build diary

September 22, 2006:
There was a set of 18" wheels off a pimped-out Miata sitting in the shop, and the Seven was sitting nearby.
I don't think those front fenders are going to fit over the wheels, but I'll have to bolt them on just to see. Well, you just have to, don't you?
entry 1295

October 10, 2006:
The Seven is living in a temporary home - as am I.
I have to walk by the poor thing every morning as I head off to work. Non-stop rain means I can't take it out to play. It's starting to drive me nuts!

Thankfully, I'll get some chance for some fun in the next few weeks. This weekend is another Corvette autocross. Then two weeks later, a Red Rock Racers autocross. The weekend after that, a two-day event at the local track as well as a one-day event in Pueblo. Oooh, that's a tough choice to make. Since we take possession of the new garage - sorry, "house" - a day or two before, I think an out-of-town trip is out of the question. If the rain lets up, I might have to go for a blat around my local roads just for grins. One of the local hidden twisties just got repaved. Hmm...

Something that might be entertaining. I've become involved with the build and possibly sale of Miata-based Westfields. This means that I have access to all sorts of interesting details. One thing I've put together is an online configurator that lets you play with options. The kit is a bit out of Locost territory, but it's about half the price of the equivalent Caterham.
entry 1296

October 15, 2006:
Autocross time again.
Once again, I was out dodging cones with the Corvette club. They're remarkably good-natured about having non-Corvettes take part. Especially when, after all the experienced Corvette drivers have had three shots at the course, I knock 4.6 seconds off the fastest time on my first run. Heh heh, whoops. Overall, just a normal autocross event. My fourth run (we get six, in two races) was a little eventful. I was having a really good run. With fairly cool temperatures the tires weren't sticking all that well but the engine was happy, so I was mostly steering with the rear of the car. On one sweeper I was keeping the rear loose by using just a bit too much throttle and it got a half step ahead of me. I spun the car and missed a gate - so I slotted into first, lit up the back end, spun around to go through the gate then left the car in first for the final 180 and over the line. The rear wheels were smoking the whole time and my sideways trip across the finish seemed to entertain the spectators. I still managed to put down a pretty good time too! My fastest lap was a 51.8, about 4.3 seconds ahead of the next fastest car - also not a Corvette. I have to enjoy this while I can, because when Bill has his Westfield up and running I'm going to have some serious competition. Good thing he doesn't like autocrossing then.

There was one odd thing during the day. The venue is about a half hour from my current house. The drive out was fine (and refreshing!), but on the way home the car just cut out at a steady cruise. I coasted to the side of the road and restarted, but what the heck was that? I forgot to check to see if the ECU has lost power. I'm going to start monitoring that.
entry 1297

October 16, 2006:
New video.
It's been a long time since I've had any video to add to the site. Thanks to a friendly bystander with a fancy digital camera, I have video of my first run at yesterday's autocross. The color on the camera was all screwed up so I corrected it as best as I could. The first run was quick but there was still a second to come off in later runs. Still, it's kind of fun to watch the car from outside and to see just slow it looks through some sections. Not always slow though. During my FTD run (which had pretty much unuseable video, so you won't get to see it), it's possible to hear someone beside the cameraman say "Jeeeeez!" in response to my fairly late braking at one point.
entry 1298

October 17, 2006:
Zoom! There's a new video from the October 15th autocross up.
entry 1299

October 20, 2006:
Sexy engine on the dyno.
We had an engine I've been lusting over on the dyno today at work. It's very similar to the one that's in the Seven now - except that it's 25% larger. 2020cc in size instead of my 1640cc, with the same sort of compression and head modifications. There are even a set of roller-barrel throttle bodies installed. I have high hopes for this powerplant. Given the better head that's on it, it should be good for 200 hp at the wheels.

Well, it goes very well up to 6000 rpm. At 4000, it has 150 lb-ft of torque compared to my 100 lb-ft. Boy, you'd sure feel that! Unfortunately, it falls off at 6000 and doesn't fulfill all the promise. If the power curve kept going and continued to mirror mine, it would be right around 195 or so. We think the cams aren't up to the job. We'll sort that out!
entry 1300

October 25, 2006:
You can't see it, but I'm reworking the greasy underpinnings of the site.
It'll soon have much better integration of pictures and text - no more flipping back and forth! It'll also have more powerful searching capabilities. Heck, it'll probably do my laundry.

In the meantime, I've been driving the car. A quick blat here and there while I can - just because. I'm not going to get to autocross it this weekend because I can't be bothered with trailers and the like, but at least it's getting some use

We're all waiting eagerly at work for "our" Westfield to show up. I've been going through the assembly manual and some of the pictures have me ready to cut the back end off my car and redo it. I think I could drop a fair bit of weight, get better geometry and have a much cleaner setup. Big words - it might happen. Someday. Probably once Bill starts taking my lap records away from me!
entry 1301

October 30, 2006:
Another autocross.
The Red Rock Racers were out on the weekend again. The events are held in the parking lot for a ski area at a fair elevation (9000' or so) and there was certainly some worry about the weather. Lucky for us, it turned out to be sunny and warm. Well, sunny and not cold anyhow. It was another fairly small group but a good one with a fair mix of cars. We all managed to get a dozen runs in.

For some reason, I was having difficulty putting down a good clean run at first. The biggest problem was a 270 degree corner that I had suggested. Going in too fast meant loads of understeer, and while I could break the back end free with power that was a little risky because it was tough to line up the exit smoothly. Naturally, you had to do it twice per run. There was one section of the course that was quite quick - at least, it was for me. Apparently I was far faster through there than anyone else. It sure was hectic with a fairly smooth but narrow line available. At one point, I messed up my braking, got into a little tank-slapper and managed to collect two adjacent cones with opposite sides of the car! Whoops. My typical times were around 1:14, which was a second faster than my (much smoother) friend Mark in his Miata. Then finally, I got it right on one run. The guys in the timing booth thought something had gone wrong with the timing gear - I'd pulled 3 seconds off my time! I did manage to back it up a little slower on subsequent runs, but it left me with another FTD by a fair margin. I'll have to work on those 270s, tight slow corners are my weakest point. I have to admit that it was crazy fun letting the rear end just smear across the pavement. There were a few spots on the course that were well suited to walking the back end around with the throttle. It's the part I miss the most about driving a FWD.

We're closing on the new house today. There will be much chaos and hard work ahead for the next couple of weeks. Very little of it will have to do with the Seven.

The latest autocross.
Luckily, the snowballs were kept to a minumum. The pavement was cold but clean and the air was warm. What a great way to end the season!
entry 1303
It's fun watching the different cars at an autocross.
The Isuzu was surprisingly agile around the cones, able to move the back end around without the crushing understeer you usually see on econoboxes. The Miata was up to the usual Miata antics, the MINI Cooper S driver was a neophyte and simply trying to figure out where the course went, the WRX driver was quick and of course there's the noisy little orange thing.
entry 1304

November 3, 2006:
The new site is up!
Okay, so maybe it's not a big exciting event for many people. But the pictures and text are now integrated much better (right back to the beginning!). I'll soon have the option of going to a certain date, a better search, etc. Please be patient, and I think I set things up so regular readers won't find themselves losing their place. I hope so, anyhow...
entry 1305

November 10, 2006:
Much excitement!
The Westfield showed up at Flyin' Miata today. Wow, it's a beautiful piece of work. As it should be, given that this kit cost around four times as much as mine did. But it's easy to see why. The rear suspension is a work of art, and I'm seriously considering cutting the back of my chassis off and duplicating it. It's going to be a lot of fun building this critter. If you want to follow it, watch the FM Westfield website.

Meanwhile, I continue with the move into my new garage...
entry 1306

November 21, 2006:
I'm working on a Seven, just not mine!
The FM Westfield build has been taking up time at work. It's a little frustrating. Why? Because I have to do other things and I can't spend all of my time on the Westie! Argh. One of my coworkers has been gone for over two weeks and I'm trying to keep our salvage operation running as well as my own work. It means that I spend more time poking around the Westfield than I do working on it. I'd wanted to be elbow deep in the entire project and that's just not working out.

It has been interesting stuff, though. This is the first LHD version of this particular car, so we have a little trouble-shooting to do. The manual isn't finished so there's also some work in trying to reverse-engineer the ideas of the Westfield guys. Sounds a little familiar, doesn't it? Well, not to the same extent as my build! But it is fun. I hadn't realised how much I'd enjoyed the problem-solving aspect of the build and the Westie provides just enough of that to keep me hooked. I think I'm being useful as well - having been through the whole thing before, I have a really good idea of how it's all going to fit together. It's also really cool being paid to do things like this.

Meanwhile, the work at home continues. The Seven is now living in its new garage, although it's more a case of having a little burrow for the car inside the collection of boxes that still rule the space. The weather is cool enough to discourage me from driving it to work. I might do that next week just to prove I can. With a good jacket on.
entry 1307

November 26, 2006:
It's no wonder I'm not working on the Seven right now.
Here's the state of the garage. Sure, a bunch of the boxes are empty, but that's still not helping. The car in the foreground is a completely stripped Miata shell. The good news is that I'll have loads of room as soon as I get this all cleared out.
entry 1308

December 3, 2006:
A few thoughts.
I received an email recently that made a comment about how much free time and money I have. That's been bouncing around my head for a while.

Free time. This one seems tough - none of us has the free time we want. But it's really a matter of priorities. According to the AC Nielson company, the average American spends more than 4 hours a day in front of the television. Ouch. Replace TV time with garage time and I'm still way below average. I am lucky that I have a very understanding girlfriend who's been around since the whole Seven saga started (and in a further burst of understanding or possibly a tragic misunderstanding, she is now my fiancee) and no kids. But still, four hours a day? Even an hour a day is enough to get a lot done in the garage.

So what about the money? Let's pretend the Seven is a real car. I started by paying about $3000 on the frame. Over the next three years, I've spent an average of $194/month on the car if we're going to use the $10,000 budget that appeared Car and Driver. That budget is at retail, which is less than my actual cost. But still, I think the car would easily sell for $10,000 as it sits now. Think of that in terms of financing a car. $3000 down and $194/month for 36 months. I just checked, and I can't even get a base Kia Rio for those numbers if I could find 0% financing - and I doubt a three-year-old Kia has 100% resale value. I'm also pretty sure a Rio won't set lap records or outbrake a Carrera GT. To be fair, it probably has a roof.

On top of that, my daily driver is a 1988 Mazda 323 GTX. A cool little turbocharged AWD critter that's the predecessor of the WRX and EVOs. The difference? I paid $800 for mine. So I don't have to worry about car payments even though I drive a fun car to work. Maybe my vehicular choices aren't so expensive after all.

There's also the educational value - how much would it cost me to learn what I've learned?

Enough of that rambling. Any news? Yes! After chatting with Dennis from DPcars.net about his use of motorcycle mufflers in over-powerful applications, I'm going to try fitting a Hayabusa muffler to the Seven. I chose the Busa because it's a very powerful bike and thus should have a free-flowing muffler, and also because the muffler attaches with a nice three-bolt flange. It didn't hurt that I found a used one for sale for $10 on eBay. If it works out, maybe I'll spring for one of those cool carbon cans.

I'm also going to try out some new upper front control arms (the best of my control arms, but never mind that) from Kinetic. I'm even eying the very cool race seats from Westfield after learning that they'll fit. Waterproof, light and very supportive. Also worth two "payments" each, ouch. Hmm...
entry 1309

December 8, 2006:
The Hayabusa muffler arrived yesterday.
It's a neat piece. I hope it'll work well without being restrictive. According to the information stamped on the side, it will keep a 'Busa down to 80 dB. Well, it and a friend for the other two cylinders. It has a nice big 2.5" inlet but the actual pipe that goes into said inlet is actually only 1.5" ID. Boo! That's not a big problem, I can easily enough use just the flange and make it work nicely. I'm going to keep my eyes open for a single aftermarket unit as well. You'd think that guys would be throwing these bikes down the road with some regularity and so there would be scratched and orphaned mufflers around, but I haven't found them yet. No worries, I'll do the fitting with this one. Imagine, I might be able to have different mufflers that simply bolt on for different noise levels. That would be cool. As well as my "SuperTipp" setup works, I'd be happy to lose it.

Of course, right after I received this, I discovered that a Triumph Daytona uses a single can - and the Daytona 955 made 147 hp. So maybe I should have bought one of those. Hmm...
entry 1310

The stock Hayabusa muffler and pipe.
This is what $10 on eBay will get you.
entry 1311
The dirty secret of Hayabusa riders.
Their exhausts look like big fat 2.5" pipes, when really the ID is 1.5". Compensation or heatshielding?
entry 1312

December 11, 2006:
I've been having some fun on eBay.
On a tip from a motorcyclist, I decided to look for ZX-10R mufflers. They're a 162 hp bike with a single muffler - and it only weighs 375 lbs dry! Yikes. Turns out they have a similar flange on the back of the muffler as the Busa. I picked up an "experienced" version for $23.50. I might have a Triumph 955 muffler before too long as well.

I also won a suede 12" kart steering wheel. I have a 13" wheel on the car now and I'm curious about how the 12" will feel. I can make a simple adaptor to try it on the existing column. For $26, it was a really cheap way to get slightly quicker steering. You can never have enough steering wheels.
entry 1313

December 14, 2006:
More mufflers!
Okay, not any new ones. But the Kawasaki ZX-10R unit showed up. It's very similar on first inspection to the Busa one, but not so much once you get the input pipe removed.

First, the inlet is quite a bit smaller. I haven't measured it yet, but I think it's 2" instead of 2.5". However, the ID of the pipe going into it is significantly bigger than the Busa unit because it's a single-wall setup instead of double-wall. That's a bit of a shame for me, I have a 2.5" ID exhaust.

The internal construction of the mufflers is quite different. The Busa unit is what I'd expect from a chambered design but the Kawasaki piece looks almost like a catalytic converter. It's not like that all the way though because I can't see any light through there as with a cat. I wonder which will be lower restriction? I think it's time for a little comparison test!

A coworker asked me why I was messing with mufflers again. He thinks the car sounds great. Well, I wouldn't mind a bit of a volume drop at WOT but it also gives me something to do while it's cold outside and my garage is still jammed full of boxes...
entry 1314

Comparing the two motorcycle mufflers.
The Kawasaki unit is on the right and the Hayabusa on the left. A very interesting comparison of internal design.
entry 1315
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