Full-Race's new R14 build thread
 

Hi everyone, it's been about 1 year since our last update on my R14 (AWD-RB26 swapped S14 240SX). We got that car pretty well developed but its at the point where it cant go too much farther and still be a "Street car". I've been so busy with the BorgWarner EFR turbocharger development that there's been no time to work on my personal projects... so ive been itching to build a dedicated ultra-lightweight track prepped race car to see what Full-Race and this R14 swap is really capable of. This thread will document that journey with photos and info. The biggest initial hurdle is to retain a full 240sx chassis, and move the engine back 7" using a lightly modified off-the-shelf R14 kit.

http://www.full-race.com/prototype/R...ce-R14-22A.jpg

The next challenge to design a front suspension that will provide improved performance and be much less weight than modified skyline front suspension:

http://www.full-race.com/prototype/R...race-R14-4.jpg

Our target is to be on the track, next Feb/March 2013. please leave comments and let us know what you think!
__________________________________________________ __________________

1) we started by organizing all the parts required for the build:

http://www.full-race.com/prototype/R...ckGTRclip2.jpg
^^donor R32 GTR clip, purchased for $3800 on ebay

http://www.full-race.com/prototype/R...TRrearsusp.jpg
^^complete R32 GTR rear suspension with factory LSD and ATESSA pump, included with the clip

http://www.full-race.com/prototype/R...framerails.jpg
^^R14 conversion kit frame rails

http://www.full-race.com/prototype/R...missionmt1.jpg
^^R14 transmission mount

http://www.full-race.com/prototype/R...ace-R14-2f.jpg
^^^the crossmembers and suspensions disassembled from the R32 GTR clip, ready for a lookover and installation into R14.2

http://www.full-race.com/prottype/R1...ace-R14-2a.jpg
^^^base model S14 (no sunroof) stripped down completely shell stripped

http://www.full-race.com/prototype/R...ace-R14-2g.jpg
^^^placed on rotisserie

2) Before we start we needed to know how far back can the RB26 move without losing AWD? This will provide proof of concept for the vehicle and also allow us to identify the exact location for the engine/transmission

http://www.full-race.com/prototype/R...ace-R14-3b.jpg
^^^first we needed to cut the RB26 Front differential/oilpan combo down to length. Fortunately Full-Race has some GIANT bandsaws here for cutting our thickwall merge collectors before CNC machining. The entire RB26 diff fit perfectly

http://www.full-race.com/prototype/R...ace-R14-3c.jpg
^^^next, we did a test fit on the shortened front diff moved 6.75" forwards

http://www.full-race.com/prototype/R...ace-R14-3a.jpg
^^^what it will look like in the car

3) Next we prep the chassis. I have built many cars of the years, and the worst part is always prepping the chassis. Removing sound deadening, undercoating, rust protection etc is dirty and laborious. I considered acid-dipping this chassis, but heard many horror stories of cars that continue to leak acid from the seam sealer for many months after the has already come back from paint. My good friend Andrew Wojteczko from Auto Analyzer in Canada suggested to media blast the chassis - so we took it to "The Stripping Shop" in Phoenix, AZ. these guys had the entire chassis immaculate and ready for fabrication.

http://www.full-race.com/prototype/R...race-R14-7.jpg
http://www.full-race.com/prototype/R...ace-R14-7a.jpg
^^S14 chassis stripped of all paint, undercoating and sound deadening. Ready for installation of R14 kit.

http://www.full-race.com/prototype/R...framerails.jpg
^^R14 conversion kit frame rails

http://www.full-race.com/prototype/R...ace-R14-1c.jpg
^^R14 conversion kit frame rails installed on passenger side

http://www.full-race.com/prototype/R...ace-R14-1d.jpg
^^R14 conversion kit frame rails installed on drivers side

http://www.full-race.com/prototype/R...ace-R14-1h.jpg
^^R14 conversion kit frame rails installed, verifying alignment with stock subframe bolts

http://www.full-race.com/prototype/R...ace-R14-1j.jpg
^^R14 conversion kit frame rails installed, alignment verified


http://www.full-race.com/prototype/R...ace-R14-1k.jpg
^^punch alignment marks to guide drillbit

http://www.full-race.com/prototype/R...ace-R14-1l.jpg
^^start drilling new subframe bolt holes, a 1/2" unibit drillbit and a good quality 1/2" high-speed-steel drillbit is your best friend here

http://www.full-race.com/prototype/R...ace-R14-1q.jpg
^^checking GT-R subframe fitment

http://www.full-race.com/prototype/R...ace-R14-1u.jpg
^^clamping down R14-LHD steering rack

http://www.full-race.com/prototype/R...ace-R14-1w.jpg
^^R14-LHD steering rack installed

http://www.full-race.com/prototype/R...ace-R14-1s.jpg
^^trans mount test fitted

http://www.full-race.com/prototype/R...e-R14-1ZZZ.jpg
^^R14 kit installed, ready for engine mockup



4) Next we have to make clearance for the engine/transmission from the firewall and trans tunnel. We decided that we want this swap to come out factory, so the only way to do that was to surgically remove the entire firewall/floor from the GTR-Clip we had here, and graft that into the S14 chassis, except moved back 7".


http://www.full-race.com/prototype/R...ewalldonor.jpg
^^we cut up the remains of the gtr clip, carefully removing the floor, firewall and trans tunnel. We cut much more than we actually needed initially, to make sure that what we did need would be intact

http://www.full-race.com/prototype/R...walldonor1.jpg
^^^next we cut up the S14 with fresh R14 conversion, to remove the firewall and transmission tunnel

http://www.full-race.com/prototype/R...ce-R14-12A.jpg
^^^smallish S14 tunnel compared to giant hulking R32 floor, will make working on the car MUCH easier, especially now that we have a getrag 6 speed trans form an r34 gt-r

5) Now it is time to get the motor in it's new home, 7" back. I believe very strongly in clean swaps, so I wanted to do this as OEM factory as possible. We used the stock motor mounts and stock motor mount bracket, just relocated the point:

http://www.full-race.com/prototype/R...ace-R14-13.jpg
^^ OEM skyline motor mount and bracket VS the new 7" back position. you can see the stock GT-R mount point on the right, and the Full-Race fabricated mount point on the left.

http://www.full-race.com/prototype/R...ace-R14-15.jpg
^^engine getting dropped into place

http://www.full-race.com/prototype/R...ace-R14-25.jpg
^^fabricated passenger side bracket, had to do this to clear differential

http://www.full-race.com/prototype/R...ace-R14-20.jpg
http://www.full-race.com/prototype/R...ace-R14-19.jpg
^^GTR floor in place before getting prepped for installation

http://www.full-race.com/prototype/R...ace-R14-22.jpg
^^another view of how far back this engine now sits

6) Front suspension is a critical element for GT-R's. The stock R32 nissan suspension works, and is simple but is not lightweight, and can not give high performance at very low ride heights. The R33/R34 suspension was vastly improved over R32, however it still is not light enough nor does it follow the exact path that we are looking for. the following pictures help explain this better

http://www.full-race.com/prototype/R...ckGTRclip3.jpg
^^stock R32 GT-R front susp

http://www.full-race.com/prototype/R...ace-R14-6a.jpg
^^stock R32 GT-R + R34 GT-R front spindles

http://full-race.com/prototype/R14/u...ON_front_0.jpg
^^R14 front susp, basically the same as stock R32 GT-R

http://www.full-race.com/prototype/R...ace-R14-4a.jpg
^^^another R14 we built, and a different view

http://www.full-race.com/prototype/R...race-R14-4.jpg
^^^basic idea for new suspension setup. Still using stock GTR lower control arm, spindle/hub and brakes

http://www.full-race.com/prototype/R...ce-R14-6bb.jpg
^^GT-R spindle, with upper section removed

http://www.full-race.com/prototype/R...ace-R14-6d.jpg
^^GT-R spindle next to new spherical bearing

http://www.full-race.com/prototype/R...ace-R14-6e.jpg
^^GT-R spindle lug machined down to accept spherical bearing

http://www.full-race.com/prototype/R...ace-R14-6f.jpg
^^GT-R spindle w/ spherical bearing inserted on lug


this is where we stand on this, lots more work to come this weekend/next week

7) Once the firewall is contructed and chassis is rolling, we will send it to Get Nuts Labs in Las Vegas, NV for rollcage and chassis stiffening. some of their work:

http://www.full-race.com/prototype/R14/R14.2/CAGE9.jpg
http://www.full-race.com/prototype/R14/R14.2/CAGE7.jpg
http://www.full-race.com/prototype/R14/R14.2/CAGE8.jpg
http://www.full-race.com/prototype/R14/R14.2/CAGE5.jpg
http://www.full-race.com/prototype/R14/R14.2/CAGE6.jpg

and some others i really like:
http://www.full-race.com/prototype/R14/R14.2/CAGE0.jpg
http://www.full-race.com/prototype/R14/R14.2/CAGE.jpg
http://www.full-race.com/prototype/R...2/CAGE2bl4.jpg
http://www.full-race.com/prototype/R14/R14.2/CAGE4.jpg

we will take a hybrid of these photos and make sure it is very lightweight, stiff and most importantly SAFE for our driver. Lots of pics to come of this soon.

8) DCCD Pro -- most people on this forum dont care about subaru swaps, but anyone who does a late model STi swap into an old skool subaru will require some way to control the center differential (torque split). The R14 swap is no different. I came up with a clever solution which allows us to tweak torque split based off of hydraulic pressure. The problem with this is that it is not as responsive to changing conditions as an active g-sensor system. As a result i started to research what STi enthusiasts do and how to get around this hurdle... that's when i stumbled upon DCCDpro.com and met Jeff Reid, the owner.

http://www.full-race.com/prototype/R...centerdiff.jpg

FAQ: http://dccdpro.com/main/?page_id=3
install details: http://dccdpro.com/main/wp-content/d...DPro%20UNI.pdf
online store page: http://dccdpro.com/zcart/index.php?m...8ab8b2d7334966

I sent a test rig to jeff which he could hook up on his laboratory bench and experiment with:

http://www.full-race.com/prototype/R...ATTESSAtop.jpg

and after several months of experimentation jeff has the system functioning perfectly. He will make a few small tweaks before sending me the formal prototype but we are well on our way to having a mappable and functional active-center-differential.

thanks for reading, feel free to post up feedback/ideas. btw - my front suspension project will be done for 2wd S-chassis also

Straight up engineering porn.

Great work thus far and I am SO in for future updates. This looks like it will be sick.

Wow. A lot of work would be a huge understatement. Coming along nicely.
Someday I'll strip the Evo down to the chassis :)

Keep the pics coming !


-Bink

Great Project!
 

I'd live in a tent and eat bread and water if I could do this for a living! Great Stuff!!!
{thumbup}

Very stoked to see this creation come to life in the next year! :beer:

{thumbup}

Wow, in a day when I am sick of botched/half-baked 240's done by punks, this is great to see. Subscribed!

thanks everyone, ive got to finish up a project here today, then the thrashing will commence to get this thing rolling. it leaves sat night for roll cage fabrication @ get nuts labs

just started another build thread for my daily-driver evo project if youre bored: https://www.evolutionm.net/forums/ev...ject-build.htm

This is looking great. Can I ask why you guys chose the RB motor? Was the big factor wanting to do AWD? I know its potential, but ive seen alot of 240 guys with LS swaps, granted most of them drifters and I assume they want the torque of the LS. Any other big pros im missing? Forgive my ignorance, assuming it is ignorance :)

This is sick! thats quite a project, subd...I dono why but id keep my 240 rwd...evoand future gtr for awd :-)

great question white97dsm - the reason we retained the RB engine was to keep AWD. This to me is the ultimate AWD configuration (ignoring R35 with trans in the rear, and 911TT with engine in the rear) and i already have plenty of RB experience to boot. If there was another option that made more sense and/or more power i would certainly consider it. As of right now the plan is to get the car out on the track and then next year we can think about really getting crazy with hybrid engines and custom suspension arms/subframes. I really want to keep it simple for now and get some track time.

KARo7 - i agree the RWD layout suits the S-chassis perfectly, its a great balance and a ton of fun to drive. I do have a RWD SR20 240 already, but that is my beater drift car project, for time attack and road course the awd platforum suits this chassis nicely and gives many possibilities for creative people like me

LOL, to me what your doing is FAR from simple {thumbup} I can only imagine how much of a blast this will be on track.

Oh wow 2 awesome projects on the go at once - you're a lucky/crazy man.
I can now understand why you only sleep 2 hours a day :lol:

I have to disagree with you on one thing though Geoff....... the chassis prep is never the worst job..... it's always the wiring, always! :lol:

I'm kind of a little sad to see the battleship grey colour go. I love that colour and you car inspires me to paint my car that colour.

Well that's another subscription for me. Keep up the excellent work.

Edit - I see the grey r14 in the background.... nevermind lol

After the amount of hours you've put in, have you ever thought to yourself, "Maybe I should have just built my own car from scratch?" :p

Seriously though, that is a very cool project. It will be an extremely unique car, and should be fast as stink too. I love, love, love the sound of an angry RB26. Nice work. :thumbup: