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IV-Rotor Build: 12 plugs/ 9 bearings/ 8 ports = 1 monster
The day has arrived, time to start the Defined Autoworks 4-rotor build thread. Some of you may have noticed our signature 3-rotor track FD hasn't been doing much. That of course is because it was being built into a 4-rotor track machine.
Since this was a long term project, I was able to very very carefully plan the whole thing one end to the other. Every single piece of data learned over the years with n/a tuning has been put into this one engine. Nothing was compromised and its built to be my ultimate vision of naturally aspirated horsepower. Because of that, certain parts of the car wont ever be photographed and are kept in "area 51" for the time being. This specific 4-rotor is unlike any other. Its in-house name.... D26R -Here is a cheat sheet on the specs it was built to- Three plugs per rotor (just like the 787b 4-rotor) Aluminum front and rear side housings 4-piece custom eccentric shaft 5-main bearings for very high rpm capacity 9.7:1 rotors, extensively lightened race bearings throughout 2mm ceramic apex seals Full custom p-ports in all housings custom high strength stationary gears Variable length intake, servo actuation (also like the 787b) Custom slide throttle setup 4x2200cc injectors Custom inconel header system I've been working on this for 2 years, mostly on sundays or very late after hours at our shop. (pretty sure I earn one day a week off to work on promotional cars :) ) I will start feeding in pics over the next week or so, its hard to get any free time with all the work going on at good ol' Defined Autoworks. |
First up, the transmission. My old faithful T5 dogbox was not going to handle the 4 rotors power potential, so a upgrade was needed. Using our nascar connections was the obvious choice :) This is a Mid-valley engineering 4-speed unit. I tore it apart to inspect it..... okay I tore it down because I wanted to see how badass it was! Gun-drilled high strength massive trans shafts. All needle bearing support, internal oil pump, ultra lightweight gears, reem polished. This thing is a work of art!
http://i254.photobucket.com/albums/h...s/DSC03620.jpg http://i254.photobucket.com/albums/h...s/DSC03621.jpg http://i254.photobucket.com/albums/h...s/DSC03622.jpg http://i254.photobucket.com/albums/h...s/DSC03623.jpg http://i254.photobucket.com/albums/h...s/DSC03625.jpg |
Here is the mostly real mockup 4-rotor attached to the 4-speed.
http://i254.photobucket.com/albums/h...0_174611-1.jpg The chassis needed a nice overhaul before accepting the 4-rotor. After staring at it for many hours I had a vision of how to make it much easier and cleaner to work on. The engine bay and shock tower needed some modification to fit the variable intake as well. That will all make sense as we go along :) She looks like a dirty POS. But give it a chance http://i254.photobucket.com/albums/h...4_214324-2.jpg Now I did it. Whole firewall gone. No going back now! http://i254.photobucket.com/albums/h...115_185351.jpg |
http://i254.photobucket.com/albums/h...115_185401.jpg
http://i254.photobucket.com/albums/h...115_190056.jpg http://i254.photobucket.com/albums/h...115_190103.jpg Beginning of the new cage/tube structure. This is a superior design in terms of chassis stiffness. http://i254.photobucket.com/albums/h...216_183149.jpg http://i254.photobucket.com/albums/h...216_183157.jpg http://i254.photobucket.com/albums/h...216_183203.jpg The "tripods" as I call it, fully in place. http://i254.photobucket.com/albums/h...216_201345.jpg |
http://i254.photobucket.com/albums/h...219_013506.jpg
http://i254.photobucket.com/albums/h...219_013517.jpg http://i254.photobucket.com/albums/h...9_015527-1.jpg http://i254.photobucket.com/albums/h...219_015537.jpg http://i254.photobucket.com/albums/h...219_174552.jpg http://i254.photobucket.com/albums/h...219_230024.jpg http://i254.photobucket.com/albums/h...220_004924.jpg http://i254.photobucket.com/albums/h...220_004932.jpg http://i254.photobucket.com/albums/h...220_230544.jpg |
Coming together now
http://i254.photobucket.com/albums/h...220_230600.jpg http://i254.photobucket.com/albums/h...220_230708.jpg http://i254.photobucket.com/albums/h...220_235020.jpg Sanded the whole engine bay, removed all the seam sealer. http://i254.photobucket.com/albums/h...222_205243.jpg http://i254.photobucket.com/albums/h...222_205250.jpg http://i254.photobucket.com/albums/h...222_205256.jpg Primer! http://i254.photobucket.com/albums/h...222_213328.jpg Gotta have my signature GREEEN!! http://i254.photobucket.com/albums/h...222_214259.jpg http://i254.photobucket.com/albums/h...223_165025.jpg http://i254.photobucket.com/albums/h...223_165033.jpg |
Bet you guys didnt think this was possible based off the beginning huh? I'm not a professional painter, but many guys who have stopped by think I am :)
http://i254.photobucket.com/albums/h...223_200840.jpg http://i254.photobucket.com/albums/h...223_200854.jpg This one goes to Matt, he came up with using a motor plate idea. I liked it, and started to fabricate using the dummy engine. This made the whole package so easy to install and remove http://i254.photobucket.com/albums/h...226_162541.jpg Now onto the 4-rotor! After all that is what everyone wants to see. 1st off the aluminum side housings. So light, so nice. http://i254.photobucket.com/albums/h...301_134913.jpg http://i254.photobucket.com/albums/h...301_134949.jpg The ultra-light rotors http://i254.photobucket.com/albums/h...07_resized.jpg P-port all epoxy sealed http://i254.photobucket.com/albums/h...59_resized.jpg |
All the new seals. Too much time in clearancing side seals. I always dread it
http://i254.photobucket.com/albums/h...06_resized.jpg http://i254.photobucket.com/albums/h...13_resized.jpg http://i254.photobucket.com/albums/h...55_resized.jpg The ultra ultra lightweight clutch and flywheel. 4.5lb flywheel and 9lb clutch. Alcon makes one sexy setup http://i254.photobucket.com/albums/h...230_160611.jpg |
[b] The IV-rotor housings next to the workhorse 3-rotor semi p-port housings.
http://i254.photobucket.com/albums/h...s/DSC02987.jpg And of course, the triple spark plugs. http://i254.photobucket.com/albums/h...s/DSC02985.jpg http://i254.photobucket.com/albums/h...s/DSC02986.jpg |
Some of the machine work for the center stationary gears
http://i254.photobucket.com/albums/h...s/DSC03412.jpg http://i254.photobucket.com/albums/h...s/DSC03411.jpg I wanted to save weight everywhere possible, and also make our 4-rotor look more "factory produced". So I shaved the center irons, which took some time to do. http://i254.photobucket.com/albums/h...322_164030.jpg As stated earlier, there are SO many things inside the engine that I cant photograph unfortunately. The intake ports, the exhaust ports, internal cooling methods. All this made taking engine assembly pics impossible. Sorry guys! Here she is all finished and assembled. http://i254.photobucket.com/albums/h...327_194834.jpg I made a fast custom engine stand to assemble the beast. Took a minute to think of a good way to do it. http://i254.photobucket.com/albums/h...412_211911.jpg http://i254.photobucket.com/albums/h...412_211949.jpg The drysump plate all bolted on and ready to scavenge some serious oil http://i254.photobucket.com/albums/h...5_221847-1.jpg |
Temporary waterpump installed, front drysump pulley, custom trigger wheel for the electromotive
http://i254.photobucket.com/albums/h...415_235134.jpg http://i254.photobucket.com/albums/h...43_resized.jpg http://i254.photobucket.com/albums/h...21_resized.jpg Think that is enough mag sensors? lol http://i254.photobucket.com/albums/h...427_162625.jpg http://i254.photobucket.com/albums/h...427_162634.jpg |
Coil mount finished (12 coils..... whew) And the slide throttle fully machined and finished. The slider is out, while I fabricated the intake manifold.
http://i254.photobucket.com/albums/h...8_193202-1.jpg http://i254.photobucket.com/albums/h...428_193207.jpg Does this look like a machine or what?? The R26b would be proud. Notice the very straight shot intake manifold. This was the reason for all that chassis modification. http://i254.photobucket.com/albums/h...428_204710.jpg http://i254.photobucket.com/albums/h...428_204726.jpg Wanted a nice lightweight alternator relocation bracket, so designed this one. All cnc of course. The aluminum front irons do not have any bolt provisions, so mounting brackets are little more difficult. http://i254.photobucket.com/albums/h...503_153524.jpg |
This is an endurance engine through and through, so I had to think out extensive planning on cooling methods. Having 1.5 years timeframe, it gave me time to come up with very clean and creative ideas. Here is a pic showing all the coolant feeds, and oil feeds. Once nice tight package considering there is 15 lines there!
http://i254.photobucket.com/albums/h...521_123526.jpg CNC oil port plugs. Had "DAR" cut into them. Defined Autoworks Racing of course :) http://i254.photobucket.com/albums/h...521_123547.jpg Had to go old school on this one, the ITB airhorns were anodized the same green as my very first 20b back in 2004. http://i254.photobucket.com/albums/h...07_resized.jpg Another challenge was the variable intake. Uses metals that cant be welded, so I had some split flanges cnc cut. Notice the counterbore, this gave 1/4" more travel on the intake. http://i254.photobucket.com/albums/h...29_resized.jpg http://i254.photobucket.com/albums/h...02_resized.jpg |
The famous n/a 3-rotor weight (same type 5.5" clutch, waterpump, lightweight flywheel etc. ) Impressive at 279lbs.
http://i254.photobucket.com/albums/h...206_192939.jpg http://i254.photobucket.com/albums/h...206_192933.jpg With t-5 dogbox tranny is at a low 376lbs. http://i254.photobucket.com/albums/h...206_192430.jpg http://i254.photobucket.com/albums/h...206_192422.jpg And here is the assembled 4-rotor, 285 lbs. 6lb increase over race 20b. http://i254.photobucket.com/albums/h...415_230112.jpg http://i254.photobucket.com/albums/h...415_230225.jpg And also weight with ultra heavy duty mid valley transmission. Still only 7lbs heavier. http://i254.photobucket.com/albums/h...416_224203.jpg http://i254.photobucket.com/albums/h...416_224209.jpg |
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