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115: Print Final Parts, Not Just Prototypes! May 24, 2024

Show notes

Is 3D printing going to replace CNC machining in the near future?
Even your Mum has probably heard of 3D printing at this point, but what’s not so well understood — even by enthusiasts — is just how quickly this technology is advancing, and what's now possible when it comes to making your car faster, stronger, and more capable.
One person helping to push that technological envelope is this week’s guest, Joe Dopkowski of 3D Systems.
Use “3D50” to get $50 OFF our 3D Modelling & CAD for Motorsport Course:
https://hpcdmy.co/CADb
Joe has a background in mechanical engineering, and previous to working with 3D Systems, he spent time at OEM manufacturers developing parts for new vehicles. A long-time motorsport enthusiast, Joe has been able to combine his interests and work to push technological boundaries in the pursuit of more speed, working with F1 teams and aftermarket companies like BBi Autosport and English Racing.
In this conversation, Joe starts out by talking us through the history of 3D printing, but what we’re most interested in, is where the tech is at now, and where it’s heading in the near future.
Joe gets us up to speed here, discussing just how far this field has come in a short amount of time, and exactly what’s possible right now with current 3D printing capabilities. This means printing not just prototype plastic parts, but producing ultra-strong, ultra-light finished components from titanium, aluminium, and nearly any other metal you can imagine.
This episode goes deep on all things additive manufacturing, and is going to challenge any assumptions you might have about 3D printing. Prepare to open up a whole new world of possibilities when it comes to creating bespoke performance parts for your vehicle.
Follow 3D Systems here:
IG: @3dsystems
FB: 3D Systems Corperation
YT: 3D Systems
WWW: 3dsystems.com
Don’t forget, you can use “3D50” to get $50 OFF our 3D Modelling & CAD for Motorsport Course: https://hpcdmy.co/CADb
Timestamps:
4:43 When did you develop an interest in cars?
6:19 What does a mechanical engineering degree entail?
12:20 What OE manufacturer did you work for and how was it?
18:05 What is tolerance stacking?
20:50 How did you end up working for 3D Systems?
24:41 Overview of 3D systems.
27:18 What’s your role at 3D Systems?
32:40 What does additive manufacturing mean?
39:06 How do 3D systems plastic printers work?
45:16 3D printing in F1.
54:12 3D printing materials.
1:00:20 Steps between 3D model and physically printing the part.
1:04:47 How much are these plastic printers?
1:06:54 How does metal printing work?
1:11:29 Speed of printing metal vs plastic.
1:13:11 Strength of metal printing.
1:15:15 What areas of motorsport lend themselves to metal 3D printing?
1:19:15 What is generative design?
1:22:28 Cost of metal printers.
1:26:44 3D printing in F1 part 2.
1:35:42 What is 3D printing going to look like in 5 years?
1:43:22 Final 3 questions.

Field Report: Why Do Pro Racers Remove Brake Boosters? May 22, 2024

Show notes

Brake boosters—why don't you find them on race cars? Are motorsport ABS systems harder to use than your OWM setup?
Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in
Ashley Field of 909 Motorsport answers these questions and more in relation to aftermarket ABS systems like those offered by Bosch Motorsport along with how easy they are to install, if OEM components can be used and most importantly how ABS can only regulate the braking power you give it meaning if you don't have an optimal brake package before you fit ABS it can't work any magic to change that for you!
Why fit aftermarket ABS? The likes of Bosch Motorsport ABS systems (note, we don't sell them!) offer advanced features that enhance braking performance and customization compared to standard OEM ABS systems including not going into 'ice mode' when a driver least wants that to happen! While the Bosch Motorsport ABS may require more expertise to set up and calibrate due to its professional-grade capabilities, it provides benefits like faster response times, better grip utilization, and the ability to fine-tune brake bias for improved efficiency and control according to driver preference as well as data acquisition to aid with car and aero setup.
How? Motorsport-dedicated versions of ABS have a more sophisticated 'brain' and valving system, allowing it to lock and release tyres faster, maximizing available grip more effectively.
------------------------------------
TIME STAMPS:
0:00 - Power Vs Stopping Power
0:20 - Factory ABS & Motorsport
0:45 - OEM Vs Motorsport ABS Focus
1:25 - Not All ABS Is Equal
1:50 - Is Motorsport ABS Harder To Use?
2:35 - What Is Different With Aftermarket ABS?
3:13 - 'Ice Mode'
3:38 - What Is Needed For Bosch ABS Fitment?
4:27 - OEM Parts Usage
5:04 - Brake Boosters & Pedal Boxes
6:01 - Why Remove A Brake Booster?
6:45 - Brake Bias Adjustments
7:35 - Crosslinked Brake System
8:02 - Front Rear Split
8:18 - ABS Won't Work Magic
9:00 - Driving Style Vs ABS Setup
9:58 - KEY POINT!
10:36 - Driver Adjustment Options
11:12 - Driver Preference
11:38 - Data Logging & Vehicle Dynamics
12:10 - Thanks 909 Motorsport!
12:25 - BUILD.TUNE.DRIVE

Field Report: Are Genuine Wheels Worth It? May 15, 2024

Show notes

If replica wheels are just as good as the genuine articles like many claim, why don't we see them used in top-tier motorsport?
Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in
Kosumi Wakana from Rays Japan answers this question and more on rim stiffness/compliance, how to identify a replica wheel and where to find help if you can't, along with some of the manufacturing options available to wheel manufacturers like Rays.

114: Project Binky — Stuffing a GT-Four Driveline Into a Classic Mini. May 10, 2024

Show notes

If you’ve spent any time on YouTube, you’re probably already aware of this episode’s guest and the various projects his channel is involved in — most famously “Project Binky”, a classic Mini running a Toyota Celica GT-Four engine and AWD driveline.
Richard Brunning from Bad Obsession Motorsport joins us to down a few cups of tea, talk motorsport, and run through the ins and outs of neverending project cars, the business of operating a popular automotive YouTube channel, and much more.
Use “BAD100” to get $100 OFF our HPA Motorsport Fabrication Package:
https://hpcdmy.co/fabpackageb
Richard, like many guests of this podcast, has his father to blame for his motorsport obsession. Some of his earliest memories involve hanging out in old sheds while his Dad restored vintage vehicles, tickling up RC cars to get the edge in racing, and days spent on the couch watching Formula 1.
This early focus on all things automotive drove Richard towards a life that revolved around motorsport, first starting out in kart racing, before moving on to Caterhams, formula cars, and even some Formula Mazda racing in the States. In this episode, Richard spends time talking us through these different forms of motorsport, and discusses how each type of vehicle could be set up, tweaked, and modified within the rules in order to gain more speed.
Eventually, Richard’s good friend and eventual partner in crime, Nik Blackhurst, enticed Richard back to the UK to help him go rallying, and it was at this point, way back in 1992, that Bad Obsession Motorsport began.
Fast forward a good few years, and Richard and Nick were fed up with the car modification TV shows like Pimp My Ride, Monster Garage, and their contemporaries that were on offer at the time — none of them actually showed why and how any of the work was done. This got the pair thinking that they might be able to do better, and with that goal in mind, the Bad Obsession Motorsport YouTube channel was founded.
It took a couple of years, but Richard and Nick’s channel began picking up steam, not in small part thanks to “Project Binky”, a Toyota Celica GT-4 powered and driven classic Mini. Richard dives deep into this build, answering our burning questions — chiefly ‘Why’? But also “What’s taking so long”?
This in-depth discussion around the challenges of fitting so much engine and driveline into such a small package is a great look into what it takes to complete a complicated project to a high standard. Lastly, we also spare some time time to touch on the joys of motorsport wiring, ultra-budget racing in the City Car Cup, and making a living out of building cars on YouTube.
Follow Bad Obsession Motorsport here:
IG: @badobsessionmsp
FB: Bad Obsession Motorsport
YT: Bad Obsession Motorsport
WWW: badobsessionmotorsport.co.uk
Don’t forget, you can use “BAD100” to get $100 OFF our HPA Motorsport Fabrication Package: https://hpcdmy.co/fabpackageb

Timestamps:
4:04 How did you develop an interest in cars?
7:00 Did you learn anything from racing RC cars that could transfer to driving a go-kart?
8:10 How was your experience driving karts?
17:46 What is it about karts that makes it such a good learning platform for racing?
22:53 What is a cost-effective way to get into racing?
25:26 What other motorsports have you been involved in?
32:49 Transition from racing to Bad Obsession Motorsport
36:23 Automotive skill set before starting Bad Obsession Motorsport?
40:20 What were you thinking when you decided to start a YouTube channel?
43:32 When did you s

Field Report: 1200hp+ EVO | 11,000rpm & 'Illegal' On The Track. May 08, 2024

Show notes

The KOVAL EVO is one of the most successful roll racing cars in Australia and has seen a few iterations, owners, and a couple of catch cans over the years, as well as 80-90PSI of boost and up to 11,000rpm.
Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in
At GTR Fest, where Andre pretty much only looked at EVOs (he knows his type) we caught up with Dom Rigoli of Tony Rigoli Performance (TRP), a world-famous in Australia full service workshop with a proven history of getting incredible power out of many platforms including this venerable EMtron controlled 4g63.
Dom's answer here are short, sharp and accurate covering a range of topics from dry blocks, billet vs cast, head cylinder sealing with bronze aluminium rings aka fire rings along with some insight into what a car like this might do if it was fully setup for drag racing rather than the street too.
Previously, the car had made 1200hp at the hubs but now pushes over 1500hp and uses methanol or ethanol blends depending on the legalities of the event/location with 8.8 passes so far and plenty more to come if the owner wants to upgrade the car to safely compete at 1/4 racing, which are requirements that differ from roll racing events.

Field Report: The New 'K-Swap' For Drivelines? May 01, 2024

Show notes

You won't see this B2R Motorsport 2.0L 1200hp++ EK Honda Civic up at your local skifield, but it actually has the AWD/4WD system to get there faster than you could imagine if wanted!
Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in
Making over 1200hp at 56psi boost and plans to hit between 80-90psi with a Precision 8085 turbo, Moe El-asmar's EK Honda Civic is aiming to be the first in its class to hit a 7-second pass on Australian soil. This build focuses on keeping it simple and solving one problem at a time, as opposed to going crazy and creating more with too many rushed changes, and it certainly seems to be an approach that is working.
Off-the-shelf parts for engine components are one of the aspects that follows this building principle with an OEM Honda K20 crank, SpeedFactory pistons, and BME rods housed in a Bullet Billet Block sandwiched to a 4 Piston cast head with an MLS head gasket.
Interestingly, Moe discusses how the cost of sleeving was halfway to billet but with a much shorter lifespan, helping him make the call to go with a Bullet block that is also a 'wet block', enabling him and the team to do more passes back to back vs a dry block setup.
Electronics wise, a Link G4X ECU, MoTeC PDM30 and ProWire custom wiring harness keep the smoke in the wires, with Platinum Racing Products coil packs Elixir fuel pump and Aftermarket Industries tank and hanger rounding off the electrics and fuel system.
The 4WD conversion is something Moe sees becoming more and more popular over time, with an AWD conversion from a Honda CRV mated to a Quaife sequential gearbox.

113: A “Mil-Spec” Wiring Harness is Total Overkill for Most People. Apr 26, 2024

Show notes

Looking to up your game with a super-informative masterclass on professional-level motorsport wiring? This episode of Tuned In featuring Erik Reinertsen of Hardwired Performance is exactly what you're after.
Use “HARDWIRED50” to get $50 OFF our HPA Motorsport Wiring Starter Package: https://hpcdmy.co/wiringstarterb
Erik specialises in building top-level motorsport wiring harnesses, choosing to focus primarily on the demanding offroad racing market — but wiring wasn’t always on the cards for this Californian. Despite growing up around hotrods and motorsport with a father who built cars for a living, he was actively discouraged in following his Dad’s footsteps, instead being pushed towards a more conventional career.
The problem was, you can’t really expect your kid to not become a diehard car guy when he spends all his time messing around in your shop full of cool builds and weekend after weekend at the track. So, straight after school, Erik walked into an apprenticeship at a hotrod shop and began building his skills in fabrication, engine building, and nearly everything else in the car building world — but it was wiring that he excelled at. Many years later, Erik is a self-taught maestro building ultra-high-end motorsport looms for some of the most impressive race cars and trucks out there.
In this episode, we dig deep into Erik’s huge bank of knowledge and experience, discussing a big range of wiring-related topics — from the art of concentric twisting, autosport connectors, which tools are worth the investment, the correct gauge of wire to use for different applications, and a whole lot more.
Erik also weighs in on the myth of “Milspec”, discusses the many cases in which a pro motorsport wiring harness is complete overkill, and the lessons learned from running his own wiring business — particularly when it comes to the challenge of accurately quoting work and turning down jobs that you know just aren’t right for you.
Vicious Mustang: https://www.instagram.com/viciousstang
Follow Erik here:
IG: @hardwiredperformance
Don’t forget, you can use “HARDWIRED50” to get $50 OFF our HPA Motorsport Wiring Starter Package: https://hpcdmy.co/wiringstarterb
Time Stamps:
4:06 How did you get interested in cars?
13:50 How did you get into motorsport wiring harnesses?
19:57 Why did you decide you were most passionate about wiring?
33:18 When did you go out on your own?
37:50 Overview of Hardwire Performance
44:57 Colour coding in wiring
47:41 What makes up a professional motorsport wiring harness?
52:39 Why do we concentric twist our harnesses?
1:07:44 Do you use software for designing your harnesses?
1:11:36 Coupon code
1:14:39 Advantages of an Autosport connector
1:20:53 Tooling required to work with Autosport connectors
1:34:05 What are service loops?
1:42:10 Using glue-lined boots vs non-glue-lined boots
1:46:19 Sizing wire gauge for circuits
2:00:12 Final three questions

Field Report: Does 3D Printing Have A Place In Motorsport? Apr 24, 2024

Show notes

Can 3D printed parts hold up in an engine bay or elsewhere on a car when compared to the use of lightweight aluminium or similar, or is it still just technology best leveraged for prototyping?
Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in
Grant Luttinen of Intamsys helps us understand some of the pros and cons of additive manufacturing, what is required when it comes to software and some options out there for printers as a hobbyist or professional.
We take a quick look at printing options from $1,700 to $150,000 USD, as well as printing media/materials that start from $20-40 for a spool of ABS plastic and then go to $100, $600 or more for nylon, PEEK carbon fibre and 3D printed metal options.

Field Report: Will This Save You From Engine Failure? Apr 17, 2024

Show notes

Accusumps. Whether you're a motorsport enthusiast, a professional racer, or simply keen on advanced car maintenance, this video covers many of the common questions on how an Accusump can enhance your engine's reliability and performance and bridge the gap between a wet sump and (let's be honest, expensive) dry sump upgrade.
Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-in
Iann Criscuolo from Canton Racing Products answers some of the common questions we all have when it comes to how an Accusump works by filling with oil and supplying it via manual or electronic control that can be based on RPMs, g-force and more, how easy Accusumps are to setup with their optimal -10 ('dash 10') hose sizing recommendations and how long you can expect oil to be supplied at 7-10 psi of pressure.
It's important to note that you can set your Accusump to fill much faster by using higher pressures, but that also means the oil will be supplied to your engine much faster, so racers need to find a balance that suits their application whether that is drift, drag, circuit, offroad racing or something else.

112: Building a BIG-POWER LS That Actually Lasts. Apr 12, 2024

Show notes

The formula for building a big-power LS is pretty simple — but things get a little more complicated when the motor needs to produce all that power for sustained periods of time in applications like drift or circuit racing. In this episode, we sit down with Mitch Pullen of Pullen Spec Engines, who specialises in putting together ultra-durable LS builds to discuss the ins and outs of these motors and much more.
Use “PULLEN50” to get $50 OFF our HPA Engine Building Starter Package:
https://hpcdmy.co/enginepackageb
Thanks to his father’s involvement in motorsport, Mitch Pullen started young, assisting in the pits and moving into the karting world at 10 years old. By 14, he was building engines, creating his own wiring harnesses, and figuring out fabrication. It’s probably no surprise, then, that he left school fairly early to learn everything he could about nearly all aspects of motorsport engineering.
Although Mitch is a jack of all trades, he decided to focus on performance engine building, and this now sees him running the well-respected and very busy Pullen Spec Engines based out of the Gold Coast in Queensland, Australia.
In this conversation, Mitch goes into detail about how he builds LSs, discussing their inherent weaknesses and strengths and the work that’s needed to create a motor that can sustain high horsepower and high RPMs for more than just a pull or two on the motorway or a run down the strip.
Mitch is also well known for his unique S13 Silvia competition drift car, which runs a massive Roots-style blower sitting atop a Dart iron-block LS. There are a few obvious questions when it comes to this setup — why bother with this type of supercharger, how does it behave in a drift car, and can you even see anything when you’re driving? Mitch answers all these questions and more.
The conversation finishes with some great discussions around car setup, forged vs cast engine parts, performance aircraft engine builds, and more.
Watts linkage illustration: https://hpcdmy.co/watts
Follow Mitch here:
IG: @pullenspecengines, @mitchellpullen
FB: Pullen Spec Engines
WWW: pullenspec.com
Don’t forget, you can use“PULLEN50” to get $50 OFF our HPA Engine Building Starter Package: https://hpcdmy.co/enginepackageb
Timestamps:
4:08 How did you form an interest in cars?
11:31 Did you do any formal engine-building training?
15:09 Where did you go from rebuilding 2 stroke karts?
20:07 Watts link vs Pan hard rod overview.
24:53 Getting more power in the KE70.
31:43 How did you learn all these skills at such a young age?
32:52 What happened after the Khanacross?
35:03 Learning about LS engines and circuit cars.
45:40 Load on an engine for a sustained amount of time.
48:52 What do you do in your LS to make it live?
59:08 LS engine package.
1:07:27 Forged vs cast pistons.
1:16:52 Does the LS have enough factory clearance for boosted applications.
1:27:16 Why the roots blower?
1:35:57 Overview of Pullen Spec Engines.
1:45:50 Focusing on the LS.
1:48:47 Final three questions.

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