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Meanwhile in Czech republic part2 2015 build/FIBERGLASS 2G SHELL/ LIGHTEST 2G Auto AWD attempt

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MarsaGSX

15+ Year Contributor
487
29
Feb 15, 2004
Czech republic,, Europe
Hi guys.
This is next part of my build..Prewiously wanted start new thread after finish my build.. but got some free time so why not start it now..
Gotta say Iam owner of this 2G AWD since 09/2003! so its kinda evolution LOL
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First of gotta say BIG THANKS to my friend Tyler Hassing from http://www.forceengineered.com/ He is awesome guy..friendly and yeah.. he knows next to everything about this DSMs..Its really awesome have someone like him when building engine and mostly everything about race cars B) Tyler shared lots of know how w me and I appreciate it! Thank you Man!

Last year built new engine.. using Tylers/Force BME aluminum rods and Wiseco HD2 pistons w real 10.5:1cr. Is really shame hide them..put this beauty inside engine LOL
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http://i559.photobucket.com/albums/ss34/9secVenca/2G DSM WEIGHTLOSS/1966708_10202109743998845_2104312390_n.jpg
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stock uncuted crank , kiggly main girdle.
next FORCE stuff is custom crankcase ventilation w baffle plate. That way oil can return from cyl head to oil pan easily.
Extended oem oil pan and some oil pump finishing..just like Tyler said LOL.
Removed Oil thermostat and using remote oil filter for easier change, plus who wants warm up oil filter w 3,5" downpipe..:)

On head went w oem sized Supertechs ,Kelford 294 hl´s , Kiggly race beehives and kiggly oil press regulator. As for porting we went w Tylers idea ..which is say secret LOL

Permatorque and L19s should seal up this two amazing units w boost up to 50psi


Now for this winter build.. main headword is WEIGHTLOSS! as much as possible..
At the end of last seasson weighed my car in say street trim.. and well.. wasnt happy..1340kgs w full tools and spare.. so thats like 1300kgs /2860lbs.
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Gotta say I was pissed cus on the car is almost nothing.. mean I removed ABS, PS,Airbag ecu..really all the common stuff you can find at forums..all was removed..small battery.. Tubular front end, aluminum sheet at rear cargo. light fiberglass seats.all the no need metal brackets are gone.
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Decided go down on weight, but you know the feeling you wanna stay streetable and drive it at streets.. so its pretty hard remove some realy weight plus in my country there is no way drive w roll cage, cops would kick your ass and you would pay high cash..
Last year new drag race series begins and it was very good quallity races.. until last year we had pretty crap racing here..so this Drag series was the last point to DRAG CAR only Label!

Here we start folks! 2G Entire Fiberglass body!
preparing for build mold
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finished trunk mold

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finished trunk
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random pics from fiberglass project :)
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looks like a car huh..?
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Cage will build in into fiberglass body.
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The aim.. there is no weight target at all.. just as low as possible..and as for ET.. is to reach mid 9sec pass this year/ you can say its way overkill to get only mid 9s..but..this is not Drag way racing but old airport field w concrete tracks.. so its way harder get some nice 60´..
Plus the point its pretty hard and pricey get all the drivetrain parts from US... so you really wont broke a thing..
The lighter car the bigger chance not brake.. plus since Iam auto AWD Iam loosing at second half of track..w lighter car engine got easier work :) and there is another part of this build which is be efficient as for aerodynamics.. create low Drag which just like in prewious sentence means engine got easier work for pushing me threw traps :)

Hope you like it as much as I do :)
will be back w progress!
there are few Go FAST parts in mail from Tyler :)

Venca
 
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Wow. Very cool stuff. Wish I could pay you to fiberglass a roof skin for me here in the US!

Did you by chance measure the weight of the removed front radiator cross support? The piece pictured here:
http://s559.photobucket.com/user/9secVenca/media/2G DSM WEIGHTLOSS/1690323_10202080210420524_1245048804_n.jpg.html

and also the weight of what replaced it? It's a piece I've mused about removing on my car.

Thanks!
Only the pictured part was 12,5kgs..27,5lbs plus 11,7lbs and 10lbs lower member which is bolted to the radiator wall.. and finished chromeo front end is 14kgs/ 30,8lbs :) and you can see from pics, my CM front end got lots of bracing cus I was about street racing it... Now will cut out some of the tubing :) looking on every gram LOL)
 
Awesome to see a Kiggly main girdle out there in the Czech Republic! And that fiberglass project looks great. Looking forward to seeing more.
 
Very cool I'm interested to see where this build goes! What part of the czech republic are you in? I travel to prague and kolin for work a couple times a year.
 
Awesome to see a Kiggly main girdle out there in the Czech Republic! And that fiberglass project looks great. Looking forward to seeing more.

Thanks Kevin! Nice to hear this kind of words from DSM Guru! :)
My car rocks lots of Kiggly stuff..high press beehives, HLA press regulator,Front clutch pack,6Bolt in 2G kit :)

Thanks!
 
Very cool I'm interested to see where this build goes! What part of the czech republic are you in? I travel to prague and kolin for work a couple times a year.

Thanks!
Iam about 20miles from German border.. and like 100miles to Praque. Czech is small country :)
 
Very nice congratulations, I also made mine and 2 others completly out of fiber although I took a different path, some parts I did overlays and others from a mold, I did individual pieces instead, since these are road race cars and contact happens, that way only the damage part would have to be replaced.
Will you be able to use a roll cage now for safety and support?
What else will you be doing to reduce weight, I am also a weight nut, take a look at my build, I think I will end up with the lightest DSM ever, even if I have not posted on mine lately, I have made more progress on it.
What lay up are you using?
Mandy
 
Some more pics from Engine build :)
coolant pump mod
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some mess on bench
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plastigage
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some weighing
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checking
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this is not gonan happen LOL)
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oil pump finishing
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All for ONE!
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L19s on!
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Felpro on its place
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Head
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Some lift :)
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Timings w BME solid tensioner on!
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Very nice congratulations, I also made mine and 2 others completly out of fiber although I took a different path, some parts I did overlays and others from a mold, I did individual pieces instead, since these are road race cars and contact happens, that way only the damage part would have to be replaced.
Will you be able to use a roll cage now for safety and support?
What else will you be doing to reduce weight, I am also a weight nut, take a look at my build, I think I will end up with the lightest DSM ever, even if I have not posted on mine lately, I have made more progress on it.
What lay up are you using?
Mandy

Thanks :)
I wanted do whole body and left only front windows opening.. like nascar .. but that would be bit weird LOL.

Roll cage is deff must now... car would broke in half without it LOL Roll cage structure will substitute for metal body.
well.. will remove piece of floor as lots of guys doin. Then wanna cut out rear frame rails right after subframe and whole cargo replace w aluminum sheet. will put CM tube between frame rails. hopefully can add parachute so the CM tube btween rails will use for mounting it. Next remove some brackets and metal pieces at firewall..
 
Some Update!
This weekend cuted my roof and whole body out, plus removed all the unnecessary metal braces and second and third walls. That was tuff...my drill did not want work at all.. milion times had to sharpen..
Weight is going down pound after pound..Still got some metal to cut out at cargo area and rear tail light wall..
Thought about remove wheel well.. but thats the only part which will hold movement of whole car during launching.. If I would cut that whole part out gotta fab some bracing between Tower/ shock mounting point and upper control arms to the frame rail. Not sure if thats worth it.. plus build wheel well from fiberglass or aluminum sheet.

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Finally first time w new FG body
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How you like it guys?
 
You said that bits kept dulling. Are you using a proper spot weld bit? Some times factory spot welds thin 'soft' metal to hardened structure (good example being door crash bars attached to door structure) and so a bit will go easily through the soft layer, but then would practically stop once it hits that hardened section. In that case it might be better to use a grinder and grind off (out) the spot welds, especially since you are not trying to re-use the panels.
 
Hi venca.
You are doing great, do not remove the inner wheel wells yet, you may be able to when you build your cage, try to stick to the one I mentioned to you before.
TIP for your roll cage, I some times use PVC pipe for difficult to measure lenghts and bends and since you are incorporating it in the body it may be of help, although by the picture you sent, you guys will have no problems.
You will also have to clip the very tail of the rear quarter panels so the new piece can slide forward more and a little grinding on that same edge forward will drop in better.
Remember in your case coming of a mold you are trying to replace what is there already.
Leave your floor for last as discussed before
You will have the lightest AWD and I will have the lightest FWD.
How come your turbo set up is so heavy?

Mandy
 
You said that bits kept dulling. Are you using a proper spot weld bit? Some times factory spot welds thin 'soft' metal to hardened structure (good example being door crash bars attached to door structure) and so a bit will go easily through the soft layer, but then would practically stop once it hits that hardened section. In that case it might be better to use a grinder and grind off (out) the spot welds, especially since you are not trying to re-use the panels.
I did my own spot weld bit.. and yeah.. glad Iam over it LOL
Thanks!
 
Hi venca.
You are doing great, do not remove the inner wheel wells yet, you may be able to when you build your cage, try to stick to the one I mentioned to you before.
TIP for your roll cage, I some times use PVC pipe for difficult to measure lenghts and bends and since you are incorporating it in the body it may be of help, although by the picture you sent, you guys will have no problems.
You will also have to clip the very tail of the rear quarter panels so the new piece can slide forward more and a little grinding on that same edge forward will drop in better.
Remember in your case coming of a mold you are trying to replace what is there already.
Leave your floor for last as discussed before
You will have the lightest AWD and I will have the lightest FWD.
How come your turbo set up is so heavy?

Mandy

Yes, will stay w my inner wheel wells now/this year.
Stared working on my cage..did jig for the main hoop
and bars to the front roof hoop and "windshield post runner" into one bar¨ gotta redo main hoop.. cus not fit nicely :(
I´ll be glad w 2300lbs and less :(
Thanks!
 
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