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Author Topic: How I built the "Flying Brick"  (Read 7082 times)

MD

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Re: How I built the "Flying Brick"
« Reply #45 on: September 13, 2011, 06:38:14 PM »
The Exhaust side of things.

Decided to retain the original exhaust valve size of 38mm based on intake to exhaust valve ratios. All valves were re-profiled and lighter overall. No sodium valves were used without any detriment.

I made the extractor set for it and used a commercially available four-into-one merge collector. The balance of the system was fabricated to my specs by a local custom exhaust shop.

The headers are 38mm ID x 860mm and secondary pipes is 62mmIDx 720mm.
The pistons are CP brand custom made in the US and coupled to Carillo rods.
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MD

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Re: How I built the "Flying Brick"
« Reply #46 on: September 13, 2011, 06:39:45 PM »
A few more pics to round off the exhaust stuff..
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MD

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Re: How I built the "Flying Brick"
« Reply #47 on: September 13, 2011, 08:27:34 PM »
Well I think I have covered pretty much most of the key modifications without going into every nuance which is not necessary. I hope you have enjoyed the evolution. As you can see, with some determination even the humble four door brick can assert some aggression in a racing sense.

It was a lot of work and cost some serious bucks. Was it worth it? Are these toys ever worth it?

I will leave you to be the judge.

Cheers, MD
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scuzzyGTV

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Re: How I built the "Flying Brick"
« Reply #48 on: September 13, 2011, 08:43:13 PM »
MD thanks very much for sharing, I certainly appreciate it  ;D
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Evan Bottcher

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Re: How I built the "Flying Brick"
« Reply #49 on: September 13, 2011, 08:54:42 PM »
Thanks very much for sharing all this MD.  I remember seeing the car at Alfesta in Mooloolaba in '08 and marvelling at the level of detail.

I hope you'll share some more details of your new project soon ;)
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pep105

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Re: How I built the "Flying Brick"
« Reply #50 on: September 13, 2011, 09:28:10 PM »
Thanks for the insight MD I think you covered this in the right amount of detail

Thanks for sharing, questions will follow no doubt would love to hear the details of your new project GTV (?)
one day when your ready

MD = Dr Transaxle
 
Quote from: MD on September 02, 2011, 10:00:44 AM
This thread is longer than pep's wish list  :)

My wish list is pretty long  :) difference is this thread was just the right length 
and it got completed...

Cheers
Pep
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Storm_X

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Re: How I built the "Flying Brick"
« Reply #51 on: September 25, 2011, 10:40:14 AM »
OMG i only seen this thread until now. I am so jealous.

I have a few questions The brake pedal box where did you get it from / who made it?? I need one so BAD,also where did you get your shockers from?

Thats the exact same brake rotors and callipers i am putting on the front of my Giulietta.
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MD

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Re: How I built the "Flying Brick"
« Reply #52 on: September 25, 2011, 11:43:06 AM »
StormX

Happy to see you are enjoying the topic and getting some inspiration. I must admit jealousy is not a reaction I ever anticipated. You certainly have an alternative take on things. :)

Now, the pedal box is the original factory unit modified hugely to fit my special circumstances. It can also be the basis for your own project.

The dampers are Koni yellows re-valved for my spring rates front and rear. They have coil over adaptors for the front set.

If you are using my rotors and calipers, consider installing a 25mm bore brake master cylinder with a minimal 6.5 lever ratio on the brake pedal.

Best of luck with your project.
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Storm_X

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Re: How I built the "Flying Brick"
« Reply #53 on: September 25, 2011, 04:32:00 PM »
I might try a bm44 or a bm50 with the Nissan callipers on the front and Alfa 75 brembros out boarded on the rear. I will try and see if i can get my pedal box modified like yours, i was planing to just keep the booster but after taking it out i dont want to put it back.
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Duk

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Re: How I built the "Flying Brick"
« Reply #54 on: October 23, 2011, 01:05:00 PM »
Hey MD, is there anything in the rules that says you couldn't move the engine and/or driver back and down?
I was thinking about this when watching something about the V8 Poopoo cars (I actually like  the racing  ;)), get as much of the mass as central and as low as possible, and thought it could be applied well to a purpose built track Alfa (prolly need a dry sump to move the donk very far, though). Floor mounted pedals (like in the V8's) would save some grief with inlet system clearance.
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MD

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Re: How I built the "Flying Brick"
« Reply #55 on: October 23, 2011, 09:53:17 PM »
Yes Duk you are in the swim with these ideas but off course it has all been done before and probably the best approach is a space frame front end but how far do you want to go? Why stop at half a space frame?,,,I think you know what I am saying.

As for the pedals, well, all you have to do is look at a 105 for the answer. Have them come up from the floor as you have covered already.

Nothing in local rules say that you couldn't do all these mods and still compete in AASA comps. Look at the rear engined Sud for example being campaigned here. The ex Jim Nielsen Giulietta comes to mind regarding a "hybrid" approach along the lines you are raising although it is more to do with weight saving from what I can recollect as it has the original firewall from memory. Perhaps Jim will clarify it for us.. :)
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hammer

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Re: How I built the "Flying Brick"
« Reply #56 on: October 24, 2011, 10:54:04 AM »
Giulietta's engine is a little lower than standard but I think it's position in relation to the firewall is the same.

Cheers,

Brent
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Sam

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Re: How I built the "Flying Brick"
« Reply #57 on: November 07, 2011, 12:42:04 AM »
Hi MD

Great build,  very inspirational.

I wonder if you can provide some info on the Rotisserie you built.

It looks like you used the car’s  front and rear Bumper mounting points, to attach it to the Rotisserie is this correct?

I'm thinking of building one for an Alfetta GTV and I was thinking of using the same mounting points,  but I wasn’t sure if they were strong enough or if there were any issues supporting the weight.

My car is currently only a shell, but I may want to mount suspension and gearbox bits while it’s on the Rotisserie.

What are your thoughts?

Sam
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MD

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Re: How I built the "Flying Brick"
« Reply #58 on: November 07, 2011, 06:44:05 PM »
Hi Sam,

Yes I did use the bumper mounting points front and rear. Please see photo of the front mount which bolted on via some 10mm plates extending through to the rotisserie support frame.

The rear  is a bit more tricky and  I am sorry to say I have no photos of how to do it. Basically you have to alter the body work to make it strong enough with some plating and then bolt onto that.

There is no problem with the mounts holding the chassis only and the roll cage. Putting other mechanicals I have no experience with and cannot really advise. Please remember that it is not a hoist and shouldn't be used as a substitute for one. Also think of how you will remove it from the rotisserie once you are done.

About the only useful thing to do that doesn't involve any weight to speak of is to relocate the brake and clutch lines away from the tunnel in case the prop shaft munches them up if it gets loose. (and they do !)

I just remembered the GTV front bumper mount differently to the sedan and I would think you would need to weld up that front box section well so that you could bolt onto the captive nuts securely.
« Last Edit: November 07, 2011, 06:46:48 PM by MD »
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Sam

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Re: How I built the "Flying Brick"
« Reply #59 on: November 07, 2011, 09:06:01 PM »
Hi MD

Quote
Also think of how you will remove it from the rotisserie once you are done.

I was thinking of building it like this one  ...

 http://redwingsteelworksplans.com/wp-content/uploads/2009/05/100_0571.jpg

so raising and lowering should be easly done !?

Sam
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