needed to go, based on the last test and tune results, and then worked on some minor issues (grilles in the hood, and a seal to the hood around the top of the intake) until 11:00.  I went to bed and set the alarm for 6:00 because Steve was going to be over at 6:30.

Even though the alarm came on early I still felt better than I had in a couple of days.  By 6:30 I had packed all my clothes and headed out to the shop to start getting all the stuff ready for the trip.  After a bunch of years at Drag Week I have a three page checklist that I go through to make sure I don't forget any tools, spare parts, or other important stuff.  Each year it is a little different based on the car I take, but I'd been working on it during the week to make it up to date for this car, so I got started with it right away, just as Steve showed up.  There were a few spare parts that I was bringing along that required disassembly; for example, I brought a spare pair of SOHC cams, but these were bolted into another set of heads so the cam caps had to be removed before I could get the cams out.  Also, I only have two complete sets of the T&D rockers, so I had to take one of the heads that's on my Galaxie apart to grab some spares.  After 2008 I will always take some spare SOHC rockers LOL!  All the spares, tools, and chemicals got collected in one spot of the garage, and then Steve put them in boxes and started getting them loaded into the back of my pickup.  We had already loaded the Drag Week trailer into the truck, so after that was tied down a bunch of stuff went right into the trailer.  As usual all this took longer than expected, but by 10:30 we were ready to hit the road for the 11 hour drive to Tulsa.  Here's a picture of the truck and trailer; that's Steve by the passenger door:



The drive to Tulsa was long and boring, thank goodness  ;D  We got in right about 9:30, and are now at the hotel.  We expect to be at the race track by 7:30 tomorrow morning for registration, and should be able to get through registration and run the test and tune by around noon or so.  I'm looking forward to seeing some of my Drag Week pals again, and getting some pictures of other people's cars.  I'll post another update tomorrow night.

192
So I'm just getting around to putting some of the final touches on my Shelby clone.  One of them is the steel grating that goes in all the hood openings, and the two front fender openings.  It looks like I have to trim and glue these pieces somehow to the fiberglass.  Any suggestions on what adhesive I should use?  It should probably be clear, or black to match the grating, and it needs to stick pretty well to steel, raw fiberglass, and painted fiberglass.  The pictures below show the grates and the inside of one of the hood openings:






193
The Road to Drag Week 2014 / The Road to Drag Week 2014 - August 31
« on: September 01, 2014, 12:09:41 AM »
This week my objective was to get the car street drivable, and get it to the track and make some passes to further tune the suspension.  On Tuesday I decided on a new set of race tires, and had them mounted and balanced by Thursday.  The specs from Hoosier said that these tires were only 0.2" larger in diameter than my existing tires, but they turned out to be 0.75" larger in diameter instead.  I got them mounted on the car on Thursday night and realized I wasn't going to have enough clearance.  I felt I needed the tire, though, so I did a little wheelwell trimming to make sure that I'd have the required clearance at the track.  This went off pretty well except for one spot at the rear of the driver's side fenderwell, where I had trimmed the fenders originally before I painted the car.  There was a little body filler there, and as I trimmed the wheelwell it cracked and a small chip came out.  No big deal, and my friend Steve said he can fix that up this week during the week so the car will still look good at Drag Week.

Also this week I tuned the EFI system to run a little better at low engine speeds, and added a drain to the bottom of the fuel tank so I could drain out the pump gas and fill up with race gas at the track.  Finally I machined some air cleaner bottoms for the Accufab throttle bodies, and cut some tops out of some 1/8" aluminum sheet, so I could run air cleaners on the street.   Friday night I filled the tank with 92 octane pump premium and went out for the first street drive in the car.  I was a little concerned about how it would cool at freeway speeds with the electric water pump, but it ran down the road at 70 MPH and 3000 RPM at 180 degrees, and would drop to 170 at 2500 RPM.  The weather was kind of cool, though, so down at Drag Week I think I'm going to have to watch the temperature, but I think it will stay in the 200 degree range on the freeway even if its 95 degrees out.  The car needed a little more idle setting with the pump gas, but it behaved fine in traffic and was perfectly happy at idle and part throttle conditions.  Towards the end of my shake down cruise it started raining, and I found out pretty quickly that I'm going to have to be light on the throttle in wet weather, as the rear end of the car came around on me a couple of times with pretty minimal acceleration.  Other than that it seemed to handle in the rain OK.  After about 40 miles of mixed driving I came back home, satisfied that the car was streetworthy.

Saturday morning was practice for Drag Week.  I was up early, hooking up the Drag Week trailer to the car, then packing it with the race tires, race fuel, tools, jack and jack stands, etc.  By 7:15 I was on the road with a friend of mine who was visiting from California, and my pal Steve following in his minivan.  We were headed for a local 1/8 mile track for their test and tune, about 70 miles away.  The weather was overcast when we left, but the weather report said that it would be clear at least until early afternoon, so I figured I could get some passes in after the track opened at 9:00.  Halfway to the track, though, that plan evaporated when it started to rain.  It sprinkled on and off all the way to the track, so when we got there I just parked the car and waited.  After and hour or so the rain stopped and it started to lighten up.  When the track dryer started working on the track I disconnected the trailer and started getting the car track ready.  I got the car teched and was ready to race by 11:30 or so, but they were still working on the track; apparently the light and timing system was wet and giving them some problems.  Finally, around 12:30, the track announcer came on and called the test and tune cars down to the staging lanes.  But, literally within 30 seconds of his announcement, it started to rain again.  We ended up waiting around for another hour, and then they called the test and tune.  So, I got rained out on the test and tune.  We put the car back into street trim and headed home.

The drive home was uneventful, and I now have over 150 miles on the car with no issues.  But I still haven't run with the new tires, and still haven't really finished tuning the suspension.  Tomorrow since I have the day off I'm pulling the transmission back out, because my new converter is supposed to be here on Tuesday.  I have a punch list of about 20 small tasks to do on the car besides swapping converters, plus I have to get packed up and on the road to Tulsa next Saturday.  Its going to be another busy week.  Drag Week registration and test and tune is one week from today, and the race starts a week from tomorrow.  I'll post another update from the event next weekend.


194
So I'm thinking that my Drag Week car could use a new set of tires to optimize traction.  The engine is pretty strong, and only 42% of the car's weight is on the rear tires, so the hook is a challenge.  The current tires are Hoosiers, 29.5/10.5 - 15, about three years old.  They have limited use, probably only a couple dozen passes on them, but at 3 years old I think they are not in prime condition anymore, so I've decided I want to replace them before Drag Week.  This past weekend I had the best luck running only 12 psi in them.  One of the guys who was at the track with me this weekend thought that the outer 3/4" to 1" of the tires was not making good contact to the track, so if anything I will probably need to go down in pressure.

Also, I'm considering going tubeless next time around.  Those tubes are heavy and take a fair amount of horsepower to turn, so I'd like to ditch them if possible.  Currently I'm running tubes in the tires, because I had a bad experience going tubeless back in 2007, but I think I'd like to give it another go. 

Finally, I want to stick with bias ply tires.  I've tried radials and found them to be very sensitive to suspension settings.  Since I'm just working out the suspension on this car, I don't want to add the variable of a radial into the equation.

I've kind of narrowed down my options to these three:

- Stick with the setup I've got, and just get new tires of the same size/brand from Hoosier.  Use the same tubes, and live with the extra rotating weight of the tubes.

- Get new Hoosier tires, but run them tubeless.  The issue here is that the tube helps stiffen the sidewall of the tire, so without the tubes the sidewalls will get even more out of shape than they do currently.  Add in the potential for a lower tire pressure, and the potential for the car to get out of shape on the top end is growing.  Also, I've been reading that heavy, higher horsepower cars like a stiffer sidewall, and of course going tubeless with the same tires is moving in the wrong direction.

- Try a different brand/size of tire.  I have my eye on a Mickey Thompson ET slick, #3068W, which is about the same size as the Hoosiers except for the diameter, which is about 0.75" larger.  As it is I'm very, very close to  hitting the fenderlips with the tires I've got, so that's a downside of the larger diameter.  But the M/Ts have the stiff sidewall, so I could run them tubeless.  Probably have to trim the back of the fenders to make these tires work, which I really don't want to do.

Any opinions on this?  Or any better ideas?

195
The Road to Drag Week 2014 / The Road to Drag Week 2014 - August 24
« on: August 24, 2014, 09:33:40 PM »
FINALLY made it to the track this week.  Monday night through Friday night I went through a fairly major punch list to get the car ready for the track, as follows:

- Revamp throttle linkage so it fits under the hood
- Install the hood and adjust
- Measure locations of four link holes
- Plot 4 link possibilities in CAD program, calculate possible instant centers
- Adjust for "best guess" four link bar locations
- Install collector tethers (new NHRA rule)
- Install up to date seat belts/harness
- Install hood hold down latch
- Fabricate installation straps for flywheel cover, install cover
- Install dash pad, connect oil pressure warning light and shift light
- Tie up wiring on wiring panel, reinstall panel under the dash
- Wrap the wiring under the hood with protective sheathing
- Install roll cage side bars
- Install parachute and connect parachute cable
- Wash car, vacuum interior

As I'm sure you can see I had a busy week, burning lots of midnight oil to get all this done.  I finally got done on Friday night but was too tired out to load the car on the trailer, so I left that for Saturday morning before I headed for the track.

One of the interesting parts of the week was  trying to figure out the best location for the four link bars.  There's lots of online information on this subject, and so I spent some time in the evenings doing a little research after I had mapped out the hole locations and drawn up a picture of the car in my CAD program.  According to the online web sites on this topic, one thing you need to know is where your "anti-squat", or "normal" line is.  This is a line connecting the rear tire contact patch to the intersection of a horizontal line running forward from the car's CG to a vertical line running straight up from the center of the front wheel.  The instant center is then calculated by extending lines forward from the four link bars until they intersect.  The position of the instant center relative to the anti-squat line will tell you something about how the car will behave on launch.

Having the instant center directly on the anti-squat line, and lined up with the CG, is supposed to give you the most efficient launch.  Using the CAD program I was able to find an upper and lower bar position that was very close to this point.  Here's a picture from my CAD program showing these positions:



In this drawing the instant center is about 4.5" behind the CG, and is right on the anti-squat line (referred to as 100% anti-squat).  Another alternative was to have the instant center below the anti-squat line; the web sites said that this less than 100% anti-squat, and would cause the rear of the car to squat when it leaves.  This results in a softer "hit" on the tires.  Stick cars that drop the clutch or automatic cars that use a trans-brake are supposed to hit the tires pretty hard to begin with, and so they may need less than 100% anti-squat to maintain traction.  The drawing below shows one of the positions I mapped that had much less than 100% anti-squat:



Notice also that the drawing above has the instant center far forward of the CG.  This will tend to raise the front end on launch.  An instant center behind the CG will tend to raise the rear end of the car on launch.

You can also position the instant center above the anti-squat line, for more than 100% anti-squat.  This is supposed to hit the tires harder and result in better traction, but at the cost of wasting energy by raising the rear of the car on launch.  In the drawing below the instant center is positioned for much more than 100% anti-squat, and also it is behind the CG, causing the rear of the car to rise on launch:



I have a transbrake on my car but was planning to footbrake it on the launch at the track; just holding the RPM to 3000 or so on the line, and then releasing the brake and mashing the accelerator on the last yellow.  As a result, based on what I'd been reading, I figured if anything I might need more than 100% anti-squat, and I also wanted to be sure to sneak up on any instant center location forward of the CG, in order to avoid an unexpected wheelie.  So, I set up the car to be neutral as shown in the first drawing above.

Saturday morning my friend Kevin came over early and helped me get the car loaded on the trailer and truck all loaded up.  We hit the road for the track around 7:30.  After a few miles I stopped in a Menards parking lot to check the trailer and the car tie downs; here's a picture:



And yes, that is my brand new F-150  ;D ;D  It has the Ecoboost V6, a built in electric brake controller, and other options like trailer sway control.  It pulled the trailer beautifully on the 120 mile trip to the track, and got about 13 MPG while doing it, which was much better than my 2005 F-150 with the 5.4L ever got.  I am rather amazed at the power and driveability they got out of that little 3.6 liter V-6.  The two turbos certainly help...

At the track we were met by my friends Kurt and Steve P., who had come to help out.  The weather report said that there was a chance of thunderstorms and it sure looked like it, with the weather being overcast and extremely humid, but we must have lucked out because it turned out to be dry all day.  After getting the car unloaded and then through tech, I started making some passes right away.  I had no idea what to expect on my first pass, so I just did a pretty good burnout and let 'er rip on the last yellow.  The front of the car came up but the wheels spun violently.  I made a complete pass but was pretty much all over the track doing it.  The time was not too impressive, much slower than I had been hoping for.  Track prep was obviously a problem, but so was the car's setup.

After coming back to the pits I talked with the other guys about how the car was working.  It was leaving with no rear end movement, indicating that the instant center was indeed on or very close to the anti-squat line.  The guys also told me that the track was wet forward of the water box, and that I needed to release the line lock and come out of the box a good ten feet with the tires spinning to get them dried off.  After kicking it around a little I decided to change the instant center right away, moving the bars so that I had more than 100% anti-squat.  I had brought all my CAD charts with me so I knew where all the different positions of the bars would put the IC, and I picked the one below, to keep the IC close to the CG but just give me a harder hit to the tires:



After making the adjustments I went back out for the next pass.  This one was positively embarrassing.  After doing a pretty good burnout, which I'd hoped would help, the car left the line spinning even harder than before.  The next instant the rear view mirror flew off the windshield and landed on the shifter, and the shift light flashed, and I shifted all the way past second into neutral and hit the rev limiter.  I let off and coasted down the track to an 18 second ET  >:(

Back in the pits Steve P asked me how it was possible to miss a shift with a two speed transmission.  That smartass LOL!  After a ten minute break I went back out, determined to do a little better.  I had put the rear view mirror back on, but it needed a Torx wrench to tighten it, and I didn't have one, so I did the best I could with an allen wrench.  Didn't help, the damned thing flew off again on the launch.  Again I had no traction, and got out of the groove after the 1-2 shift, and coasted down to a 12 second ET.

Back in the pits we were thinking that the tire spinning had gotten worse, not better, with the change to the instant center.  We decided to do one more thing before going back in to mess with the bars again, and that was to lower the tire pressure.  I had been running at about 13.5 psi, so we reduced it to 12.  I hadn't really wanted to do that, because going much below 13 makes the car kind of squirrely on the top end, and at the speeds I was running I didn't relish that possibility, but then if I didn't have any traction it was a worse situation, so we brought the tires down to 12 psi.  Back out on the track I had given up on the rear view mirror and left it in the pits, so at least I didn't have that distraction.  The car still spun the tires but I was able to stay in it this time and get in a full pass.  60 foot time was no better than any of the others, but the car at least seemed more drivable off the line with the lower tire pressure.

It was around noon now and so we took a break for some track food, and then I crawled back under the car to reset the four link bars.  I was pretty convinced I'd gone the wrong direction the first time, and that I need to lower the instant center for less than 100% anti-squat.  I also thought it would be a good idea to move the instant center forward of the CG, because the car had shown no tendency to pull the front tires on any of the previous runs.  The IC position I ended up at is shown in the drawing below:



The next pass was much better; the tires still spun hard but the car was much more controllable on this pass.  60 foot time was still dog slow, but the car just felt better.  I was convinced that moving the instant center was an improvement this time.  For the next pass, I decided to try some pre-load on the right rear tire, to help even out the traction.  You do this by shortening the right upper bar in the four link setup; I shortened it by about a half turn.  I also set the front struts a couple clicks softer on the extension setting, so that the front end would rise more easily.  Back out on the track the car felt about the same, with a very marginal improvement in 60 foot time and ET.  Still nowhere near where I thought it should be, but at least we were moving in the right direction.  With the air we had, and the slippery track, I knew there was going to be a limit to how well the car did.

My friend Kurt had been coaching me on the four link stuff, because I'm kind of a newb when it comes to that, and he has set up a bunch of four link cars.  He had been putting tie wraps around the rear shock shafts to see how far the shocks had been moving on the launch, and now he crawled under the car with me and showed me that the right rear shock was bottoming out on its travel, while the left rear still had a good half inch of  travel left.  Kurt suggested we adjust the right rear coil spring on the coilover shocks to make it stiffer, and try to keep that shock from bottoming out.  So, I put two turns on the collar to compress the spring on the right rear shock, and went back out for pass #7.  This time something funny happened.  Before the burnout as I sat in the box, one of the track guys came along and was looking very carefully at the starting line.  Kind of like he was looking for a problem.  After a minute or so he gave up, and they gave me the signal to do the burnout.  But this time when I launched the car darted to the left on the launch, and I had to back out of the pass after 100 feet or so.

Back in the pits we concluded that it must have been the track, because none of us could see how the change to the spring could have caused that big of a change in the car's launch characteristic.  We were almost out of time for the test and tune, but I decided to make one more pass.  We got the tire pressure right back to 12 psi, and this time I chose the other lane for the run.  The result was the best run of the day, more than two tenths quicker than the best previous run.  Sixty foot time improved by .05, but it still sucked. 

At this point I figured I was track limited, and with the test and tune over we packed up and headed home.  Today I got the car back into street trim with mufflers and street tires; this week's project is to get the car tuned up on pump premium and put a few miles on it before next weekend, just to check everything out for street driving.  Next Saturday is another test and tune, at a different track which is only 1/8 mile, but has a reputation for better starting line prep.  I'll be continuing the chassis tuning next weekend, hopefully with some better 60 foot times.  Drag Week starts two weeks from today, and while I'm sure I won't have the car perfectly dialed in, at least it will be in the ballpark before the start of the event.  Here's a picture of the car sitting in the pits, and another picture of it doing a burnout at the track on Saturday, courtesy of my friend Kip, who showed up to spectate later in the morning; I'll post another update next weekend.





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