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Testing 2004 at Carlini's
First mini spool failures, caused by insufficient radius at base of slot. |
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Antigo 2004
Axle failure caused by insufficient electrical tape wrapping. |
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Testing 2004 at Schwalbe's
Binding in telecoping splines caused axles to pull out of CV's, tubular axle weld failure, and damaged suspension. This was after a harsh landing. |
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Crandon 2004
Crank journals should not be visible from outside the engine. |
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Kansas 2004
Further axle bind caused damaged uprights (upgraded wheel bearing on right), elongated suspension mounts, and caused one wheel to "fly higher than anything I've seen that wasn't bolted to a plane" in the words of one spectator. |
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| Inboard CV bolts also sheared, ending our weekend. Later upgraded to grade 8 and used all 8 bolts to drive CV's. |
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Bark River 2004
Further axle bind caused CV damage. Improper setup caused spider gear failure. |
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| Baffles in ducts kept radiators spotless but caused overheating. Later adding hardware cloth-covered windows in these solved problem. |
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Crandon 2004
Fatigue and excessive suspension damping caused suspension failure in practice. By the end of the weekend we'd broken another mini spool due to an excessive recess in the part. |
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Casey 2004
The frame cracked. It was then reinforced. |
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Post-Season 2004
During testing, trashed yet another Honda valvetrain. By this point we have accumulated a lot of axles, many of them broken. |
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Antigo 2005
Improper shock assembly led to excessive bottoming and a broken engine mount.
This damaged the timing belt, causing the engine to stop running. |
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| This can not happen again as we fixed the shocks and stopped using that engine mount and use the air compressor and intermediate shaft bosses instead. We also added an engine plate. |
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Testing early 2005
Poor fitting air filter assembly allowed dirt to enter the engine, preventing the piston rings from moving (and sealing).
The timing belt was also too short since so much material had been milled off the head and skipped a few teeth.
These factors caused the engine to stop running. |
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Post-Kansas 2005
Engine bearing failure caused by excessively baffled aftermarket oilpan. |
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Bark River 2005
In a pileup over a blind hill, the suspension failed.
Shown below are tabs torn open, a-arms and tie rods bent, frame buckled. |
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These areas of the frame were reinforced after the season with gussets and another diagaonal. |
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After some bumping at the start of the race and a head on collision the bumper was badly damaged. |
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Crandon Fall 2005engine failure. |
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| this was remedied in part by modifying the oil pan for 2+ quart increased capacity and a trapdoor. |
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| We now have four complete Honda B series engines. |
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Casey 2005 Sunday 200km enduro
A few laps from the end of the 30 lap enduro, the left rear wheel failed.
This was caused by using only four wheel studs for most of the season, fairly small wheel inserts, relatively thin (.160") wheels, and having a sharp corner on the edge of the hub.
Twice during this weekend our inboard CV's overextended and came apart. This was solved by creating high strength, long plunge tripod joints, available through RCV Performance. |
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Cradon September 2006
During Friday practice the #2 cylinder barrel cracked, allowing water to mix with oil and destroy the rod bearings.
During the second lap of Sunday's race one of the shift fork pins broke past the cotter pin retaining it and allowed the transmission to be in 3rd and 1st at the same time.
This destroyed those gears as well as the front spider gears and the rear ring and pinion.
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| We upgraded to R180 differentials (from R160's) and made planetary assemblies for them with larger splines. |
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