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The old 'too light rotating assembly for street' debate

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Injected

15+ Year Contributor
704
16
Apr 29, 2004
Houston, Texas
In my quest for knowledge I have run into a dilemma. I have been researching the affects of changing reciprocating weight for quite some time and have run into people who will say that you can't go too light for street use, and others who will say that you can. Obviously the application matters, and I am talking about street use. When launching the car with a lighter rotating assembly (RA) it is necessary to rev to a higher RPM because the lesser force of the rotating mass (RM) will be offset at lower RPMs to overcome the force necessary to accelerate the mass of the car (physics people and engineers nod if your with me). If the rotating mass is "too light", then presumably the work (actual term relating to force) to accelerate the car at a specific rate will bog if the RPMs if launched too low.

A lighter RA is seemingly accepted by the general population as a good thing for street use as you see light weight pulleys, gears, knife edging cranks, etc. Is there a tolerance level or threshold associated with lightening the RA for street use? Is there anyone out there with a rotating assembly that is too light and they can't easily drive it on the street? Or is the culprit the clutch necessary to launch at such high RPMs without bogging?

RRE's site says "Which one do you want? Aluminum, XACT or lightened stocker? They are all good. Get the lightest one that you are comfortable with and that your budget allows," and I believe that when they sold the Fidanza flywheels they had a little excerpt about those not being too light. That may be tolerable if that is all you do to lighted the RA, but there are many other things that you can do.

FFWD Connection, who is making quite a name for themselves, sells their almost-world-famous "butcherized" cranks, about which they say "As if that was not enough, and feeling a little sassy, we lighten the crank by 7 pounds which results in even quicker revs and increased horsepower by eliminating that extra rotating weight. Now, I know what you're thinking but don't sweat it...our lightening procedure does NOT hinder its reliability nor its function. In other words, GO POUND ON IT! Couple that with an aluminum flywheel and rods, and you're talking about a motor that will rev as quickly as a crotch rocket."

Can someone shed some light or open up discussion about this subject?

Oh, and to throw numbers at it, using the formula for changes in effective mass by reducing RM given by Dave Coleman, using a ligthweight flywheel (9 pounds lighter than stock) and the "butcherized" crank (7 pound reduction), a 2G GSX would accelerate as if you had removed about 250 pounds from the chasis in first gear. Add some lightweight pulleys, lighter pistons and rods, and cam gears and your probably looking at closer to 325 pounds.

Thanks in advance to anyone who will help. I'll throw some rep points to anyone with good information/experience.
 
Although I won't be able to add to much to the technical side of this I do have vast personal experiance with this subject so I figure I can help a bit.

I do beleive there is "too light" for the street for some people, it all really depends on what you can tollerate. I don't know how much my eagle/wiseco combo removes from the RA but I also have a Fidanza flywheel. I have also extensivly driven a car that had a knifedged crank/fidanza flywheel. As far as my car goes It does in fact rev much freeier(is this even a word??) and alot faster than it did with the stock flywheel in the car. It is a deffinate must to launch the car at a higher rpm. My first time out at the track with the new flywheel was a very frusterating experience for me as I had to learn to launch the car all over again. This also translates to you having to change your driving habits on the street.


You will first notice that your car feels noticably torquier when driving off boost around town. Throttle repsonse seems to be a bit more responsive and the revs fall alot faster between shifts. It gives the car a much more "crisp" feeling I guess you could call it. There isn't that lag between where the car starts climbing in revs and starts to fall again. However all of this comes at a price for street driving. It really doesn't bother me and you do get used to it but some people might be bothered by the inherent negatives that you get from lightening your RA.


The first thing you notice when driving the car on the street is that you much rev the car higher for take off and you need to slip the clutch alot more. If you don't obviously you bog. The next thing you notice is that is take a decent amount of clutch modulation to get smooth shifts between gears. If you try to shift like you normally would the car jerks and you look like a tool. Alas, it is nothing you can't learn to drive around. The big kicker when lightening your rotating assembly is driving in traffic. I will be blunt here, it ####ing sucks!! I am used to it but I detest driving in traffic with a lightened flywheel. The car wants to lunge at low rpms not matter what you do. You constantly have to be on the clutch and gas modulating back and forth to ensure a smooth ride. This will eventually lead to premature clutch life and a very large left leg:D . This won't really be a problem if you don't DD the car but for discussions sake we'll just assume that you do daily the car. During traffic driving you must keep the car above 2k rpm or be moving at a decent speed if you ar to keep it under 2k.

Driving the car hard however is where the true benefits of these mods shine. Rev matching/heel-toe/whatever you want to call it is super easy. Shifting between gears at higher rpms seems easier as well, although I can't back this up just personal feelings. The car seems to accelerate better as well. You really have to drive one to see the difference. Like I said I have also driven a car with a knifedged crank and it turns our engines into honda like revving machines. Its rediculous how fast the engine revs with a KE crank and lightened flywheel. Once you get moving it pretty much the same as driving with only a lightened flywheel but the car does rev alot more freely.
 
Well.. 7#'s off the crank from knife edging is'nt a very high Hp to $ mod...

A lightflywheel... I prefer SSG... Is needed as you will need a SFI approved one anyway to avoid flywheel explosions..


There is a BIG difference between the effects of reciprocating.. Up down... Vs rotating weight..

I'd run wiseco pistons and eagles... You can go fancier with the rods. SBR has the biggest selection look/ask for weights. Even the lightest aftermarket rod will handle what most ppl will throw at it hp wise.. Looking for like 1,000hp no but anything with a GT35R and under wont kill eagles on a good tune... There is carillo and others..

I think 1 ounce of reciprocating weight like a lighter piston is equal to taking a pound of the rotating mass..

A crank is just rotating mass.

A rod is both recip and rotating..

The big end is rotating mass and the small reciprocating.. The middle (beam) is a bit of both...

Pistons are all reciprocating...

It takes a bit more finess to get a light bottom end to not bog in grandma like driving at lights...
 
when my car was last running i had a clutch/flywheel combo that weighed in just over 14 pounds..... that entire assembly was lighter than just the stock flywheel... not including a clutch.... also the clutch was a racing twin disc unit that functioned more like an on/off switch than anything else.....

daily driving was definitly a pain for the first week or so till i got used to it.... and the low rpm low speed lunging previously mentioned is not fun at all..... but once you drive it for awhile you will get to a point where nobody can drive your car like you can, and you will love the extra power at the track... but it does kinda suck in heavy traffic.
 
Thanks for your responses guys.

There is actually a formula used for calculating the effect of taking mass of the RA vs taking it off of the chassis. You must use the radius of the object, the gear ratio in which you want the calculation and final gear, total tire height, and the mass change of the rotating object. 1 pound off the crank is like taking 10.69 pounds off of the car. 1 pound off of the flywheel is like taking 20.83 off of the car. The difference is the radius of the objects. With something small like a pulley, the affect is lessened to more like 5 pounds of effective weight depending on which pulley and the mass change.

Drivability is my main concern, modulating the clutch isn't really a big deal to me. The idea is to use a KE crank, lightweight flywheel, aftermarket rods, lightweight pulleys (all of them, but not a non-harmonic crank pulley), lightweight adjustable cam gears, yada yada yada...

I guess now I should determine what clutch is optimal for a setup like this. I'm thinking the 3500 carbon kevlar clutch from SBR.

"This kit uses a 2500psi pressure plate with 1/2 the pedal pressure of an ACT 2600. Its easier on hydraulics, pivot balls, clutch forks, and best of all THRUST bearings. The This kit also uses an alloy backplate to act as a heatsink for more durability. The disc is made of Carbon Kevlar weave NOT Fiber like Clutch Masters (CM requires perfect break in otherwise it slips). Our clutch has no Break in, just put it in and drive! The lining of our discs are softer than ACT and will not chatter (perfect replacement for ACT street disc). Kit includes a factory Mitsu throwout bearing and alignment tool.

This is the same clutch used in our 400whp 16g car!" - Slowboy Website

Sounds like a good clutch.
 
One opinion which may be good to ask of would be Ludacris'. If I'm remembering correctly, there's a thread around here somewhere discussing his issues with his car stalling and the cause was suspected as "too light" of a rotating assembly.
 
Scrymerr said:
Does anyone have evidence pertaining to undampened crank pulleys and their longterm affects on an engine (both balanced and stock.)

If you are trying to lighten the RA, start with a flywheel as it will have the greatest affect. I would save the undampened crank pulley for a race only application, I have heard of it being the suspected cause of uneven wear of crank bearings. Not sure as to what you mean by unbalanced vs. stock. An unbalanced crank pulley will not absorb the oscillations of the crankshaft any more than a balanced one.
 
ISUJakey said:
One opinion which may be good to ask of would be Ludacris'. If I'm remembering correctly, there's a thread around here somewhere discussing his issues with his car stalling and the cause was suspected as "too light" of a rotating assembly.

Can you find the thread and post a link?
 
Injected said:
If you are trying to lighten the RA, start with a flywheel as it will have the greatest affect. I would save the undampened crank pulley for a race only application, I have heard of it being the suspected cause of uneven wear of crank bearings. Not sure as to what you mean by unbalanced vs. stock. An unbalanced crank pulley will not absorb the oscillations of the crankshaft any more than a balanced one.

Thank you for the response, however I think you missed what I said. First of all, I have already have an aftermarket FW. Secondly, I have 'heard' it being the 'suspected' cause of premature bearing wear as well, but have no evidence. The balanced vs unbalanced is in reference to the RA. If the rotating assembly has already been balanced, then I have heard that the dampener is not necessary, but again have no proof.
 
Scrymerr said:
Thank you for the response, however I think you missed what I said. First of all, I have already have an aftermarket FW. Secondly, I have 'heard' it being the 'suspected' cause of premature bearing wear as well, but have no evidence. The balanced vs unbalanced is in reference to the RA. If the rotating assembly has already been balanced, then I have heard that the dampener is not necessary, but again have no proof.

The DAMPER is necessary... Its a DAMPER not a balancer.

Read this..

Damper Basics
http://www.atiperformanceproducts.com/products/dampers/101/index.htm

Why power pulleys suck.
http://www.atiperformanceproducts.com/products/dampers/damper_dinan.htm
 
MNGSX said:
The DAMPER is necessary... Its a DAMPER not a balancer.

Read this..

Damper Basics
http://www.atiperformanceproducts.com/products/dampers/101/index.htm

Why power pulleys suck.
http://www.atiperformanceproducts.com/products/dampers/damper_dinan.htm

Well, I guess that answers Scrymerr's question. I'd give you more rep points MNGSX, but it won't let me now.
Scrymerr said:
Thank you for the response, however I think you missed what I said. First of all, I have already have an aftermarket FW. Secondly, I have 'heard' it being the 'suspected' cause of premature bearing wear as well, but have no evidence. The balanced vs unbalanced is in reference to the RA. If the rotating assembly has already been balanced, then I have heard that the dampener is not necessary, but again have no proof.
I'm not sure that I had much to miss or take away from what you originally said. If you have a lightweight flywheel, then I would go with pulleys next. Now that MNGSX has provided us with evidence on why the dampning pulley is needed, you can look for a lightweight dampened underdrive pulley. I think Buschur makes one. Let us know if they have much of an affect.
 
99gst_racer said:
Here you go: http://www.dsmtuners.com/forums/showthread.php?t=161642&highlight=flywheel

I do believe there is such thing as "too light" for a street application, however, I do not believe a lightweight flywheel and/or knife edged crank should be classified as "too light". But that's just my opinion.....
Dammit, I can't give 99gst_racer anymore rep points either. Oh well, he's a mod and probably can give himself as many as he wants. :D

Seriously though, I know why we have that rule, but it's a bit to restrictive. I run into people who help all the time and can't give them rep points, which is the whole point in accumulating them.:notgood:
 
The KE crank is just the most expensive of the lightening methods..

A lighter flywheel has a greater effect.. Even just a 7lb lighter one as the dimeter is greater so the mass reduction has the most effect... weight at a greater distance from center has more inertia.

Weight that must move up and down must be accellerated and decellerated increadibly fast and constantly.. Which is why rod and piston/pin assembly weight is good for ALOT.

Also a KE crank is'nt the ultimate either.. You can CNC lathe the weights into a pendelum cut profile. You could also get a custom SCAT feather weight.. Not in the catalog but they say for the right price they will deliver one..

The windage reduction and subsequent power gain of KE'ing a stocker would be beat by using a belt driven vac pump like a moroso.... Windage would drop. Dipsticks stay put and rings seal better...

ATI has a new damper in the works for us and the evo... I posted it a while back...

It dampens alot better than the stock one and is lighter with a much better crank gear....
I guess the engineers found the stock gear to give too much to acheive the full dampening effect.

As for engine stalling it only occurs during free decelleration..

Hop off the throttle and floor the clutch to let the motor twirl down from high rpm...= stall...

Slow the engines decelleration using more clutch friction and you are fine..

Also many aftermarket ecus alow you to make up for it with the engine decel spark timing curve..
 
Getting used to a lightened RA, is persay like getting used to a new short throw shifter. For the first few days, its like a completely new car, and your still getting used to the way it works. You may miss some shifts and look like an ass the first few days, but after you get the hang of it, your golden.

Everyone I know that is running a aftermarket XACT or Fidanza Flywheel along w/ a clutch setup, love it. They all DD the car and all say its just the initial getting used to the new setup is key. If its quite difficult for you, try practicing driving on a non populated road, and pretend if you were in heavy traffic.

FWIW, this season I will be runing a 2.3L w/ Eagles and Wiseco's. Crank is not lightened. Of course no balance shafts. The crank, pistons and rods have been balanced as a RA. I will also be using a ACT 2100PP w/ SBR streat disk along w/ a Fidanza AL Flywheel. The car will be a DD summer car and see weekend track use.
 
I can give alittle input here to as i've been running an ACT 2600/Xact combo for about 2 years now.

Throttle response was definately improved. That was the first thing i noticed. The car decelerates much quicker when downshifting or just gettin off the gas too. It was a bit of a pain to relearn shifting the first couple days but nothing that was horrid or anything. I can't speak for having to launch higher as my car still had the original clutch in it when i bought it so i didn't want to take any chances till it got replaced.

The only downside is exactically what people here have already stated. Slow stop and go driving. Traffic can suck if your stuck in it too long. But i feel that's more of the clutch than the flywheel. No doubt that you have to work the clutch and gas alot more to keep a nice steady 0-5mph creep going on but if the clutch pedal was lighter it wouldn't be as big a deal (not that it is a big deal). Occasionally when your at these low speed creeps if you hit the gas alittle too much the front of the car will jump up and then you get off the gas real quick and it'll drop back down real fast. Sometimes they can actually get quite violent if you let it go like that. It takes more finesse is what i'm saying. The worst thing i've come across is if you happen to have a bad case of idle surge. I feel the light weight flywheel only makes it worse. It will rev and drop pretty fast sometimes which really takes a toll on parking lot driving. But you should fix that damn surge anyways so you could look at it as a bigger incentive to do so.

Hope this helps.
 
MNGSX said:
ATI has a new damper in the works for us and the evo... I posted it a while back...

It dampens alot better than the stock one and is lighter with a much better crank gear....
I guess the engineers found the stock gear to give too much to acheive the full dampening effect.


Do you have any idea when this would be available? The BR one is about $350, but I didn't see it on their page last I checked.
 
Thanks for the link about Luda, but it doesn't say how he resolved the issue. Go figure.
 
ISUJakey said:
Thanks for posting the link. I hadn't had a chance to search for it.
Yeah, no problem. :thumb:

Injected said:
Thanks for the link about Luda, but it doesn't say how he resolved the issue. Go figure.
I'm sure if you PM him and ask him to follow-up on his thread, he would gladly do so.
 
I'll hit Luda up for the information.

Does anyone know if DSM Link allows an adjustment for the problem that some are experiencing with light RA's?
 
I would imagine. One of the things I do to help fight the issue of stalling after shifting to neutral is to have aem hold my idle at 1100 rpm untill I am under 5mph. That way it is a high enough idle to keep the car from dying. Below 5mph and my idle is a smooth 850rpm.
 
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